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Spray Height Controller UC4+ SERVICE MANUAL 2012

1. Possible Cause Action Section Input wires may be damaged or not Test the switch inputs 3 9 installed correctly The system resets when a valve is turned on Possible Cause Action Section Poor power or ground connection Check the power supply 3 4 The system will not power up Possible Cause Action Section Poor power or ground connection Check the power supply 3 4 system intermittently goes into manual mode Possible Cause Action Section The Height Sensors are reading NR Test the Height Sensors 3 1 The interface cable may be damaged or Ensure the interface cable is installed N A not installed correctly correctly and not damaged Refer to your installation manual There may be noise on the sprayer s Ensure the interface cable is not routed N A electrical system near the sprayer s valve coils Add a power line filter or freewheeling N A diodes on one or more of the sprayer s solenoid valves 2 2 Operational Messages NC No Communication Possible Cause Action Section Failed sensor or CANbus Test the communication 3 5 NR or NoRdg No Reading Possible Cause Action Section Height Sensor is reporting NR It is normal to see this message 3 1 occasionally for Height Sensors If you are seeing this message all the time the Height Sensor may be havin
2. switch to resume 18 The display will show the following calibration messages if applicable as it is calibrating the boom Message Function Message Function Parameter Tt DZ Left Up Deadzone DZ Right Up Deadzone KP Left Up Gain Right Up Gain 02 Deadzone DZ 4 Right Down Deadzone KP Left Down Gain KP Right Down Gain DZT Main Up Deadzone 2 Deadzone TKPT Main Up Gain 07 Main Down Deadzone DZ Roll CCW Deadzone KP Main Down Gain KP Roll CCW Gain Figure 25 Hydraulic Calibration Messages 19 When the setup is finished the display will show Done Your NORAC UC4 system is now configured and ready for operation 55 43 Retune The following section describes how to perform the Retune For troubleshooting Retune problems please refer to Section 2 5 Preparation Unfold the sprayer in a location that is relatively level and where the sensors are over bare soil or gravel Do not conduct the Retune over standing crop weeds grass wet concrete water or snow Ensure the boom roll suspension system is functioning properly and smoothly For best results the hydraulic system should be under a normal load and at a normal working temperature e Start the solution pump and run the sprayer s engine at a normal working RPM for the entire setup e Cycle all boom sectio
3. 3 The temperature reading is the surface temperature of the valve block It should be reasonably close to the hydraulic oil temperature and should change as the sprayer warms up Incorrect temperature reading Possible Cause Action Section The temperature sensor is not mounted The temperature probe is the black N A correctly cable extending from the Roll Sensor with a ring terminal on the end of it It must be mounted to the surface of the Norac valve block as outlined in the installation manual This cable is not a ground connection The Roll Sensor may not be Test the Roll Sensor 3 2 communicating Faulty Roll Sensor Replace the Roll Sensor 4 8 26 3 4 UC4 system be powered using different power supply cables Refer to your height control installation manual for a description and schematic of the power supply cable The Control Panel display will be illuminated and show characters on the screen if the power switch is on and there is system power To properly check the power supply you should measure the voltage as described below Note Some configurations incorporate the fuse into the battery cable and some configurations utilize the existing fuse in the sprayer s electrical system m S N Figure 2 Typical UC4 Power Supply Configuration I Measure the voltage between pin 3 GND and pin 12 VDC on connect
4. Before beginning write down the serial number and location for each of the sensors The serial number is located on the bottom of the sensor housing beside the foam disc Note Older versions of sensors have the serial number located on the side of the housing so it may be necessary to remove the sensor from the bracket to view the serial number 1 Navigate to the Sensor Setup menu Run Screen gt toggle Sensor Display until More gt toggle Yes gt toggle Sensor Display until Left Right etc gt toggle Yes 2 The left channel menu prompts are shown below For other channels the basic structure and behavior of the prompts is the same Liht 42 5 Left Inner Height Display Left Inner Serial Number Setup BENE 10140 Left Outer Serial Number Figure 41 Sensor Setup Menu for Left Channel 3 Navigate to the sensor location you would like to change for example LO for the left outer sensor This screen will show the previously installed sensor serial number if any as shown in Figure 41 4 Toggle the switch once to search for all the connected sensors Use the switch to toggle through a list of available sensor serial numbers with their respective live height readings When the desired serial number is shown toggle Auto Yes switch to confirm To return to the Run Screen press and hold the Setup No or Sensor Display switch for two seconds 70
5. 47 Sensor Mounting Active 64 48 66 4 9 Height Sensor Io NU m 70 4 10 Roll Sensor Setup Passive 72 411 Roll Sensor Setup Enhanced Stability 74 4 12 Roll Sensor Setup Active Roll 75 4 13 Output Channel Valve Setup ccce erste Sn restes rp bid 76 414 Geometry Calibration sisi deett reine tereti retta 78 445 Updating the Firmwale cnici edente vedete aset tette tanda endi aiat R ardens 78 Sprayer o VOS Bap tede hsp es cha de dieu nodes ein dede 79 ACNE WMaintenaliceo e d Rv NH ONE b RURAL NL 80 5 WARRANTY amp SUPPORT 81 b Technical 5 areal heel anne 8 5 2 Registering Your Prodiict eee erinnere prosa Teste ueni teda riprese sedes eds 8l 5 3 Statement of Limited Warranty sooo otio ene eene Pal tere ep 82 1 Getting Started 1 1 Safety Precautions The UC4 Spray Height Control system wil
6. BF The screen will show the previously installed sensor serial number if any as shown in Figure 42 Toggle the switch once to search for all the connected sensors Use the switch to toggle through a list of available sensor serial numbers When the desired serial number is shown toggle Auto Yes switch to confirm Repeat for the Intermediate Frame IF Roll Sensor NGO UV w To return to the Run Screen press and hold the Setup No or Sensor Display switch for two seconds 72 4 10 2 Calibrating Sensors The Passive Roll Sensors are calibrated during the Automatic Setup and do not need further calibration unless your system also has slant control If your system has the slant function enabled on off valve for roll then the BFh and IFh roll sensor values must be zero when the sprayer chassis and boom are level The following instructions explain how to zero the readings Ensure the sprayer chassis and boom is level 2 Navigate to the Roll Sensor Setup menu Run Screen gt toggle Sensor Display until More gt toggle gt toggle Sensor Display until Roll toggle Yes gt toggle Sensor Display until BFh 3 Set the roll sensor reading to zero using the switch The switch will increase the reading the switch will decrease the reading 4 Repeat for the Intermediate Frame Roll Sensor IF To return to the Run Screen press and hold the
7. Repeat this test for the failed output 3 8 channel Systematically test the output while working your way back to the Control Panel to find the faulty cable Refer to your installation manual for cable schematics Failed Control Panel drivers Replace the Control Panel 4 8 5 41 3 9 Switch Inputs Test This test will confirm if the sprayer switches are correctly connected to the UC4 system 1 Navigate to the main run screen Press the left up sprayer switch 2 3 Ensure the left up arrow is shown on the screen 4 Repeat Steps 2 and 3 for all the other boom functions Left Down Right Up Down Up Down Roll and Roll CCW Note manual for your sprayer type to determine which functions your system supports Wrong input detected da Right Not all sprayer types will have all the functions listed above Refer to the UC4 installation Possible Cause Action Section The UC4 interface cable may not be Refer to the installation manual for N A correctly installed correct installation instructions The corresponding arrow does not show up on the display Possible Cause Action Section UC4 interface cable may not be Refer to the installation manual for N A connected correctly to the sprayer s correct installation instructions Use a wiring harness test light or voltmeter to confirm you have the correct conne
8. Setup No or Sensor Display switch for two seconds 73 4 11 Roll Sensor Setup Enhanced Stability The Roll Sensors are automatically configured and calibrated during the Automatic Setup for Enhanced Stability and should not be configured manually To confirm the sensors are configured correctly follow the instructions below I Navigate to the Roll Sensor Setup menu Run Screen gt toggle Sensor Display until More gt toggle Yes gt toggle Sensor Display until Roll gt toggle Yes gt toggle Sensor Display until 2 Ensure the BF serial number matches the serial number of the Roll Sensor on the boom frame Repeat for the IF and RF sensors 4 The Roll Sensors must be installed in the following serial number order Serial Number Roll Sensor Location Lowest Intermediate Frame IF Middle Boom Frame BF Highest Reference Frame RF Figure 43 Enhanced Stability Roll Sensor Serial Number Order 74 4 12 Roll Sensor Setup Active Roll 4 12 1 Configuring the Sensor The Active Roll Sensor is automatically configured during the Automatic Setup and should not be configured manually 4 12 2 Calibrating the Sensor Ensure the sprayer chassis and boom is level 2 Navigate to the Roll Sensor Setup menu Run Screen gt toggle Sensor Display until More gt toggle gt toggle Sensor Display until Roll gt toggle Ye
9. shows the typical cabling for the valve drive outputs Refer to your installation manual for complete schematics iy N LI gt tun N ut k Function Connector Pin Ground Pin Left Up P2B 2 Left Down P2D 2 Right Up P2A 2 Right Down P2C 2 Main T6B A N A Main Down T6B B N A 53 Roll CCW 53 Figure 11 Default Valve Drive Outputs Note 1 Not all sprayer types will have the functions listed in the table in Figure 11 40 Disconnect the valve cables from each coil Attach a test light or voltmeter to the cable labeled Left Up Connector P2B You may need to remove the wedge lock on the connector to attach your probe to the pin Navigate to the Left Up Gain screen in the Setup menu Run Screen gt toggle Setup until More gt toggle Yes gt toggle Setup until Left toggle Yes gt toggle Setup until KP Press and hold the Manual switch The controller will drive the selected function for one second at 100 You should get a 12 VDC reading on your voltmeter Repeat steps to 3 for all the other boom functions Left Down Right Up Right Down Up Down Roll Clockwise and Roll Counter Clockwise One or more of the functions does not operate Possible Cause Action Section Damaged valve cables
10. zero 36 One of the proportional boom functions does not operate Possible Cause Action Section The outputs may not be correctly If you have not completed an Automatic 4 2 configured Setup then complete it now The valve cable may be damaged or a Test the valve drivers 3 8 valve driver in the Control Panel may have failed The coil may have failed Try swapping valve coils with another N A valve that is known to work correctly If this solves the problem then replace the failed coil The hydraulics may have failed Perform the manual valve override test 3 7 The deadzone value may be set close to Check the deadzone setting 3 12 1 zero More than one proportional boom function does not operate Possible Cause Action Section The outputs may not be correctly If you have not completed an Automatic 4 2 configured Setup then complete it now The Norac hydraulic valve block may Repeat the boom function test while 3 6 not be receiving hydraulic pressure pressing and holding another function on This may be caused by the bypass jam the sprayer joystick such as an unfold valve cable or load sense line not being function installparconrecny This will activate the bypass jam valve If the boom functions move now then the bypass jam valve wiring or load sense is not installed correctly The valve cable or a valve driver may Test the valve drivers 3 8 have failed The pressure
11. 15 the number of sensors not communicating 2 Sensor configuration menu 1 Navigate to the sensor configuration menu from the run screen press Sensor Display until gt Yes gt press Sensor Display until Left gt press gt Sensor Display until LOht 2 The screen will show the current reading of the Left Outer Height Sensor If the sensor is not communicating it will show NC 3 Repeat this for all of the applicable sensors e Left LOht Llht Right ROht Riht Main MLht Roll BFh IFh RFh 29 3 5 3 Visual Check Before diagnosing any communication problems start by performing a visual check of all the CANbus cabling The majority of communication problems are related to damaged cabling that may have been installed incorrectly Look for any pinched or stretched cables especially near the boom pivot points such as the main lift and fold points Ensure all the connectors are free of corrosion clean and plugged in Note Dielectric grease must never be used on any of the CANbus connections 3 5 4 Moving the Sensor to a New Location If there is only one sensor that is not communicating you can try removing the sensor from its current location and plugging it into another CANbus connector This step is not required however it is useful to quickly diagnose a problem if only one sensor is not communicating 1 Power down the system Unp
12. 19 3 3 Temperature Sensor 26 34 Power Supply TOSE 27 3 5 Communication MEETUPS 28 2 6 Boom Functions undis isein epa 35 3 7 Manual Valve Override 38 3 0 Valve Driver D6st osse oM UR 40 42 MEE 42 3 10 BOOM SHEE HE RA RN RAD 43 3 11 Checking Mechanical Components Ern Fr I 44 3 12 Checking Setting Seeerei ei YQ Fee ERR IN Dt Erin 48 4 DE PIE ANE EN sisene sorsia 52 4 1 Menu Structure beber nd rb hte onte une quas 52 4 2 Automatic System SEU 53 43 56 44 Height Sensor Pn 57 4 5 Roll sensor Mounting Passive Roll seite Fue RUND UM tM DE 59 46 Roll Sensor Mounting 5 63
13. 4 9 2 Note Calibrating the Sensor Height Navigate to the Sensor Setup menu Run Screen gt toggle Sensor Display until More gt toggle gt toggle Sensor Display until Left Right etc gt toggle Figure 41 Select the sensor location Example LOht Left Outer Height Measure from the ground to the bottom of the nearest sprayer nozzle tip closest to the sensor location you selected If the currently displayed live height reading is not correct adjust it using the nn switch The switch will increase the reading the switch will decrease the reading To return to the Run Screen press and hold the Setup No or Sensor Display switch for two seconds To view the absolute height reading from the sensor to the ground press and hold the AUTO YES switch from the LOht menu This height reading can be useful for troubleshooting purposes 71 4 10 Roll Sensor Setup Passive Roll 4 10 1 Configuring the Sensors 1 Navigate to the Sensor Setup menu Run Screen gt toggle Sensor Display until More gt toggle gt toggle Sensor Display until Roll gt toggle 3 Intermediate Frame Reading Display Intermediate Frame Serial Number Setup Bh 0 Boom Frame Reading BF 33609 Boom Frame Serial Number Figure 42 Roll Sensor Setup Menu 2 Navigate to the Boom Frame Roll Sensor
14. dealer or contact Norac directly at NORAC Systems International Inc NORAC Inc 3702 Kinnear Place 6667 West Old Shakopee Road Suite 111 Saskatoon SK Bloomington MN S7P 0 6 55438 Canada United States T 1 306 664 6711 T 1 952 224 4142 T 1 800 667 3921 FREE T 1 866 306 6722 TOLL FREE Email service norac ca NORAC Europe sarl Web www norac ca Rue de l hermitage 1090 Guereins France T 33 426 470 442 Before contacting Norac for support please have the following information available e Product model UC4 or UC5 Product owner information name and location Sprayer make and model e Control Panel serial number and firmware version e Installation date 5 2 Registering Your Product To activate your warranty the product must be registered at the time of installation or delivery Products can be registered online at www norac ca Extended parts warranty can also be purchased when registering the product warranty Note Extended parts warranty must be purchased within 30 days of equipment purchase 8l 5 3 Statement of Limited Warranty NORAC SYSTEMS INTERNATIONAL INC also known as warrants all equipment of its manufacture to be free of defects in material and workmanship for a period of one year This warranty period is for a period of twelve months from the date the equipment is delivered by NORAC or its authorized dealer to the purchaser Items include weighing systems
15. instrumentation and control systems manufactured by NORAC Auxiliary components not manufactured by NORAC such as tires axles pumps or rebuilt parts are covered by a 6 month warranty only NORAC will repair free of charge items returned within the warranty period to one of NORAC s authorized Service Centers Freight will be paid one way and returned by the same carrier unless instructed differently NORAC or its authorized Service Center will repair or replace at its option any defective part or component at no cost to the purchaser during the warranty period If service in the field is required NORAC will authorize on site repairs at no charge for parts and labor Travel time travel costs and per diem expenses to and from the place where repairs are made will be charged to the purchaser at prevailing rates For the nearest Service Center visit our website at www norac ca or call 306 664 6711 Any evidence of negligent or abnormal use alteration of serial numbers not using NORAC certified or recommended parts or repairs attempted by other than NORAC authorized personnel automatically voids the warranty Normal wear is not covered under this warranty NORAC will not warranty any complaints relating to inadequate installation unless the installation was performed by NORAC adjustments or calibration The forgoing states the entire liability of NORAC regarding the purchase and use of its equipment NORAC will not be held responsible
16. lift if possible Accumulators If the sprayer has accumulators on the wing tilt cylinders they should have orifices restrictors installed between the accumulator and the hydraulic circuit The orifices are used to restrict the amount of effect the accumulators have on the hydraulic circuit NORAC recommends Imm to 1 5 mm restrictors All Accumulators main lift and tilt must be charged to their recommended setting Boom Suspension Ensure the sprayer s boom suspension is operating correctly and moving freely If the suspension is sticking or too loose the boom will be unstable If the boom is unstable in manual mode the height control system will not make it more stable For optimal performance the boom suspension should be critically damped Figure 13 illustrates how to check if the boom is critically damped gt Tip Height Time Figure 13 Critically Damped Boom If the boom is not critically damped then check the boom damper shocks and replace them if they are worn If the suspension is adjustable then adjust it so the boom is critically damped 44 3 11 2 Active Roll Systems John Deere If you have a John Deere Active Roll System check these additional items Rod Alignment Check the rod alignment as described in the Active Roll Sensor mounting Section 4 7 Secondary Pressure and Tank Lines Ensure the secondary pressure and tank lines have been installed Wi
17. of actions under the symptom until you have found and solved the problem Initial Troubleshooting Section 1 4 Test Procedure 5 Section 3 h ind the symptom gt List of Actions or Section 2 Reference Section 4 Figure 1 Troubleshooting Flowchart 1 4 Initial Troubleshooting Before troubleshooting the problem gather some basic information about the problem and the sprayer What is the sprayer make and model Are there additional options Active Roll Severe Terrain Enhanced Stability or Proportional Main Lift Customer information name and location What is the firmware version and serial number of the UC4 Control Panel Is this a new installation Are there any error messages What is the perceived problem Can you recreate the problem Is it intermittent Has anything changed since the system was working Have any settings changed or has an Automatic Setup or Retune been attempted 2 Symptoms 2 1 General Operation The system will not go into automatic mode Possible Cause Action Section The Automatic System Setup has not If you have not completed an Automatic 4 2 been completed Setup then complete it now The Height Sensors are out of range Lower the booms to normal working N A height Poor Height Sensor readings Test the Height Sensors 3 1 The system will not go into manual when the sprayer switches are pressed
18. reading from 10 inches 25 cm to 80 inches 200 cm Repeat steps 2 to 6 for each of the Height Sensors Repeat steps 2 to 7 in Crop Mode Refer to the following sections for troubleshooting if you experience any of the following errors Error message Page 17 Error message Page 18 Inaccurate or erratic height reading Page 18 Error message Possible Cause Action Section The sensor may be saturated with water If the sensors get saturated with rain water unfold the booms so the sensors point towards the ground and allow the sensors to dry out You can also remove the sensor foams squeeze the water out of them and reinstall them into the sensors The system can be left running while the sensors dry out N A The sensor may be covered in mud or debris The sensor foams are designed to keep mud and debris off of the sensor transducer If the sensor foams become dirty you can replace them or remove them from the sensor clean them and reinstall them into the sensors If the transducer becomes dirty you can gently wash it out with clean water Do not use any high pressure water or chemicals on the transducer N A The sensor may be reading off a poor target such as snow water ice or concrete When testing the sensors always test over level bare soil or gravel N A The sensor may be reading off the boom Try moving the sensor to a different locati
19. troubleshooting as described earlier in this section Please refer to the installation manual for your sprayer type for your exact system layout 7 2 ES Tp ai y P T T de Tos 1 i us Figure 8 Test Point TP Examples 34 3 6 Boom Functions Important While performing this test the boom functions will move at 100 speed for one second Ensure the sprayer booms have full range of movement By performing the following boom functions test you will confirm that the UC4 system is able to drive the corresponding boom functions This will confirm that the electrical and hydraulic portions of the UC4 boom function outputs are operating correctly 1 Navigate to the Left Up Gain screen in the Setup menu from the run screen press Setup until More gt press gt Setup until Left gt press Yes gt press Setup until Press and hold the Manual switch The controller will drive the selected function for second at 100 Ensure the Left Up boom function operates ur Repeat steps to 4 for all the other boom functions Left Down Right Up Right Down Up Down Roll Clockwise and Roll Counter Clockwise Note Not all sprayer types will have all the functions listed above Refer to the UC4 installation manual for your sprayer type to determin
20. 40253 Left Up Channel Dead Zone Left Up Channel Gain Set ch 402 51 Left Down Channel Dead Zone Figure 21 Hydraulic Setup Menu for Left Channel The gain value relates to the maximum speed of the boom This value is dependent on the sprayer type and therefore can be quite different for each sprayer type When checking gain values the left up and right up gain value should be close within 20 The left down and right down values should also be close within 20 and are typically half of the up value for most sprayer types Generally the faster the boom speed the lower the gain value Function Valve Type Typical n Wings Proportional 80 200 Wings down Proportional 40 150 Main Lift All N A N A N A Roll Proportional N A N A N A Roll Slant On Off 10 40 Figure 22 Typical Values If the gain value is outside of the specified range or to confirm if it has been calibrated correctly calibrate the gain as described in Section 4 13 2 49 3 12 3 Boom Geometry Values To view the Boom Geometry Values press and hold MANUAL from the run screen The screen will appear as shown below BF Pol IF Pol LWSF RWSF Figure 23 Boom Geometry Values The boom geometry values relate to the position of the Roll Sensors boom type and position of the Height Sensors The left LWSF and right RWSF values should normally be very close within 10 For sprayers which
21. AIND A Z ROLL CONTROL Spray Height Controller UC4 SERVICE MANUAL 2012 Printed in Canada Copyright 2012 by NORAC Systems International Inc Reorder P N UC4 SERVICE MANUAL 2012 Rev B 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 Contents I GETTING 25552509 055540 Pel Safety M Pez Related 2 l3 How to Us This Matldl ue Dub oper n 2 1 4 Initial Troubleshooting BIER PME 3 2 55955 4 2 1 General ree 4 22 Operational dini died 6 22020 Um 8 24 10 25 Automatic Setup or Retune 12 3 TEST PROCEDURES 16 Height SERS al 16 9 0 SENSOR TeSt peiriers iuterne siaii ia aias eri sedesi eiaei
22. Alignment 65 4 8 Replacing Components The sensors are connected to the UC4 Control Panel using one common CANbus The controller knows where each Height Sensor and Roll Sensor is located by its serial number and not by where it is physically connected to the CANbus cable Each sensor serial number is assigned to its location during the Automatic Setup or by manually assigning it in the setup menu If you move a Height Sensor or Roll Sensor to a new location on the sprayer the controller will not know that you have moved the sensor It will still report the sensor as being in the previous location until you have changed the serial number location in the setup menu 4 8 1 Height Sensors Moving the Sensor to a Different Location The following instructions are for moving a Height Sensor from one location to another For example moving the existing left outer sensor to the right outer location Turn off the system power 2 Move the sensor to its new location 3 Turn on the power At this point the controller does not know the sensor is in a new location 4 Assign each Height Sensor serial number to the new location Section 4 9 1 The previous calibration value for the new location will be used An Automatic Setup Retune or further calibration is not required for moving the sensor Replacing the Sensor with a New Sensor Turn off the system power 2 Remove the old sensor from the sprayer and install the new se
23. ISPLAY for two seconds to return to the run screen 52 4 2 Automatic System Setup The following section describes how to perform the Automatic System Setup For troubleshooting Automatic Setup problems please refer to Section 2 5 Note It is not a requirement to default the Control Panel before performing an Automatic Setup Preparation Unfold the sprayer in a location that is relatively level and where the sensors are over bare soil or gravel Do not conduct the system setup or retune procedures over standing crop weeds grass wet concrete water or snow Ensure the boom roll suspension system is functioning properly and smoothly For best results the hydraulic system should be under a normal load and at a normal working temperature e Start the solution pump and run the sprayer s engine at a normal working RPM for the entire setup e Cycle all boom sections up and down manually for five minutes to warm the oil e For trailed sprayers ensure any hydraulic flow controls are adjusted for normal field operation e Changing the hydraulic flow controls after or during the system setup will affect the performance Starting the Automatic System Setup I Navigate to the Automatic System Setup Run Screen gt toggle Setup until More gt toggle gt toggle Setup until Other gt toggle Yes gt toggle Setup until Install gt toggle Yes 2 Se
24. More than one boom functions do not operate Page 39 38 wrong boom function moves Possible Cause Action Section For proportional functions the raise and Check the tilt cylinder hose installation N A lower lines from the Norac valve block The raise lines must be connected to may be incorrectly installed the B ports and the lower lines must be connected to the ports Refer to your installation manual for correct hydraulic installation One of the boom functions do not operate Possible Cause Action Section Debris in the valve or valve block Check the valve and valve block for N A debris More than one boom functions do not operate Possible Cause Action Section The Norac hydraulic valve block may Ensure the bypass jam valve is being N A not be receiving hydraulic pressure activated while performing the manual This may be caused by the bypass jam valve override test valve cable or load sense line not being installed correctly If you have a load sense connection N A ensure it is correctly installed Refer to your installation manual for correct installation The pressure and tank lines may not Check the pressure and tank lines N A installed correctly Refer to your installation manual for correct installation Debris in the valve or valve block Check the valve and valve block for N A debris 39 3 8 Valve Driver Test Figure
25. Run Screen gt toggle Setup until gt toggle Yes gt toggle Setup until Left Right etc gt toggle Yes Select the KP screen for the boom function you wish to calibrate Press and hold the Auto Yes switch to calibrate Typical gain values are shown in Section 3 12 2 The manual gain test pressing and holding Manual is not intended for calibrating the gain setting The manual gain test will only drive the specified valve at 100 for one second and report the boom speed The boom speed does not change if the gain value is changed The gain values for the roll proportional and slant on off functions are typically defaulted and should not be calibrated using the automatic gain test 77 4 14 Boom Geometry Calibration The following steps will automatically calibrate the boom geometry values Ensure you are in a location that is relatively level and where the sensors are over bare soil or gravel Do not conduct the calibration over standing crop weeds grass wet concrete water or snow 2 Ensure the boom is level and approximately tol 5m 3 5 feet above the ground 3 Navigate to the Boom Geometry Calibration menu Run Screen gt toggle Setup until More gt toggle gt toggle Setup until Roll gt toggle Yes 4 Press and hold Auto Yes from the Roll On screen to launch the Boom Geometry Calibration 5 Once you launch the Boo
26. Up 20 inches sec 500 mm sec Right Up 20 inches sec 500 mm sec Left Down 10 250 mm sec Right Down 10 inches sec 250 mm sec Figure 12 Typical Booms Speeds The boom speed is outside of the specified range Possible Cause Action Section The orifices in the Norac valve block Check the orifice installation in the A N A may have been installed backwards or and ports Ensure they have been may not be seated correctly installed with the correct orientation Refer to your installation manual There may be air in the hydraulic lines Cycle the wings up and down several N A times to remove the air out of the hydraulic system 43 3 11 Checking Mechanical Components The following list describes several mechanical items to check on your sprayer For optimum performance these recommendations should be followed Please note that this list does not apply to all sprayer types Please follow the recommendations that apply to your sprayer 3 11 1 General Friction Pads Ensure the boom pivots freely If there are friction pads on the boom ensure they are well greased or clean and free from debris The friction pads must be adjusted properly to allow the boom to pivot freely and not stick or bind as the boom rolls Main Lift If there is substantial wear in the mast style main lift the boom will be too loose Install shims or adjust the mast style main
27. and tank lines may not Perform the manual valve override test 3 7 installed correctly for each valve to confirm the hydraulics is operating correctly The deadzone value may be set close to Check the deadzone setting 3 12 1 zero 37 3 7 Manual Valve Override Test Important While performing this test the boom functions will move Ensure that you are located in a safe position as to not get injured from any movements The manual valve override test is useful for determining if the hydraulics are operating correctly on the Norac valve block I If your sprayer has a bypass or jam valve you will need to active it at the same time as performing this test for the Norac valve to receive hydraulic pressure One option is to have an assistant press and hold an unfold function while you are performing this test 2 Perform the manual override test for each proportional function by pushing in the pin with a small screwdriver or awl in the center of the coil as shown in Figure 9 or Figure 10 3 The corresponding boom function should move when you perform this test Down Push pin to test Figure 9 Manual Valve Override Test Figure 10 Manual Valve Override Test early model valve block later model valve block Refer to the following sections for troubleshooting if you experience any of the following errors The wrong boom function moves Page 39 One of the boom functions do not operate Page 39
28. ay occurs Ensure there is a clean dry foam disc inserted in each sensor If it is clogged with dust or other debris clean it as described below At the end of the season Replace the oil filter in the NORAC hydraulic manifold annually NORAC P N 106285 Cleaning Ultrasonic Height Sensors 80 Remove the foam disc from the sensor and wash it with clean water Squeeze out excess water and allow the foam disc to dry The sensor can be used if the foam is wet however you may not get a valid height reading until it has completely dried out If the transducer inside the sensor is also dirty wash it using clean water Remove the sensor from the bracket and rinse debris from the transducer by pouring water across the face of the sensor Do not submerge or pressure wash the sensor A soft bristle brush can also be used to gently clean the transducer if the water alone is not sufficient Use caution not to scratch or tear the transducer as it is fragile The sensor should be left to dry with the transducer facing downwards The sensor can be used if it is wet however you may not get a valid height reading until it has completely dried out Leaving the control system powered on with the sensor connected and facing down will speed the process of drying the sensor Chemicals or compressed air should never be used to clean the sensor 5 Warranty amp Support Information 5 1 Technical Support For technical support please contact your local
29. ctions There is no output from the sprayer Confirm that there is a 12 VDC output N A wiring harness when the corresponding from the sprayer wiring harness that switch is pressed connects to the UC4 interface cables Refer to the installation manual for electrical schematics The UC4 interface cable may be Systematically test the continuity of the N A damaged cable while working your way back to the Control Panel Refer to your installation manual for cable schematics The Control Panel may have failed Replace the Control Panel 4 8 5 42 3 10 Boom Speed Important While performing this test the boom functions will move at 100 speed for second Ensure the sprayer booms have full range of movement Ensure the sprayer is at operating temperature and RPM Turn the solution pump if possible 2 Navigate to the Left Up Gain screen in the Setup menu from the run screen press Setup until More gt press gt Setup until Left gt press Yes gt press Setup until Press and hold the Manual switch 4 The controller will drive the selected function for second at 10076 and report the distance travelled This is the boom speed Repeat this test a few times to get an average boom speed reading 6 Repeat Steps 3 to 5 for the Left Down Right UP and Right Down functions Function Min Units Left
30. e 16 Pivot Bearing with Free Movement 46 Rubber Bumpers Ensure the rubber bumpers have been removed When installing the Active Roll section the rubber bumpers that are mounted between the boom and black tee frame must be removed If these are not removed when a severe correction is required the boom can roll hard and bounce off the rubber bumper When the boom bounces off it causes the system to start to oscillate Rubber Rubber bumper bumper removed removed Figure 17 Rubber Bumpers Removed Spring Adjustment Proper spring adjustment is important to make sure the boom can properly center The springs can be adjusted on a John Deere sprayer by adjusting the spring tensioners located on the boom There are two tensioners one for each side The correct adjustment is with the boom level the measurement between the spring mounting holes should be between 405 and 420 mm 16 and 16 5 Spring Spring tensioner tensioner Figure 18 Spring Tensioner Location 47 3 12 Checking Settings The following section describes how to check the most common settings on the UC4 system If you have not yet completed an Automatic Setup then perform it now before continuing 3 12 1 Deadzones 1 Navigate to the hydraulic setup menu Run Screen gt toggle Setup until More gt toggle gt toggle Setup until Left Right etc gt toggle Yes 2 The left channel menu prompts are shown below For oth
31. e shown in Section 3 12 1 The roll on off valve deadzone is typically defaulted and should not be manually calibrated If you get very inconsistent deadzone values each time you perform this test it may be an indication that there is air in the hydraulic lines or the wing accumulators do not have orifices installed If you cannot calibrate the deadzone value within the specified range or if the wing deadzones are calibrating close to 128 you may have a problem with the bypass cable It is possible for some systems to be able to calibrate the deadzone value even if a required bypass cable is not installed This occurs by the valve signal feeding back through the sprayers wiring and firing the bypass valve Check the bypass cable installation and ensure it is correctly installed This problem typically only appears on trailed Flexicoil and New Holland sprayers that require the bypass cable but do not have it installed 4 13 2 Calibrating the Gain Note Note The Gain calibration is dependent on the Deadzone value Before calibrating the Gain you must calibrate the Deadzone value first for the same channel Ensure you are in a location that is relatively level and where the sensors are over bare soil or gravel Do not conduct the calibration over standing crop weeds grass wet concrete water or snow Ensure the sprayer is at operating temperature and RPM Turn on the solution pump if possible Navigate to the hydraulic setup menu
32. e which functions your system supports Refer to the following sections for troubleshooting if you experience any of the following errors The wrong boom function moves Page 36 One or more of the on off functions do not operate Page 36 One of the proportional boom functions does not operate Page 37 More than one proportional boom function does not operate Page 37 35 wrong boom function moves Possible Cause Action Section For proportional functions the valve Check the valve cable and interface N A cable may not be correctly installed cable installation Refer to your For on off functions the interface cable installation manual may not be correctly installed y y Test the valve drivers 3 8 For proportional functions the raise and Check the hydraulics installation The N A lower lines from the Norac valve block raise lines must be connected to the B may not be correctly installed ports and the lower lines must be connected to the ports Perform a manual valve override test 3 7 One or more of the on off functions do not operate Possible Cause Action Section The outputs may not be correctly If you have not completed an Automatic 4 2 configured Setup then complete it now The interface cable may be damaged Test the valve drivers 3 8 a valve driver in the Control Panel may have failed The deadzone value may be set close to Check the deadzone setting 3 12 1
33. er channels the basic structure and behavior of the prompts is the same 3 return to the Run Screen press and hold the Setup or Sensor Display switch for two seconds Figure 19 Hydraulic Setup Menu for Left Channel Left Channel On Left Up Channel Dead Zone Left Up Channel Gain Left Down Channel Dead Zone Left Down Channel Gain The deadzone value relates to the smallest amount of boom movement the valve can produce Typical deadzone values for UC4 are as follows Function Valve Type Typical Min Wings Proportional 50 40 65 Main Lift Proportional 50 25 100 Main Lift On Off N A N A N A Roll Proportional 50 25 100 Roll Slant On Off N A N A N A Figure 20 Typical Deadzone Values If the deadzone value is outside of the specified range or to confirm if it has been calibrated correctly calibrate the deadzone as described in Section 4 13 1 48 3 12 2 Gains 1 Navigate to the hydraulic setup menu Run Screen gt toggle Setup until gt toggle Yes gt toggle Setup until Left Right etc gt toggle Yes 2 The left channel menu prompts are shown below For other channels the basic structure and behavior of the prompts is the same 3 To return to the Run Screen press and hold the Setup or Sensor Display switch for two seconds Lefton Left Channel On Sensor
34. for any consequential loss or damage of any kind This warranty is in lieu of all other warranties except as set forth above Any implied warranty merchantability or fitness for a particular purpose is hereby disclaimed This warranty is in lieu of all other warranties expressed or implied 82 NORAC Systems International Inc Phone 1 306 664 671 Toll Free 800 667 3921 3702 Kinnear Place Saskatoon SK 57 0 6 United States NORAC Inc Phone 1 763 786 3080 Toll Free 866 306 6722 6667 West Old Shakopee Road Suite 111 Bloomington MN 55438 Europe NORAC Europe Phone 33 426 470 442 Shipping Address Rue l hermitage 01090 GUEREINS France www norac ca NORAC 29
35. g difficulty obtaining a proper reading Test the Height Sensors Minimum Override Possible Cause Action Section This message is displayed when the Raise the target height N A target height is lower than the Minimum Height Mode allows Disabled Possible Cause Action Section Access to the system setup features If you need to access the setup features N A Automatic Install ReTune has been that have been disabled contact your disabled by the installer to avoid NORAC dealer unintentional system changes gt gt gt gt gt gt gt gt gt gt Possible Cause Action Section The control panel is busy with a task Wait for the arrows to disappear before N A that may take a few seconds activating any control panel switches Absent Possible Cause Action Section This message is typically shown on Test the communication 3 5 startup if one or more of the sensors are not communicating on the CANbus 2 3 Hydraulics boom will not raise or lower Possible Cause Action Section The hydraulics or electrical outputs are Perform the Boom Function Test 3 6 not functioning or are not installed correctly The boom will raise when it should lower or vice versa Possible Cause Action Section The raise and lower lines to the tilt Ensure the raise lines are connected to N A cylinders may be re
36. have 2 roll sensors installed with the cable facing the right hand wing the polarity will show until the sprayer has turned a corner or driven over a bump After the system has detected the IF polarity it will show Boom Type LWSF Typical RWSF Typical Center Pivot 80 80 40 200 High Pendulum 80 80 40 200 Trapeze 30 30 10 60 Rigid 30 30 10 60 Roll Sensor Type Orientation BF Polarity IF Polarity Passive Roll Cables facing right hand side POS NEG Passive Roll Cables facing left hand side NEG POS Active Roll JD Rods on right hand side NEG NEG Active Roll JD Rods on left hand side POS POS Active Roll LRC Right hand side NEG NEG Active Roll LRC Left hand side POS POS Figure 24 Typical Boom Geometry Values If the boom geometry values are incorrect or to confirm if they have been calibrated correctly calibrate the boom geometry as described in Section 4 14 3 12 4 Sensitivity From the Run Screen press Setup once 2 The sensitivity can be adjusted from to 10 with 5 being the default setting A lower number will reduce the system sensitivity and improve stability Higher settings will speed up the response and also create a greater demand on the hydraulics 3 For testing purposes the sensitivity should be set at the default value of 5 Once you are confident the system is working well then you can test the system a
37. he Temperature Sensor Passive Roll Sensor with a New Sensor Some Active Roll systems include a single passive roll sensor for the purpose of measuring the valve block temperature The following instructions are for replacing the single passive roll sensor on Active Roll systems l 2 68 Turn off the system power Remove the old Roll Sensor from the sprayer and install the new sensor in the same location Turn on the power The controller will recognize that it is missing a sensor serial number and will see that there is a new sensor serial number on the CANbus It will automatically assign the new serial number into the old serial number s location The previous calibration values will be used for the new sensor An Automatic Setup Retune or further calibration is not required for replacing the Roll Sensor 4 8 5 Control Panel Note Replacing the Control Panel will clear all the previous settings and require you to perform a new Automatic Setup Note Product warranty is recorded using the Control Panel serial number If you are replacing a Control Panel please report the change in serial number and owner information to Norac at service norac ca to update the warranty 1 Turn off the system power Remove the Control Panel from the sprayer and install the new Control Panel Turn on the power Perform an Automatic System Setup Section 4 2 69 4 9 Height Sensor Setup 4 91 Configuring the Sensors
38. he sensor clean them and reinstall them into the sensors If the transducer becomes dirty you can gently wash it out with clean water Do not use any high pressure water or chemicals on the transducer N A The rods may not be aligned correctly Check the Active Roll Sensor mounting 4 7 If the sensor is still reporting NR errors then it may be a faulty transducer or sensor Replace the sensor or send it to Norac for repair 4 8 4 24 Error message Possible Cause Action Section Failed sensor or CANbus Test the communication 3 5 Inaccurate or erratic roll reading Possible Cause Action Section The Active Roll Sensor may not be When the sprayer and boom center 4 12 configured or calibrated correctly section are level the BFh and IFh readings should be zero Check the Roll Sensor configuration and calibration The rods may not be aligned correctly Check the Active Roll Sensor 4 7 mounting Faulty sensor Replace the Roll Sensor 4 8 4 25 3 3 Temperature Sensor Test 1 Check the valve block temperature sensor reading From the run screen press and hold SETUP to cycle the display between the valve block temperature VT and the air temperature AT 2 If the units are set to metric cm height the temperature units will be Celsius If the units are set to imperial inch height the temperature units will be Fahrenheit
39. hold Auto Yes switch to begin the sensor detect procedure During the procedure you must hold the Auto Yes switch I If Auto Yes is released the system will ask you if you want to Retry Toggle Auto Yes to start the Sensor Detect portion of the Automatic Setup again 12 The system will now move the left boom and then the right boom to detect and assign the Height Sensor to the correct locations Boom Geometry Calibration 13 Press and hold the Auto Yes switch The system will move the booms into position for the boom geometry test 14 The system will then instruct you to exit the cab and pull the boom tip down towards the ground and then release the boom 15 When performing the Boom Geometry Calibration push the boom down approximately 2 3 feet 50 100 cm and then let go of the boom Do not push the boom tip into the ground when performing this test Ensure you stay a minimum of 3 feet Im away from any of the Height Sensors Note lf you wish to bypass the Boom Geometry Calibration toggle the Setup No switch before you push the boom The Boom Geometry Calibration may not be applicable for all sprayer types 54 Hydraulic Calibration 16 Hold the Auto Yes switch and continue holding it until you are instructed to release it The system will now calibrate the hydraulics 17 All boom sections will move If you accidentally release the switch hold the Auto Yes
40. installed in the following serial number order Serial Number Roll Sensor Location Lowest Intermediate Frame IF Middle Boom Frame BF Highest Reference Frame RF Figure 40 Enhanced Stability Roll Sensor Serial Number Order Turn on the power At this point the controller does not know the sensor is in a new location Assign each Roll Sensor serial number to the new location Section 4 9 1 The previous calibration values will be used for the new sensor An Automatic Setup Retune or further calibration is not required for replacing the sensor 67 4 8 4 Roll Sensors Active Roll Moving the Ultrasonic Roll Sensor to a Different Location If you are moving the Active Roll Sensor to a new location or moving a Height Sensor to the Active Roll location you will be required to perform a new Automatic Setup Replacing the Ultrasonic Roll Sensor with a New Sensor l 2 Turn off the system power Remove the sensor from the sprayer and install the new sensor in the same location Turn on the power The controller will recognize that it is missing a sensor serial number and will see that there is a new sensor serial number on the CANbus It will automatically assign the new serial number into the old serial number s location The previous calibration values will be used for the new sensor An Automatic Setup Retune or further calibration is not required for replacing the sensor Replacing t
41. l greatly improve your spraying height accuracy and protect the boom against damage in a wide variety of field conditions However under some circumstances performance may be limited The operator of the sprayer must remain alert at all times and override the automatic control when necessary Important Under no circumstances should service work performed the machinery while the UC4 Spray Height Control system is in Automatic Mode Always ensure that the UC4 Spray Height Control system is powered down or in Manual Mode e Before leaving the operator s seat e When transporting the machine Before working on any part of the booms e Set the UC4 system to Manual Mode e Turn the sprayer engine off Do not operate this system before e Reading and understanding the operator s manual e Thoroughly understanding the machine operation 1 2 Related Documents The following documents should be used for reference in addition to this service manual e UC4 Operator Manual e UC4 Cable Guide e UC4 Installation Manual for your sprayer type e UC4 End User Installation Manual for your sprayer type if applicable 1 3 How to Use This Manual This manual is designed to assist technicians with troubleshooting the UC4 Height Control System To use this guide follow these steps 1 Gather some initial information Section 1 4 2 Identify the symptom Section 2 3 Follow the list
42. lation manual for mounting instructions specific to your sprayer type 4 The roll sensor must be oriented so the cable faces the right hand wing Figure 36 Example of Reference Frame Roll Sensor Mounting 63 4 7 Roll Sensor Mounting Active Roll 4 7 11 John Deere Active Roll NOTE If you have Control Panel firmware version 7D or later you must install the rods on the right hand side of the sprayer Ensure the ultrasonic sensor is mounted as shown in Figure 37 below It must not be mounted directly behind the wheel 2 The frame target must be located 41 104 cm below the bottom of the sensor as shown in Figure 38 The Frame target must be aligned 2 to the left side of the centerline and must be perpendicular to the sensor 3 The spring target must be located 16 41 cm below the bottom of the sensor as shown in Figure 38 and must be perpendicular to the sensor The spring target rod must be trimmed so it is 2 5 cm past the edge of the sensor as shown in Figure 39 Sensor Bracket Spring Target Frame Target 64 Figure 37 Typical John Deere Active Roll Sensor Mounting ET SENSDR BRACKE i 5 SENSOR CENTER BOOM INE 5 CENTER DAM j FRAME F TARGET Figure 39 Active Roll PARALLEL LIFT FRAME Figure 38 Active Roll Target Location Sensor and Rod
43. lect the sprayer type using the switch The types are listed in Section 4 16 When the desired type is shown confirm the selection with the Auto Yes switch 4 f you wish to exit the install now before changing any settings toggle the Setup No switch 5 The system will now erase the previous settings and load the default settings for your sprayer type 53 Switch Test 6 The system will instruct you to press the boom function switches on the sprayer controls Press each switch momentarily as instructed on the terminal 7 When you press each of the sprayer s switches the system will check if the interface wiring is correctly installed Note If you wish to bypass the Switch Test toggle Setup No before you press any switches Some sprayer types do not support a wiring test or they may support a different style of test If you do not see any of the messages in this step simply continue as prompted by the panel Sensor Detect 8 You will be instructed to place your booms so the nozzles are 35 90cm from the ground When the measured distance is 35 90cm toggle Auto Yes At this point the system will calibrate the height of each sensor to 35 90cm 9 If you are not able to get the height to exactly 35 you can adjust the offset height Section 7 after the Automatic Setup You must get the booms reasonably close to 35 or the Automatic Setup may encounter problems 10 Press and
44. ll Sensors are mounted 45 correctly to the boom frame you will correctly not see any change in the BFh value when the boom rolls over The Roll Sensor serial numbers are not Ensure the correct serial number is 4 10 mapped to the correct locations entered for each Roll Sensor location Faulty Roll Sensor Replace the Roll Sensor 4 8 2 20 3 2 2 Note Enhanced Stability Perform a visual check of the sensors to look for any physical damage or improper mounting Refer to Section 4 6 for proper Roll Sensor mounting techniques Navigate to the Roll Sensor reading of the BF IF and RF roll sensors from the run screen press Sensor Display until More gt press Yes gt press Sensor Display until Roll 2press gt Sensor Display until BFh or When the boom is stable the BFh IFh and RFh readings should be stable within a maximum of 10 points While viewing the BFh reading with an assistant push down on the boom tip on one side hold for a second and let go You should see a continuous change in the BFh reading If you do not have someone else to help you push the boom down you can try manually lifting one boom to force the center section to roll slightly Ensure the Roll sensors are mounted with highest serial number on the reference frame RF middle serial number on the boom frame BF and the lowest serial number on the intermediate f
45. lug the non communicating sensor from the CANbus Plug the sensor into a connector that previously had a known communicating sensor Turn on the power Check if the sensor is now communicating Note sensor will still be assigned to its previous location For example if you moved the left outer sensor to the right outer location the left outer sensor will still show up as the left outer sensor The controller will not know that you have moved the sensor 6 If the sensor now communicates then it would indicate that there is a problem with the cable that it was previously connected to 7 If the sensor still does not communicate then it would indicate a problem with the sensor itself 30 3 5 5 The following test will check for any short circuits in the cabling 2 Disconnect all the height sensors and roll sensors from the CANbus Note If you are also removing the sensors from their mounting brackets ensure you write down the serial number and location of each sensor so it can be installed back in its previous location 3 There are two connectors on the UC4 Control Panel The 4 pin Amp connector P4 is the CANbus Disconnect P4 from the Control Panel Figure 3 Figure 3 Typical Control Panel Installation 4 Using an ohm meter test the resistance of every pin combination on connector P4 as shown in Figure 3 and Test Point Figure 8 The pin numbers a
46. m Geometry Calibration the display will prompt you to exit the cab and manually push either boom tip down Exit Cab push boomtip nearto 1 ground 6 Do not walk near the sensors when approaching the boom Stay least 3 feet from the sensor to not induce a measurement error 7 Push either boom tip down 3 feet 30 90 cm for a moment and then let go Do not push the boom to the ground 8 Typical boom geometry values are shown in Section 3 12 3 4 15 Updating the Firmware The UC4 Control Panel firmware can be updated by your local NORAC Dealer or by contacting NORAC 78 4 16 Sprayer Types Type Sprayer Model Type Sprayer Model 1 Figure 44 Sprayer Types 79 4 17 Maintenance NORAC Spray Height Control system requires very little maintenance but there a few pray Heig 7 4 procedures that will ensure the system continues to work correctly for many years Before each day It is highly recommended that the sprayer friction pads are greased To ensure optimum performance this should be done daily This will ensure the boom is pivoting separately from the sprayer It is very important to keep the friction pads greased on Active Roll systems Ensure the height sensor breakaway brackets are functioning correctly Apply grease to the moving parts if necessary to ensure they return to center after a break aw
47. ns up and down manually for five minutes to warm the oil e For trailed sprayers ensure any hydraulic flow controls are adjusted for normal field operation e Changing the hydraulic flow controls after or during the system setup will affect the performance Starting the Retune 1 Navigate to the Retune Run Screen gt toggle Setup until Retune gt toggle Yes Hydraulic Calibration Hold the Auto Yes switch and continue holding it until you are instructed to release it The system will now calibrate the hydraulics 2 All boom sections will move If you accidentally release the switch hold the Auto Yes switch to resume 3 The display will show messages as it is calibrating the boom Refer to Figure 25 description of calibration messages 4 When the setup is finished the display will show Done 56 4 4 Height Sensor Mounting Height Sensors can be mounted several different ways depending on the sprayer and boom type The following mounting instructions are intended for general reference only Your installation manual may contain specific Height Sensor mounting instructions Note By default the controller assigns the serial numbers in order from left to right lowest to highest If the serial numbers are not in the correct order the controller will reassign them during the Automatic Setup It is recommended to install the sensors in order for troubleshooting purposes howeve
48. nsor 58 45 Roll Sensor Mounting Passive Roll Before installing the Roll Sensors you must determine if your sprayer has a trapeze style center pivot style or high pendulum style boom Trapeze HH 1 Links Figure 29 Trapeze Style Boom Center Pivot Figure 30 Center Pivot Boom High Pendulum Figure 31 High Pendulum Boom 59 4 5 1 Trapeze Suspended Booms Mount the Roll Sensor with the temperature probe to the trapeze support chassis and the other to the trapeze link boom frame 2 For optimal performance minimize the distance from the Roll Sensors to the pivot point A amp B Ensure the Roll Sensors are relatively level when the sprayer boom and chassis are level 4 Both Roll Sensor CANbus cables should be pointing towards the right hand wing of the sprayer Figure 32 Roll Sensor Mounting on a Trapeze Suspended Boom 60 4 5 2 Center Pivot Booms I Mount the Roll Sensor with the temperature probe to the chassis non pivoting portion of the sprayer and the other Roll Sensor to the boom frame 2 For optimal performance minimize the distance between the Roll Sensors A and minimize the height from each Roll Sensor to the pivot point B Ensure the Roll Sensors are relatively level when the sprayer boom and chassis are level 4 Both Roll Sensor cables should be pointing towards the right hand wing of the sprayer Figure 33 Roll Sensor Mounting on a Center Pi
49. nsor in the same location 3 Turn on the power The controller will recognize that it is missing a sensor serial number and will see that there is a new sensor serial number on the CANbus It will automatically assign the new serial number into the old serial number s location 4 The previous calibration values will be used for the new sensor An Automatic Setup Retune or further calibration is not required for replacing the sensor 66 4 8 2 Roll Sensors Passive Roll Replacing a Roll Sensor with a New Sensor l 2 4 8 3 Turn off the system power Remove the old Roll Sensor from the sprayer and install the new sensor in the same location Turn on the power The controller will recognize that it is missing a sensor serial number and will see that there is a new sensor serial number on the CANbus It will automatically assign the new serial number into the old serial number s location The previous calibration values will be used for the new sensor An Automatic Setup Retune or further calibration is not required for replacing the Roll Sensor Roll Sensors Enhanced Stability Replacing a Roll Sensor with a New Sensor l 2 3 Turn off the system power Remove the old Roll Sensor from the sprayer The two existing Roll Sensors and the new Roll Sensor must all be installed in the correct serial number order This may involve moving the two existing Roll Sensors to a new location The Roll Sensors must be
50. ometry Calibration The boom geometry calibration fails does not finish or finishes before the boom is pushed Possible Cause Action Section Incorrect Roll Sensor mounting Check the Roll Sensor mounting as 45 shown in the installation manual for your kit Poor Height Sensor readings Test the Height Sensors 3 1 Poor Roll Sensor readings Test the Roll Sensors 3 2 The boom may not be pivoting freely Check the sprayer mechanical 3 1 components 2 5 5 Hydraulic Calibration The hydraulic calibration times out or gives an error Possible Cause Action Section Poor calibration target Ensure you are performing the calibration over bare level gravel or soil N A If the system hangs up during the Automatic Setup release the Auto switch and move the booms to normal working height and or move the sprayer forward or backward a little Press and hold the Auto switch to resume N A Poor Height Sensor readings Test the Height Sensors 3 1 Poor Height Sensor mounting 44 Check the Height Sensor mounting Poor Roll Sensor readings Test the Roll Sensors 3 2 Poor Roll Sensor mounting Check the Roll Sensor mounting 45 Excessively windy conditions If you are trying to calibrate in excessively windy conditions the boom may always be moving due to the wind and the system will not be able to calibrate correctly Calibrate the s
51. on and repeat the sensor test Check the Height Sensor mounting 44 If the sensor is still reporting errors then it may be a faulty transducer or sensor Replace the sensor or send it to your local Norac service center for repair 4 8 1 Error message Possible Cause Action Section Failed sensor or CANbus Test the communication 3 5 Inaccurate or erratic height reading Possible Cause Action Section The sensor may be reading off the Check the sensor mounting Try 44 moving the sensor to different location and repeat the sensor test Reading off the boom may be more apparent when the system is in crop mode The sensor offset height has not been Set the sensor heights 7 set correctly The Height Sensor serial numbers are Ensure the Height Sensors are properly 4 9 1 not mapped to the correct locations configured If the sensor is still reporting an Replace the sensor or send it to your 4 8 1 inaccurate or erratic reading then it may be a faulty transducer or sensor local Norac service center for repair 3 2 Roll Sensor Perform the applicable Roll Sensor Test for your system e Passive Roll Section 3 2 1 e Enhanced Stability Section 3 2 2 e Active Roll Section 3 2 3 3 2 1 Passive Roll 1 Perform a visual check of the sensors to look for any physical damage or improper mounting Refer to Section 4 5 for pro
52. or R3 reading should be 12 VDC 2 Measure the voltage between pin GND and pin 5 12 VDC on connector P16 The reading should be 12 VDC 27 3 5 Communication 3 5 1 Troubleshooting the CANbus Check Communication Status Section 3 5 2 Perform a Visual Check Section 3 5 3 Y Move the Sensor to a New Location Section 3 5 4 Y Perform an Ohm Test Section 3 5 5 Y Perform a Voltage Test Section 3 5 6 Y Reconnect Sensors to the CANbus Section 3 5 7 Note Section 3 5 8 contains schematics and an overview of the CANbus system 28 3 5 2 Checking Communication Status Use the methods below to determine if you have any sensors that are not communicating If you determine that there are communication problems then start testing the CANbus as described in Section 3 5 3 You must ensure that the sensors have all been configured in the system by previously going through an Auto Setup or Quick Setup If they have not been initially configured they will not show up on the CANbus Error indicator screens NC no communication error messages will appear on the main run screen at the time of the error if there are any sensors that are not communicating The system will also check the communication status of all the sensors on power up If any of the sensors are not communicating it will show X Absent where
53. ors 3 1 incorrect The boom moves all the way to the top in Crop Mode Possible Cause Action Section The sensors may be reading off of the Ensure the sensors are aligned and 44 boom in Crop Mode mounted correctly Poor Height Sensor readings Test the Height Sensors 3 1 2 5 Automatic Setup Retune Problems When performing an Automatic Setup or Retune e The sprayer must be over level bare dirt or gravel Do not perform the auto setup over vegetation concrete water or snow e The hydraulic system should be under a normal load and at a normal working temperature The oil should be warm and the sprayer s engine should be normal working RPM Start the solution pump if possible For Retune problems only follow Section 2 5 5 below 2 5 1 Starting the Automatic Setup Ensure you have selected the correct sprayer type Refer to Section 4 16 for a list of sprayer types A list of connected sensors will be displayed Ensure the list matches the sensors included in your system Automatic Setup does not show all the correct sensors are connected Possible Cause Action Section Failed sensor or CANbus Test the communication 3 5 2 5 2 Switch Test When you press the sprayer s switches during the switch test the system will check for voltage on the corresponding input line It will show OK for each correct switch press If it sees a voltage on another input line it will let you know there is an e
54. ossible Cause Action Section Automatic System Setup has not been If you have not completed an Automatic 4 2 completed Setup then complete it now Incorrect settings Check the settings 3 12 Poor Height Sensor readings Test the Height Sensors 3 1 Poor Roll Sensor readings Test the Roll Sensors 3 2 Failed Temperature Sensor Test the Temperature Sensor 3 3 There may be a problem with the Check the sprayer mechanical 3 11 mechanics of the sprayer components Failed sensor or CANbus Test the communication 3 5 Incorrect Roll Sensor mounting Check the Roll Sensor mounting as 4 5 shown in the installation manual for your kit Incorrect Height Sensor mounting Check the Height Sensor mounting as 44 shown in the installation manual for your kit The system may not be driving a boom Perform the Boom Function Test 3 6 function or driving the wrong boom function Low or inconsistent boom speeds Test the boom speeds 3 10 The boom does not appear to level Automatic Mode Possible Cause Action Section The sensitivity setting may be too low Check the sensor height readings from N A the run screen if it differs from the target height then try turning up the sensitivity The default tolerance for a sensitivity setting of 5 is 6 cm 2 5 inches The Deadzone setting may be calibrated Check the Deadzone settings 3 12 1 incorrectly The sensor offset heights may be Test the Height Sens
55. per Roll Sensor mounting techniques 2 Navigate to the Roll Sensor reading of the BF and IF roll sensors from the run screen press Sensor Display until More gt press gt Sensor Display until Roll gt press gt Sensor Display until BFh or IFh 3 When the boom is stable the BFh and IFh readings should be stable within a maximum of 10 points 4 While viewing the BFh reading with an assistant push down on either boom tip hold for a second and let go You should see a continuous change in the BFh reading Note If you do not have someone else to help you push the boom down you can try manually lifting one boom to force the center section to roll slightly Refer to the following sections for troubleshooting if you experience any of the following errors Error message or Page 20 Erratic Roll Sensor reading Page 20 BFh reading does not change Page 20 Error message Possible Cause Action Section Failed sensor or CANbus Test the communication 3 5 Erratic Roll Sensor reading Possible Cause Action Section The Roll Sensor reading is erratic and Ensure the Roll Sensors are mounted 45 not stable when the boom is stable correctly Replace the Roll Sensor 4 8 2 BFh reading does not change Possible Cause Action Section If the BF Roll Sensor is not mounted Ensure the Ro
56. r it is not necessary Height Sensor Mounting Guidelines The following rules should be followed for both the wing sensors and the main lift middle sensor I In its lowest position the sensor must be 9 inches 23 cm or more from the ground A The centerline of the acoustic cone should be approximately vertical at normal operating heights A 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 Ensure there are no other obstructions with a 12 inch 23 cm diameter circle projected directly below the sensor D Ultrasonic Acoustic Cone D Figure 26 Height Sensor Mounting Guidelines 57 6 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 controller is switched from soil to crop mode Figure 27 Figure 27 Sensor Reading Off Boom 7 Avoid mounting the main lift sensor over or near a wheel track Measurements from the wheel track do not provide an accurate crop height and will cause measurement and control error 8 Ensure that there are no hoses or sprayer components that can move underneath the main lift sensor during the full range of the main lift Figure 28 Example Mounting of the Main Lift Se
57. rame IF Refer to the following sections for troubleshooting if you experience any of the following errors Error message or Page 22 Erratic Roll Sensor reading Page 22 BFh reading does not change Page 22 21 Error message Possible Cause Action Section Failed sensor or CANbus Test the communication 3 5 Erratic Roll Sensor reading Possible Cause Action Section The Roll Sensor reading is erratic and Ensure the Roll Sensors are mounted 4 6 not stable when the boom is stable correctly Replace the Roll Sensor 4 8 3 BFh reading does not change Possible Cause Action Section If the BF Roll Sensor is not mounted Ensure the Roll Sensors are mounted 4 6 correctly to the boom frame you will correctly not see any change in the BFh value when the boom rolls over The Roll Sensor serial numbers are not Ensure the correct serial number is 4 11 mapped to the correct locations entered for each Roll Sensor location Faulty Roll Sensor Replace the Roll Sensor 4 8 3 22 3 2 3 Note Active Roll Perform a visual check of the sensors to look for any physical damage or improper mounting Refer to Section 4 7for proper Roll Sensor mounting techniques Ensure the sprayer and center section of the boom is level View the Roll Sensor readings of the BF and IF Roll Sensors from the run screen press Sensor Display un
58. re labeled inside the connector The following table lists the values for each pin combination Pin Pin Value 2 Open Circuit Open Circuit Open Circuit Open Circuit 750 100 Open Circuit w Ni N A A w A 0 Figure 4 Typical Norac Bus Ohm Test Values 5 If you measured differently than the values in Figure 4 continue by testing at the next connection towards the rear of the sprayer Test Point 2 3 4 etc Figure 8 until you isolate the problem cable 31 3 5 6 3 5 7 Voltage Test The following test will check for continuity in the cabling Ensure the height sensors and roll sensors are still disconnected from the CANbus Reconnect the 4 pin Amp connector P4 to the Control Panel Figure 3 Using a voltmeter measure the voltage of the following pin combinations at each of the sensor connections Test Point 4 5 7 8 and 9 Figure 8 Pin Pin Value 4 L2 LLL 05 6VDC 3 3 213 VbC 4 005 6 0 Figure 5 Typical Norac Bus Voltages If you measured differently than the values in Figure 5 continue by testing at the next connection towards the front of the sprayer Test Point 6 3 2 etc Figure 8 until you isolate the problem cable Reconnect Sensors to the CANbus Once you have confirmed the CANbus cabling is ok by performing the Ohm Test and Voltage Test you can start reconnecting the sensors one at a time to the CANb
59. rror The system does not detect a switch press or indicates there is an error Possible Cause The interface cable may not be correctly Check the inputs 3 9 installed Note Not all sprayer types will perform the Switch Test 2 5 3 Sensor Detect During this test the system will set the sensors height at 35 inches 90 cm and then move the booms to determine which sensors are located where on the sprayer The left or right wing does not move during the sensor detect test Possible Cause Action Section The hydraulics are not functioning or not installed correctly The electrical outputs to the valves are not functioning or are installed incorrectly Perform a boom function test 3 6 The left and right wings move up but the sensor detect test does not finish or gives an error Possible Cause Action Section Poor Height Sensor readings Test the Height Sensors 3 1 The left and right wings will move down Perform a boom function test 3 6 after the sensor detect test If the test times out or stalls after the right wing moves up then the down functions may not be functioning correctly 2 5 4 Boom Geometry Calibration When calibrating the boom geometry push the boom down approximately 2 3 feet 50 100 cm and then let go of the boom Do not push the boom tip into the ground when performing this test Note Not all sprayer types will perform the Boom Ge
60. s gt toggle Sensor Display until 3 Set the roll sensor reading to zero using the switch The switch will increase the reading the switch will decrease the reading 4 Repeat for the Intermediate Frame Roll Sensor IF To return to the Run Screen press and hold the Setup No or Sensor Display switch for two seconds 75 4 13 Output Channel Valve Setup 4 13 1 Calibrating the Deadzone Note Note Note 76 Ensure you are in a location that is relatively level and where the sensors are over bare soil or gravel Do not conduct the calibration over standing crop weeds grass wet concrete water or snow Ensure the sprayer is at operating temperature and RPM Turn on the solution pump if possible Navigate to the hydraulic setup menu Run Screen gt toggle Setup until More gt toggle Yes gt toggle Setup until Left Right etc gt toggle Yes Select the DZ screen for the boom function you wish to calibrate Press and hold the Manual switch Continue to hold it until the boom stops moving and the live reading of the distance travelled stabilizes When properly tuned the distance travelled should be 1 2 inches 2 5cm Adjust the deadzone value until the distance travelled is within the range Alternatively you can press and hold the Auto Yes switch to automatically calibrate the deadzone Typical deadzone values ar
61. t higher sensitivities Some sprayer types may be unstable at higher sensitivities 3 12 5 Crop and Soil Mode From the Run Screen press Setup twice 2 Soil Mode allows the sensors to read a height from the spray nozzles to the ground whereas Crop Mode will read the height from the spray nozzles to the top of the crop canopy 3 For testing purposes the system should initially be set to Soil Once you are confident the system is working well in Soil Mode then you can test the system in Crop Mode For more information on Crop and Soil Mode refer to the UC4 Operator Manual 5 4 Reference 41 Menu Structure Map RF of f NHS 10 Ifh 2 10 IF 32080 Units cm BFh 1 More 2080 MLht 55 1 Rol ML 12368 TUM Sensor Ri ght Display RI ht 57 Left RI 12369 LI ht 55 a Yes ROht 56 LI 12367 Ti ps On 12370 LOht 54 70 12366 55 4 57 56 54 55 4 55 5 Soi On x Ret une 48 37 Left Ri ght Mai n Rol On Ot her Rol OnU 1021 10 RemS 1 02 20 TKP 72 Install 10 402 5 7 20 IKP 51 KP 10 Use the switch to change settings Press and hold SETUP or SENSOR D
62. thout the secondary pressure and tank lines the Spray Height Control System will operate but it will not perform to its full capabilities due to slower boom speeds Refer to the installation manual for installation instructions Roll Cylinder Mounts Ensure there is no free movement in the top roll cylinder mount Check the mounting bolts on the cylinder and ensure they are tight A common problem is that the top hole where the roll cylinder mounts will become loose and eventually oblong This allows the cylinder to move without actually moving the boom It is recommended that this pin always be welded to prevent the hole from wearing If the pin is welded inspect the weld for cracking If there is free movement on any of the other cylinder mounts they should have gussets added or spacers added to provide more strength and reduce free movements of the cylinder Top cylinder mount Bottom cylinder mount Figure 14 Roll Cylinder Mounts 45 Ensure the top roll cylinder pin does not bind the boom frame as shown in Figure 15 a Lu e 3 Cnr be w 2 ULE Figure 15 Example of Roll Cylinder Pin Binding Main Pivot Bearing Check for wear on the main pivot bearing The bearing can come loose and move out of place It is essential that this bearing remain tight and be inspected for proper pivot Loose bearing can move freely Figur
63. til More gt press Yes gt press Sensor Display until Roll gt press Yes 2press Sensor Display until BFh or When the sprayer and boom are level the BFh and IFh readings should be zero If they are not then zero the roll readings While viewing the BFh reading press the roll CW switch on the sprayer to manually roll the boom over to one side You should see a continuous change in the BFh reading without any NR errors At the very extreme roll position the roll sensor might display some NR errors this is normal Manually roll the boom over to the other side You should see a continuous change in the BFh reading without any NR errors Refer to the following sections for troubleshooting if you experience any of the following errors Error message Page 24 Error message Page 25 Inaccurate or erratic roll reading Page 25 23 Error message Possible Cause Action Section The sensor may be saturated with water Allow the sensors to dry out You can also remove the sensor foams squeeze the water out of them and reinstall them into the sensors The system can be left running while the sensors dry out N A The sensor may be covered in mud or debris The sensor foams are designed to keep mud and debris off of the sensor transducer If the sensor foams become dirty you can replace them or remove them from t
64. us to ensure each sensor is communicating l 2 32 Reconnect one sensor to the CANbus Check if the sensor is communicating If the sensor is not communicating then remove it from the CANbus and set it aside to be replaced If the sensor is communicating then leave it connected to the CANbus Repeat steps to 4 for each of the sensors until they are all connected to the CANbus Replace any sensors that do not communicate 3 5 8 CANbus Overview The NORAC UC4 CANbus consists of four wires that are connected to all of the sensors in the system Ground 12 VDC and The sensors and the control panel all communicate with each other via the CANbus The controller knows where each sensor is located by its serial number and not by the physical location that it is plugged into Figure 6 shows a simplified schematic of the network cable Figure 6 Simplified Network Schematic The CANbus has two 150 termination resistors incorporated into the connector that plugs into each of the outer height sensors at the wing tips Figure 7 The two termination resistors are in parallel for a total termination resistance of 75 O cE S j D dl iN 3 Figure 7 Location of Termination Resistors uU 33 Figure 8 shows typical system layout with test points labeled for
65. versed the B ports and the lower lines are connected to the ports Perform the Boom Function Test 3 6 The hydraulic oil is overheating Possible Cause Action Section Using the UC4 system at higher Try lowering the sensitivity N A sensitivities may create a greater demand on the sprayer s hydraulics The hydraulic system may require an An open center valve block option is N A open center valve block available from Norac which may reduce heating on certain hydraulic systems Contact your NORAC dealer for more details The boom will creep up or down Manual Mode Possible Cause Action Section The raise and lower lines to the tilt Ensure the raise lines are connected to N A cylinders may be reversed the B ports and the lower lines are connected to the ports There may be an internal problem with If possible try removing any foreign N A the NORAC valve block Some possible objects in the valve The valve block causes are a sticky valve worn valve may also need to be repaired or faulty check valves or a foreign object replaced stuck in the valve block This may be caused by a problem with Check the sprayer hydraulics Check if N A the sprayer s hydraulic system the tilt cylinders are leaking and replace the seals if needed 2 4 Performance The boom is unstable erratic or sluggish in Automatic Mode P
66. vot Suspended Boom 61 4 5 3 62 High Pendulum Booms When mounting the Roll Sensors mount one to the boom frame and one to the chassis non pivoting portion of the sprayer For optimal performance minimize the distance between the Roll Sensors and minimize the height from each Roll Sensor to the pivot point A amp B If the system is driving the slant function the Roll Sensor must be mounted to the boom frame as shown below If slant control is not enabled the boom frame Roll Sensor should be mounted on or near the top pendulum pivot point Ensure the Roll Sensors are relatively level when the sprayer boom and chassis are level Both Roll Sensor CANbus cables must be pointing towards the right hand wing of the sprayer Figure 34 Roll Sensor Mounting ona High Pendulum Boom 4 6 Roll Sensor Mounting Enhanced Stability The Roll Sensors must be installed in the following serial number order Serial Number Roll Sensor Location Lowest Intermediate Frame IF Middle Boom Frame BF Highest Reference Frame RF Figure 35 UC4 Enhanced Stability Roll Sensor Serial Number Order 2 Mount the boom frame BF and intermediate frame IF Roll Sensors as described in the Passive Roll Sensor Mounting Section 4 5 3 Mount the reference frame RF roll sensor on the chassis of the sprayer close to the rear of the sprayer An example of this is shown in Figure 36 Please refer to your instal
67. ystem in less windy conditions N A Problem with the sprayer mechanics Check the sprayer mechanics The sensors went out of range during the calibration If the system hangs up during the Automatic Setup release the Auto switch and move the booms to normal working height Press and hold the Auto switch to resume N A The boom was not set close to 35 90 cm during the Sensor Detect Restart the Automatic Setup and ensure the boom is at 35 90 cm for the Sensor Detect N A 3 Test Procedures 3 1 Before Height Sensor Test testing the Height Sensors perform a visual check of the sensors to look for any physical damage or improper mounting Refer to Section 4 4 for proper Height Sensor mounting Ensure the system has previously completed an Automatic Setup If the system has not passed the Sensor Detect portion of the Automatic Setup then the sensors may not be configured to the correct locations Perform this test over level bare soil or gravel The system must be in Manual and Soil mode Level the booms and adjust the main lift to 10 inches 25 cm above the ground or to the bottom of the stroke Press Sensor Display to navigate to the Left Outer height reading screen Check the height reading of the Left Outer Height Sensor while raising the left boom manually up to 80 inches 200 cm You should see a continuous and accurate height

Spray Height Controller UC4+ SERVICE MANUAL 2012

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