Norac UC4.5 Installation Manual

Copyright  2016 by NORAC Systems International Inc. Reorder P/N: UC4.5-BC-SC4-INST Rev D (SPRA-COUPE 4000 Series) 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.

2 General UC4.5 System Layout ................................................................................. 2 3 Kit Parts ...................................................................................................................... 3 4 Pre-Install Checklist ................................................................................................... 7 5 Ultrasonic Sensor Installation .................................................................................. 8 6 Roll Sensor Installation ............................................................................................ 12 7 Electrical Installation ............................................................................................... 13 8 Hydraulic Installation .............................................................................................. 17 9 Hydraulic Valve Block Adjustments ...................................................................... 21 10  Software Setup ......................................................................................................... 23 11  Cable Drawings ........................................................................................................ 24

system is manufactured with top quality components and is engineered using the latest technology to provide operating 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. Every effort has been made to ensure the accuracy of the information contained in this manual. All parts supplied are selected to specially 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.

Figure 1 illustrates the general layout of the UC4.5 system components: Figure 1: General UC4.5 System Layout

Item Part Number Name Quantity B05 44706-01 KIT CABLE TIE BLACK 10 PCS 21 IN 150 PCS 7.5 IN 1 B10 44728 MOUNTING BRACKET COMPLETE UC4 BREAKAWAY EXTENDED 2 B15 105415 CLAMP ROUND 2IN SS 4 C03 44656D CABLE VALVE VARIABLE RATE DT 1 C05 43210-20 CABLE UC5 NETWORK 18 AWG 20M 2 C10 44650-60 CABLE UC4.5 INTERFACE SPRA COUPE 1 E01 45100 UC4.5 BOOM CONTROL PANEL 1 E03 43742 UC5 ROLL SENSOR W TEMPERATURE PROBE 1 E05 43750 UC5 ULTRASONIC SENSOR 2 E11 43765 UC5 NETWORK COUPLER 8-WAY 1 E20 43764T UC5 NETWORK COUPLER 2-WAY WITH TERMINATOR 2 H02 44863-07 HOSE ASSEMBLY 122R2-06 60 IN L 6FJX 6FJX90 4 H03 44863-12 HOSE ASSEMBLY 122R2-06 80 IN L 6FJX 8MBX90 2 H10 44865-62 HYDRAULICS FITTING KIT - SC4 1 M01 UC4.5-BC-MANUAL- OPERATOR OPERATOR MANUAL UC4.5 SPRAY HEIGHT CONTROL 1 M02 UC4.5-BC-SC4-INST MANUAL INSTALLATION UC4.5 SPRAY COUPE 4000 SERIES 1 P03 105882 UC5 NETWORK 6 PIN PLUG 4 V01 44959D-SC4 VALVE BLOCK ASSEMBLY 2 STATION OC/LS PROP DT 4 BOLT PRESET PSI 1

Item Part Number Name Quantity Picture F02 103839 JIC T COUPLER - 6FJXR 6MJT 4 F03 103312 MALE ADAPTER - 6MB 6MJ 4 F04 104386 MALE TO FEMALE ADAPTER - 8FJ 6MJ 2 F05 44927 ORIFICE INSERT .031 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 J - JIC OR - FLAT FACE P - PIPE Fitting Name Example: Do not use high speed power tools/drills when installing hardware. 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.

installation. 1. Unfold the sprayer over a flat, unobstructed area (i.e. no power lines…etc.). 2. Ensure all boom-fold operations are functional (place a check mark in boxes below). 3. Bring engine to field-operational RPM and record below. 4. Record the time (seconds) it takes for a full stroke for all boom functions. To ensure repeatable measurements, take the average of 3 trials. 5. Not all sprayers will have the functions listed below in Figure 4. Ensure the boom has sufficient travel so it does not contact the ground during these tests. Figure 4: Pre-Install Boom Speeds

5.1 Bracket Assembly Assemble the breakaway sensor bracket as illustrated in Figure 5, following the instructions below. Figure 5: Breakaway Bracket Assembly 1. Compress the spring and insert it together with the collar into the base. 2. Slide the tube through the assembled part. 3. Using the bolt and nut, tighten the collar to the tube with the sensor tube centered. 4. Apply a small amount of grease to the rotating surfaces of the bracket.

When installing the sensors, start with the smallest serial number on the left-hand side, and proceed to the largest serial number on the right hand side. Each sensor has a serial number stamped on the sensor housing. Apply a light coating of the supplied Permatex Anti-seize grease to all threaded parts upon installation. Figure 6: Sensor Serial Number Arrangement

The following guidelines will ensure optimal sensor performance and prevent sensor measurement error. These rules should be followed for both the wing sensors and the main lift (middle) sensor. 1. In its lowest position, the sensor must be 9 inches (23 cm) or more from the ground (A). 2. The centerline of the acoustic cone should be approximately vertical at normal operating heights (A). 3. The bottom of the sensor must be at least 9 inches in front of the spray nozzles and boom structure (B). (This does not apply for the main lift sensor) 4. The bottom of the sensor must be at least 9 inches above the spray nozzles (C). 5. Ensure there are no other obstructions with a 12 inch (23 cm) diameter circle projected directly below the sensor (D). Figure 7: Sensor Mounting Guidelines Figure 8: Sensor Reading Off Boom

1. The sensor bracket should be oriented forward (ahead of the boom). 2. Typically the best mounting location for the wing sensor brackets will be near the end of the boom tips, approximately two feet (60cm) from the end. 3. Depending on the boom design, some breakaway sections will lift upwards as they break back. If the sensor is mounted to this portion of the boom, the system will force the boom downwards towards the ground as the boom folds backwards. 4. Fasten the sensor bracket to the round tube structure using the supplied round clamps (B15). 5. Mount the NORAC ultrasonic sensor into the sensor bracket and run the sensor cable through the sensor tube. Figure 9: Wing Sensor Mounting (80ft Boom) Figure 10: Wing Sensor Mounting (60ft Boom) A problem can arise if a sensor is not mounted correctly. It is possible for the sensor to read off of the boom instead of the ground. This may only become apparent once the control system is switched from soil to crop mode. Also be careful that the sensor bracket does not collide with any other part of the boom when the boom is folded to transport position. If possible, mount the sensor brackets while the booms are folded to ensure they will not cause interference.

For this installation, the roll sensor is only being used for temperature compensation. 1. Securely mount the roll sensors to the included roll sensor brackets using the #6 machine screws. Tighten screws to 10 in-lbs (1.1 Nm). Figure 11: Mounting Roll Sensor to Bracket 2. Attach the roll sensor and roll sensor bracket to the boom, near the NORAC valve block using the provided cable ties. 3. Once the block is mounted, fasten the temperature probe from E03 to the NORAC valve block using the included 3/8x1/2” bolt as illustrated in Figure 12. Figure 12: NORAC Valve Block with Temperature Probe Installed

will be clearly visible and within easy reach of the operator. A good spot to mount the UC4.5 control panel is on the right hand side of the cab to the Roll Over Protection Bar. 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. These can be found at your local outdoor store as a RAM mount part number RAM-B-236. (See http://www.ram- mount.com/) Figure 13: Cable Configurations: C10 and C03 Figure 14: Access Plate Under Dash

2. Route cable C10 into the cab into the cab. Ensure that the cable is not wrapped around the drive shaft beneath the sprayer. 3. The access hole can be located either beneath the dash (Figure 14) or in front of the seat (Figure 15). There is a removable access plate beneath the dash (on the left, towards the door). A slot may be cut in the access plate so that it can be replaced (Figure 14). It is recommended to use a rubber grommet in the cutout slot to avoid cable damage. 4. Connect C10 to the UC4.5 Control Panel (E01) in the sprayer cab (Figure 13). Cable tie C10 to the RAM mount to help provide strain relief. Ensure the UC4 Control Panel’s power is OFF for the remaining installation (Bottom of switch pressed IN). 5. Connect the ring terminal connections on C10 to a 12V source. 6. Route C10 to the back of the sprayer. 7. Route the end of C10 with the 2-pin Deutsch and 2-pin weatherpack connectors to the SpraCoupe Bypass/Jam valve (Figure 16). 8. Disconnect the SpraCoupe 2-pin connectors at the Bypass/Jam valve and insert either the 2-pin Deutsch or 2-pin weatherpack connector tee (depending on the sprayer) on C10 between them. Connect the unused connectors on cable C10 together.

9. Connect the valve interface cable (C03) to connector S6 on (C10). 10. Connect the 2-pin connectors on the valve interface cable to the NORAC valve block, as shown in Figure 17. 11. The connectors on the valve cable (C03) are marked RIGHT UP, LEFT UP, RIGHT DOWN and LEFT DOWN. Cables labeled with UP go on the same side as the hydraulic hoses. Figure 17: Valve Cable Connections Bypass/Jam Valve

coupler. 13. Connect the roll sensor to the 8-way coupler. 14. Connect two cables (C05) to the 8-way coupler and route along the booms to the wing sensors. Follow existing cables and hoses to be sure the cable will not be pinched or stretched. 15. At the sensor brackets, attach a 2-way coupler with terminator (E20) to the sprayer boom. The 2-way coupler with terminator is the white two way coupler. Plug the sensor and the CANbus cable into the 2-way coupler. IMPORTANT: Provide enough slack in all cables to account for the movement of the main section, parallel lift, and FOLDING boom movement.

or fittings. Hydraulic pressure will exist on the wing tilt circuits unless the wings are being supported by other means. The hydraulic installation may be performed with the wings in transport position, resting on the ground or with the tilt cylinders fully extended. Component failure due to oil contamination is not covered under the NORAC UC4.5 system warranty. It is recommended that a qualified technician perform the hydraulic installation. 8.1 Valve Assembly 1. On a clean surface remove the plastic plugs from the block. 2. Insert the orifices (F05) into the “B” ports with the notch facing out. 3. Insert the orifices (F05) into the “A” ports with the notch facing in. 4. Install the 6MB-6MJ (F03) fittings into the “A” and “B” ports on the NORAC block. Tighten to 18 ft-lbs (24 Nm). Figure 18: NORAC Valve Block Details

Ensure that no hydraulic components will interfere with any sprayer parts or be pulled tight at any time. 1. Mount the NORAC valve (V01) on the sprayer using the valve mounting bracket. 2. Insert the threaded rod into the block and use a hex nut to hold the rod. The block holes are 3/8” NC-1” deep. If bolts are used instead of the threaded rod, ensure the bolts thread in at least 3/8”. 3. Use the remaining hardware to secure the block to the sprayer. 4. Cut off excess threaded rod, if necessary. Figure 19: Valve Mounting Example

hydraulics are fully installed. 1. After the NORAC valves are mounted, the hydraulic hoses and fittings can be plumbed. The plumbing for the hydraulic circuit is shown schematically in Figure 3. 2. Lower the wings to relieve holding pressure. 3. Disconnect the junction of the steel hydraulic line and the hose of the SpraCoupe circuit. Connect a 6FJXR 6MJT tee fitting (F02) between the steel line and the hose (Figure 21). 4. Connect the 90 degree fittings of hoses H02 to the “A” and “B” ports of the NORAC block (Figure 20). Route hoses H02 from the NORAC valve block to the tee fittings (F02) (Figure 21). 5. The “B” ports leading from the NORAC valve block are the “raise” lines, and must be connected to the boom raise cylinders via the existing lines and the tee fittings (Figure 21). 6. The “A” ports leading from the NORAC valve block are the “lower” lines, and must be connected to the boom lower cylinders via the existing lines and the tee fitting (Figure 21). 7. Connect the 90 degree end of hoses H03 to the tank and pressure ports of the NORAC valve block (Figure 20) (NOTE: This end of the hose has an adapter fitting already installed.). Route hoses H03 to the SpraCoupe valve block. 8. Remove the existing SpraCoupe pressure line from between the SpraCoupe valve block and tee. 9. Connect the hose (H03) from the NORAC Tank line to the pressure port on the SpraCoupe valve block using an 8FJ 6MJ fitting (F04) (Figure 22). 10. Connect the hose (H03) from the NORAC Pressure line to the SpraCoupe pressure tee using an 8FJ 6MJ fitting (F04) (Figure 22).

Block Figure 21: Raise and Lower Line Connections Figure 22: Tank and Pressure Connections NORAC Pressure Line (H03) NORAC Tank Line (H03) SpraCoupe Pressure Port F04 SpraCoupe Pressure Tee F04 “Lower” Lines (H02) Tank Line (H03) Pressure Line (H03) “Raise” Lines (H02) H02 Existing Steel Lines Existing Hoses F02

The NORAC valve block is factory-set however depending on the boom weight and size adjustments to the NORAC valve V01 (Figure 23) may be required to ensure optimal performance and efficiency. The following adjustments should be made with the system in operating position and at operating temperature. Figure 23: Valve Component Locations 9.1 Adjusting the PR Max Pressure Setting 1. Manually activate a wing raise valve by pushing the manual override on the end of the valve to determine which direction is raise (the side indicated in Figure 23). To manually activate a valve, press into the end of the solenoid valve using a small blunt 1/8” object. 2. Loosen the locking nut on the PR relief valve. 3. Turn the adjustment screw counterclockwise two (2) turns. 4. Using the blunt object, manually activate a boom valve to raise the boom. While the valve is active, turn the PR adjustment screw clockwise until the boom begins to lift. If the boom begins moving before any adjustment is made, turn the screw out one turn and retry. 5. Once the boom begins to lift, stop activating the valve and turn the PR adjustment ¾ turn more clockwise and lock the adjustment nut. PR – Manifold MAX Pressure Setting AR – “A” Port Pressure Setting SOL – Bypass Valve Solenoid Wing Lower Manual Override Pin Wing Raise Manual Override Pin

1. Loosen the locking nut on the AR relief valve. 2. Turn the adjustment screw counterclockwise approximately two (2) turns. 3. Using the blunt object, press into the end of the solenoid valve to manually activate the valve to lower the boom (indicated in Figure 23). While the valve is active, turn the AR adjustment screw clockwise until the boom begins to lower. 4. Once the boom begins to lower, stop activating the valve and turn the AR adjustment ¾ turn more clockwise. 5. Ensure the AR pressure is sufficient to lower the wing after raising it to the top of stroke using the Spra-Coupe controls: a) Raise a boom wing to the top of stroke using the sprayer controls. b) Attempt to lower the wing by pressing on the manual override pin using the blunt object. c) If the wing does not lower, turn the AR setting clockwise until the boom begins to lower. 6. Lock the AR adjustment nut.

1. Start up the sprayer and test the sprayer’s functionality. The NORAC control panel does not need to be powered on for the original boom function switches to operate. Unfold the booms and raise/lower each boom and the main section. Confirm that the cabling and hoses are 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. 3. Turn on the power for the UC4.5 Control Panel using the switch on the side of its chassis. 4. The procedure for the installation of the UC4.5 Spray Height Control system is now complete. Begin the AUTOMATIC SYSTEM SETUP procedure as described in the UC4.5 Spray Height Control Operator’s Manual (M01).

3702 Kinnear Place Saskatoon, SK S7P 0A6 TOPCON Agriculture Americas W5527 Hwy 106 Fort Atkinson, WI 53538 TOPCON Precision Agriculture Europe Avenida de la industria, 35, Tres Cantos, España Spain Support Phone: 888 979 9509 E-mail: [email protected] Web: www.norac.ca