Avery Weigh-Tronix FLSC 05 Service Manual

CONFIDENTIAL

FLSC 05 Forklift Scale

with FLI 225 Instrument

Service Manual

original instructions

AWT 35-500234

Issue AK

Avery W eigh-T ronix is a t rademark of the Illinois Tool Works group of comp anies whose ultima te par ent
company is Illinois T ool Works Inc (“Illinois T ool W orks”). Copyright © 2013 Illinois T ool Works. All rights
reserved.

No part of this publication may be reproduced by making a facsimile copy, by the making of a copy in three
dimensions of a two-dimensional work and the making of a copy in two dimensio ns of a three-dimensiona l work,
stored in any medium by electronic means, or transmitted in any form or by any means, including electronic,
mechanical, broadcasting, recording or otherwise without the prio r written consent of the copyright owner , under
license, or as permitted by law.

This publication was correct at the time of going to print, however Avery Weig h-T ronix reserves the right to alter
without notice the specification, design, price or conditions of supply of any product or service at any time.

FLSC05_FLI225_s_en_500234.book

Table of Contents

page

Manual Revision History ...........................................................................................................................6

Chapter 1 General information and warnings ............................................................. ............................ 7

About This Manual .............................................................................................................7

Text conventions .........................................................................................................7

Special messages .......................................................................................................7

Installation ....................................... .................................... ...................................... .........8

Routine Maintenance .........................................................................................................8

Cleaning the Machine ........................................................................................................8

Training ..................................... ................................................................ .........................9

Keypad Operation ..............................................................................................................9

FCC and EMC Declarations of compliance .......................................................................9

Chapter 2 Introduction ............................................................................................................................ 12

Front Panel and Keys ......................................................................................................12

Data Entry Procedure ...................................................................................................... 13

Display and Annunciators ................................................................................................13

FLR 100 Remote Display Option .....................................................................................14

Chapter 3 Overview of the Menus and Modules ................................................................................... 15

Accessing and Exiting the Menus ....................................................................................16

Overview of the Modules .................................................................................................17

User Settings .............................................................................................................17

About FLI 225 ............................................................................................................17

Audit Trail Viewer ............... ... ... ... .... ...................................... .... ... ... ... .... ... ... ... ... .... ... 17

Audit Trail Counter ....................................................................................................17

Diagnostics Manager .................................................................................................17

Supervisor Settings ................................................................................................... 18

Setup Manager ..........................................................................................................18

Chapter 4 User Settings Module ............................................................................................................ 19

Time ....................................... ................................................................ ..........................19

Date .................................................................................................................................20

Display Contrast ...............................................................................................................20

Seal Status .......................................................................................................................21

Chapter 5 About FLI 225 Module ............................................................ ................................................22

Chapter 6 Audit Trail Viewer Module ..................................................................................................... 23

View Audit Trail Record ...................................................................................................23

Print the Audit Trail ... ...................................... .... ... ... ... .... ... ... ....................................... ...24

Audit Trail Counter ............. .... ..........................................................................................24

Chapter 7 Diagnostics Manager Module ............................................................................................... 25

Communications .............................................................................................................. 25

Keypad ...................................... ................................ .................................... ...................27

Display .............................................................................................................................27

Analog Option Card .. ... ... ... .... ... ... ....................................................................................27

Digital Carriage ................................................................................................................27

FLJ 100 Status ..........................................................................................................28

View FLJ 100 Counts ................................................................................................28

Inputs ...............................................................................................................................29

Seal Switch ......................................................................................................................29

Error Log Viewer ..............................................................................................................29

FLSC 05 w/FLI 225 Instrument Service Manual 3

Chapter 8 Supervisor Settings Module .............................................. ....................... .......................... ...31

Zero Band ................................. ... ... ... .... ...................................... .... ... ... ... .... ... ... .............31

Timeouts ..........................................................................................................................32

Prompt Timeout .........................................................................................................32

Shutdown Timer ........................................................................................................32

Identification .............................................................................................................33

Chapter 9 Setup Manager Module ...................................................... ....................................................34

Calibrate the FLSC 05 with FLI 225 ... ....... .......................................................................36

Determining if Calibration is Needed (NA) ................................................................37

Determining if Calibration is Needed (EU) ................................................................40

Gravity Compensation ........................ .......................................... ... ..........................44

Zero ...........................................................................................................................46

Span .......................................................................................................................... 46

FLSC Calibration .......................................................................................................47

Scale ...................................... ................................................................ ..........................55

Units ..........................................................................................................................56

Settings .....................................................................................................................57

Filtering ..................................... ....................... ...................... ....................... .............58

Motion/AZT .................................. .................................................... ..........................59

Auto Tare Clear .........................................................................................................61

Ranges ...................................................................................................................... 61

Communications .............................................................................................................. 64

Print Strings . ...................................... .... ... ... ... .... ... ... ....................................... ... ... ... .......66

Print String Editor ............... ... ... ....................................... ... ... .... ... ... ... .... ...................67

Strings to Print ....................... ... ... .... ...................................... .... ... ... ... .......................71

App Selection ..................................................................................................................72

Country Code ...................................................................................................................73

Miscellaneous ..................................................................................................................74

Inputs .................................. ................... .................... ................... ................... ..........74

Reset System ............................................................................................................75

Passwords ....................................... ....................................................... ................... 76

Display ...................................... ....................... ...................... ....................... .............76

Time / Date ................................................................................................................77

Enable or Disable Keys ............................................................................................. 77

Diagnostics Tools ......................................................................................................78

Chapter 10 Extras ....................................................................................................................................79

Making a Ramp for Tilting the Forklift ..............................................................................79

Calculating New Lift Capacity .......................................................................................... 80

Class II 5,000 lb Models ........................................ .... ... ... ... ... ....................................81

Resistance Test for FLSC Weigh Bars ............................................................................81

Replacing Weigh Bars on the FLSC 05 Carriage ............................................................ 82

Disassembly of the Carriage .....................................................................................82

Reassembly ................................. ....................... ....................... ...................... ..........85

Tightening Procedure ................................................................................................90

Installing the FLW 100 Wireless Carriage Option ........................ .................................... 91

Charging the Battery .................................................................................................97

Optional Scanner Connection ................ ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... 98

RM-200 Connection ........ ... .... ... ....................................... ... ... ... ... .... ... ... ..........................98

SMA Protocol .................................................................................................................100

Forklift Scale Grounding ................................................................................................102

Testing Procedure ...................................................................................................102

Chapter 11 Technical Illustrations ....................................................................................................... 103

Introduction ....................................................................................................................103

FLI 225 Digital System Block Diagram ..........................................................................103

Exploded View of FLSC 05 Carriage Assembly ............... ... ... ... ... ..................................104

4 FLSC 05 w/FLI 225 Instrument Service Manual

Carriage Assembly Parts List .........................................................................................105

Exploded View of FLI 225 AWT05-500348 ....................................................................106

FLI 225 Instrument Parts List & Options ........................................................................107

Menu Maps ............................... ... ... ....................................... ... ... .... ..............................108

FLSC 05 w/FLI 225 Instrument Service Manual 5

Manual Revision History

Current

Issue

AA June 2008 Issue new manual
AB August 2008 Updated illustration of ramps on page 71. Corrected reference numbers / part numbers on

AC January 2009 Added labels to show relationship between TB1 (COM 1), TB2 (COM 3) TB3 (COM 2) and RS232

AD March 2009 a‘Changed part number AWT25-500015 to AWT15-500682 on page 95.
AE July 2009 Updated copyright statement. Added statement on p. 7 that this manual is used worldwide.

AF July 2010 Changed part number AWT20-500353 to AWT20-503844 and AWT20-500356 to AWT20-

AG Sept. 2010 Changed PN on Main Board in the digital system block diagram on page 101.
AH June 2012 Added info to section 10.8, SMA Protocol.
AJ July 2013 Updated DofC. Added “original instructions” to front page.
AK December 2013 Updated coypyright statement. Added “CONFIDENTIAL” to front page. Added Grounding section

Date Created Details of Changes

exploded view of carriage on pages 94-95. Updated Carriage Assembly drawing on p. 94.
Removed part number for ref 1 on p. 95 as this part is NA. Corrected description of exploded view
on p. 96. Included additional notes on installing the wireless carriage on p. 82.

connections on page 91. Corrected part number AWT25-500013 to AWT25-500342 on page 95.

Updated "Special Messages" section on p. 7 as per requirements. Added statement about Class
A product on p. 9. Added section 3.2.4 "Audit Trail Counter" with summary. Updated Summary
description of Setup Manager on p. 18. Added Section 6.3 "Audit Trail Counter" with details.
Added section on determining if calibration is required for EU (Section 9.1.2) which includes 2
Calibration tests with weights in KG starting on p. 40. Added tables showing default settings for
ranges, depending on country configuration on p. 62 - 63. Added new print tokens to table on p.

69. Updated drawing and dimensions of ramps to include metric measurements on p. 80. Added
section 10.7 RM-200 Connection on p. 99. Added section 10.8 to show supported SMA Protocol
commands and results. Updated parts list on p. 105. Added menu maps on p. 106. Updated date
to July 2009 and Issue to AE. Added tables on p. 73 - 74 showing default settings by country
code.

503765. See notes for serial number cutover for these parts on page 105. Updated drawing on
page 104 to show new gasket (AWT20-503765). Updated date and issue number on front cover.

to chapter 10.

6 FLSC 05 w/FLI 225 Instrument Service Manual

1 General information and warnings

1.1 About This Manual

This manual is divided into chapters as shown by the chapter number and the large text
at the top of a page. Subsections are labeled as shown by the 1.1 above and may
include additional subsections. The name of the chapter and th e next subsection level
appear at the top of alternating page s of the manual to remind you of where you are in
the manual. The manual name and page numbers appear at the bottom of the pages.

This manual covers the service procedures of the FLI 225 instrument for multiple
regions worldwide.

1.1.1 Text conventions

Key names are shown in bold and reflect the case of the key being described. This
applies to hard keys and onscreen or soft keys.

Displayed messages appear in bold italic type and reflect the case of the displayed
message.

1.1.2 Special messages

Examples of special messages you will see in this manual are defined below. The
signal words have specific meanings to alert you to additional inform ation or the relative
level of hazard.

DANGER!
THIS IS A DANGER SYMBOL.
DANGER MEANS THAT FAILURE TO FOLLOW SPECIFIC PRACTICES
OR PROCEDURES WILL CAUSE INJURY OR DEATH.

ELECTRICAL WARNING!
THIS IS AN ELECTRICAL WARNING SYMBOL.
ELECTRICAL WARNINGS MEAN THAT FAILURE TO FOLLOW
SPECIFIC PRACTICES OR PROCEDURES MAY RESULT IN
ELECTROCUTION, ARC BURNS, EXPLOSIONS OR OTHER HAZARDS
THAT MAY CAUSE INJURY OR DEATH.

WARNING!
This is a Warning symbol.
Warnings mean that failure to follow specific practices and procedures may
have major consequences such as injury or death.

FLSC 05 w/FLI 225 Instrument Service Manual 7

CAUTION!
This is a Caution symbol.
Cautions give information about procedures that, if not observed, could result
in damage to equipment or corruption to and loss of data.

NOTE: This is a Note symbol. Notes give additional and important information, hints
and tips that help you to use your product.

1.2 Installation

DANGER: RISK OF ELECTRICAL SHOCK. NO USER SERVICEABLE
PARTS. REFER TO QUALIFIED SERVICE PERSONNEL FOR SERVICE.

1.3 Routine Maintenance

IMPORTANT: This equipment must be routinely checked for prop er operation
and calibration. Application and usage will determine the frequency of
calibration required for safe operation.

Always turn off the machine and isolate from the power supply before starting any
maintenance to avoid the possibility of electric shock.

Make sure that it is placed securely on a flat and level surface.

1.4 Cleaning the Machine

Table 1.1 Cleaning DOs and DON’Ts

DO DO NOT

Wipe down the outside of standard products
with a clean cloth, moistened with water and
a small amount of mild detergent

Attempt to clean the inside of the machine
Use harsh abrasives, solvents, scouring cleaners or

alkaline cleaning solutions

8 FLSC 05 w/FLI 225 Instrument Service Manual

1 Training

1.5 Training

Do not attempt to operate or complete any procedure on a machine unless you have
received the appropriate training or read the instruction books.

1.6 Keypad Operation

CAUTION: Do not attempt to operate the keypad with objects such as
screwdrivers or long fingernails as this may cause damage to the instrument.

1.7 FCC and EMC Declarations of compliance

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own
expense.

European Countries

WARNING: This is a Class A product. In a domestic environment, this product may cause radio interference in which the user may be
required to take adequate measures.

FLSC 05 w/FLI 225 Instrument Service Manual 9

10 FLSC 05 w/FLI 225 Instrument Service Manual

1 FCC and EMC Declarations of compliance

FLSC 05 w/FLI 225 Instrument Service Manual 11

2 Introduction

The FLSC05 w/ FLI 225 Instrument is a fully digital, legal-for -trade system for weighing,
storing and transmitting information to peripherals such as a computer system directly
from the forklift.

This system can have one of the following configurations:

Classic Mode with Print combines powerful weighing, printing, and ease

Classic Mode with Accumulate adds the ability to accumulate totals and generate

Expanded Mode allows the user to print and store totals but also

For information on how to configure the instrument for these modes, refer to chapter 9,
App Selection on page 72.

2.1 Front Panel and Keys

The 5 hard keys and 4 softkeys on the front panel of the FLI 225 have multiple
functions.

of use. Transactions are not stored.

reports.

adds features that set it apart from the two classic
modes.

Figure 2.1 FLI 225 Front Panel.

Table 2.1 Key Definitions

Reference Key Name Key Function(s)

1 TARE

2 STANDBY

3 SELECT

4 PRINT

5 ZERO

12 FLSC 05 w/FLI 225 Instrument Service Manual

Tare the weight on the scale for net weighing. Factory default for this key is
OFF. See Enable or Disable Keys on page 77

Turn the instrument on.
Put the instrument into standby mode.

Toggle Gross, Tare, Net and Transaction views. Factory default for this

function is OFF. See Enable or Disable Keys on page 77.

Backspace (delete previous character) when in data entry mode.
Send data to a printer or other connected device.

Store (save) transactions for future download, depending on configuration.
Access report menu in certain modes.

Zero the instrument to compensate for minor weight changes.
Move to the right in data entry mode.

Table 2.1 Key Definitions

Reference Key Name Key Function(s)

2 Data Entry Procedure

6 F1 - F4
6a Esc softkey Abort a procedure or return to previous menu.
6b

6c
6d Enter softkey Accept an entry.

Up Arrow

softkey

Down Arrow

softkey

2.2 Data Entry Procedure

You can key in: 0-9, A-Z, a-z and space. Follow these instructions for data entry.

1. Press the Up or Down Arrow softkey to scroll up or down from zero as
necessary.

2. Press the ZERO key to move to the right

3. Repeat steps 1 and 2 until all the information has been entered.

If you make a mistake, press the SELECT key to backsp ace and delete one character
or press the Esc softkey to abort.

Collectively called the softkey because their function changes with the title.
Common softkeys (6a - 6d) are shown.

Scroll up from zero and then forward through the alphabet.

Scroll backwards from zero and then backwards through the alphabet.

4. Press the Enter softkey when complete.

2.3 Display and Annunciators

Throughout this manual, annunciators are typically shown in bold italics and in the
case they appear. Therefore, Gross indicates the annunciator for gross weight, etc.

The most common annunciators are explained in Table 2.2

Table 2.2 Definition of Annunciators

Annunciator Description

~

>0< Gross Zero Band indicates that the instrument is within the zero range.

lb Indicates that the weight displayed is in pounds.

kg Indicates that the weight displayed is in kilograms.

–

Gross Indicates that the instrument is in gross weight mode.

Net The instrument is in net weight mode. Weight displayed is the net weight.

Tare Weight displayed is the tare weight only.

The weight is in motion and is not stable.

Indicates a negative weight.

FLSC 05 w/FLI 225 Instrument Service Manual 13

Table 2.2 Definition of Annunciators

Annunciator Description

Underload Indicates that the scale is outside the gross zero range (under weight).

Overload Indicates that the scale is overloaded.

Over Angle Indicates that the scale is tipped (right, left, forward or back) too far.

(

) Indicates that the instrument is set to FLSC W ireless and is

Y

Y Indicates that the instrument is set to FLSC Wireless but wireless

communicating wirelessly with the carriage.

communications to the carriage has been interrupted.
Indicates the approximate charge remaining on the battery used for

wireless communications from the scale carriage to the instrument.

2.4 FLR 100 Remote Display Option

Figure 2.2 shows the FLR 100 remote display option. This display can be hard wired to
to one of the COM ports on the communications board of the instrument. See FLI 225
Digital System Block Diagram on page 103. The COM port must be configured for
remote display operation.

Figure 2.2 FLR 100 Remote display option

Key function

F1 key Not used at present
PRINT key Mimics the function of the PRINT key on the FLI 225 instrument
ZERO key Mimics the function of the ZERO key on the FLI 225 instrument

14 FLSC 05 w/FLI 225 Instrument Service Manual

3 Overview of the Menus and Modules

The FLI 225 has four password protected menus. Each menu give s access to specific
modules or areas of instrument function, setup or diagnostics and may be further
divided.

The four password protected menus in the FLI 225 instrument are:

User Management Menu default password = 111
Diagnostics Management Menu default password = 911
Supervisor Management Menu default password = 1793
Admin. Management Menu default password = 522

Figure 3.1 is a table explaining the module access granted by the different passwords.
There are eight modules and four of them appear in all four menus. A module remains

the same no matter which menu it appears in.

Each successive menu shown in Figure 3.1 accesses more modules. This allows you
to control access to more sensitive information by giving personnel only the password
they need for their level of clearance.

Figure 3.1 Menus and the modules they contain

FLSC 05 w/FLI 225 Instrument Service Manual 15

3.1 Accessing and Exiting the Menus

The procedure for accessing most of the menus is the same and is explained below.

The Admin Management menu may require unsealing the instrument. See Change
Seal Status on page 35 for details.

1. From the operating screen, press and hold the SELECT key for approximately
five seconds.

The screen will flash to indicate when to release the key.

2. Release the SELECT key.

The screen prompts you for a password

Figure 3.2 Password Screen

3. Scroll in the password for the menu you need to access using the Data Entry
Procedure on page 13.

The display shows the available modules.

When entering the password, the numbers will be visible as you scroll through them
but will change to asterisks (*) once you move to the next space.

4. Press the Up or Down Arrow softkey to move to the desired module.

5. Press the Enter softkey to access the highlighted module.

6. Make any necessary change(s) to the selected module.

7. Press the Esc softkey to return to the previous screen.

8. Press the Esc softkey as necessary to exit to normal operating mode.

The instrument saves any changes and reboots into normal operating
mode.

Each module is described in the following chapters.

16 FLSC 05 w/FLI 225 Instrument Service Manual

3.2 Overview of the Modules

This section highlights each of the modules.

3.2.1 User Settings

The User Settings module appears in all four menus and lets you view / change the
following:

l Time (set the time)
l Date (set the date)
l Display Contrast (set the display contrast)
l Seal Status (check status of the seal switch)

See chapter 4, User Settings Module for more details.

3.2.2 About FLI 225

This module is available in all four menus and shows you the revision and p art number
of the firmware. See chapter 5, About FLI 225 Module for more information.

3 Overview of the Modules

3.2.3 Audit Trail Viewer

The Audit Trail Viewer is available in all four menus and displays a list of items that
have been changed on the instrument with the dates and times of the changes. See
chapter 6, Audit Trail Viewer Module for more information.

3.2.4 Audit Trail Counter

The Audit Trail Co unter is available in all four menus a nd shows the number of times
the calibration information has changed.

3.2.5 Diagnostics Manager

The Diagnostics Manager module is available in the Diagnostics, Supervisor and
Admin Management menus. It provides a way to view / test the following:

l Communications (test Com1, Com2 or Com3)
l Keypad (test and identify keypad buttons)
l Display (test the display)
l Analog Option Card (verify installation and operation of an analog card as

well as see analog counts as necessary)

l Digital Carriage (verify installation and operation of FLJ 100 as well as see

digital counts as necessary)

l Inputs (test any inputs connected to the instrument)
l Seal Switch (check the state of the seal switch)
l Error Log Viewer (view history of errors)

See chapter 7, Diagnostics Manager Module for more information.

FLSC 05 w/FLI 225 Instrument Service Manual 17

3.2.6 Supervisor Settings

This module is available in the Supervisor and Admin Management menus. It allows
you to view / change the following:

l Zero Band (set gross zero band in calibration units)
l Timeout Settings (set timers)
l Identification (enter various identification numbers for the lift truck,

installation, scale and device)

See chapter 8, Supervisor Settings Module for more information.

3.2.7 Setup Manager

The Setup Manager module is only available in the Admin Management menu and
allows access to the following:

l Calibrate (calibrate the scale) including:

m Gravity Compensation
m Zero
m Span
m FLSC Calibration (perform corner and angle calibration)
m View Live Weight

l Scale (configure various scale metrology items) including:

m Units (set calibration units, enable units of measure)
m Settings (configure capacity, divisions and carriage type)
m Filter (set various filtering components)
m Motion/AZT (configure motion and AZT)
m Auto Tare Clear (enable or disable auto tare clear)
m Ranges (set ranges for overload, underload, zero range, center of zero,

zero band, auto print and zero drift)

l Communications (configure various COM settings for COM 1, 2, 3)
l Print Strings (Access the Print String Editor and configure Strings to Print)
l App Selection (Choose the application for the ins tru m en t)
l Country Code (Set instrument to either NA or EU default settings)
l Miscellaneous (Configure various settings such as Inputs, Passwords,

Display settings, Time & Date format as well as Reset system, Enable /
Disable Keys and perform certain Diagnostics.)

See chapter 9, Setup Manager Module for more information.

18 FLSC 05 w/FLI 225 Instrument Service Manual

4 User Settings Module

The User Settings module is available when you enter any of the passwords, however ,
this section assumes the individual is entering password 111. For more information on
how to access the menus, see Overview of the Menus and Modules on page 15.

1. Use the steps in Accessing and Exiting the Menus on page 16 to access the
User Settings module.

The configurable options are displayed as shown in Figure 4.1.

Figure 4.1 User Settings

2. After completing all changes, press the Esc softkey to exit.

The changes are saved and the instrument reboots into normal
operating mode.

4.1 Time

Regardless of the format that the time is displayed, enter the time in 24 hour format. If
you do not know the seconds value, you can leave it blank and it will continue from
when you started.

1. Access the User Settings module.

2. Press the Up or Down Arrow softkey as necessary to highlight Time.

3. Press the Enter softkey.

The time is displayed in real time, 24 hour format.

Figure 4.2 Time Menu

4. Scroll in the new time using the Data Entry Procedure on page 13.

5. Press the Enter softkey to save the changes and return to User Settings.

FLSC 05 w/FLI 225 Instrument Service Manual 19

4.2 Date

1. Access the User Settings module.

2. Press the Up or Down Arrow softkey as necessary to highlight Date.

3. Press the Enter softkey.

The stored date is displayed.

Figure 4.3 Edit Date Screen

4. Scroll in the new date using the Data Entry Procedure on page 13.

5. Press the Enter softkey to save the changes and return to the User Settings
screen.

4.3 Display Contrast

To allow for various lighting environments, you can adjust the display contrast settings.

1. Access the User Settings module.

2. Press the Up or Down Arrow softkey as necessary to highlight Display
Contrast.

3. Press the Enter softkey.

4. Select a value between 1 and 5 using the Up or Down Arrow softkeys.
(Default setting is 3.)

5. Press the Enter softkey to accept and save the change.

Figure 4.4 Sample Display Contrast Screen

The value is changed and the display returns to User Settings.

6. Press the Esc softkey to exit User Settings.

The instrument saves the changes, powers off and restarts in normal
operating mode.

20 FLSC 05 w/FLI 225 Instrument Service Manual

4.4 Seal Status

The FLI 225 has a Category 3 audit trail. For locations requiring a physical seal, you
can check whether the instrument is sealed or unsealed by following these steps.

1. Access the User Settings module.

2. Press the Up or Down Arrow softkey as necessary to highlight Seal Status.

3. Press the Enter softkey.

4 Seal Status

The current status (sealed or unsealed) is displayed.

Figure 4.5 Sample Seal Status Screen

The default setting is “unsealed”.

4. Press the Esc or Enter softkey to return to the previous m odule.

The display returns to the User Settings screen.

FLSC 05 w/FLI 225 Instrument Service Manual 21

5 About FLI 225 Module

The About FLI 225 module shows you the revision and p art number of the firmware. It
is available when you enter any of the passwords, however, this section assumes the
individual is entering password 1 1 1. For more information on how to access the menus,

see Overview of the Menus and Modules on page 15.

1. Access the User Management menu as explained on page 16 using password

111.

2. Press the Down Arrow softkey as necessary to highlight About FLI 225.

3. Press the Enter softkey.

The instrument briefly shows the current firmware version and then the
part number for the instrument.

Figure 5.1 Sample Firmware Version (left) and Part Number (right)

After displaying this information, the FLI 225 returns to the previous
screen.

4. Press the Esc softkey to return to normal operating mode.

22 FLSC 05 w/FLI 225 Instrument Service Manual

6 Audit Trail Viewer Module

The Audit Trail Viewer module displays a list of dates and times when changes
occurred. It is available when you enter any of the passwords, however, this section
assumes the individual is entering password 111. For mor e inform a tio n on how to
access the menus, see Overview of the Menus and Modules on page 15.

1. Access the User Management menu as explained on page 16 using password

111.

2. Press the Down Arrow softkey as necessary to highlight Audit Trail Viewer

3. Press the Enter softkey.

The audit trail is displayed.

Figure 6.1 Sample Audit Trail

4. Press the Up or Down Arrow softkey as necessary to move through the
entries and pages.

5. After viewing / printing the audit trail, press the Esc softkey.

The instrument returns to the previous screen.

6. Press the Esc softkey to exit to normal operating mode.

6.1 View Audit Trail Record

To view a specific record in the audit trail, continue with the following instructions.

1. Select the record from the Audit Trail Viewer.

2. Press the Enter softkey.

The details for that record are displayed.

Figure 6.2 Sample Audit Trail Record

3. Press the Enter or Esc softkey to return to the Audit Trail Viewer.

FLSC 05 w/FLI 225 Instrument Service Manual 23

6.2 Print the Audit Trail

While viewing the audit trail, press the PRINT key to send the report to a printer, PC
running HyperTerminal or other connected device.

6.3 Audit Trail Counter

Figure 6.3 Sample Audit Trail Report

The Audit Trail Counter displays the number of times the system has been calibrated.
It is available when you enter any of the passwords, however, this section assumes the
individual is entering password 1 1 1. For more information on how to access the menus,
see Overview of the Menus and Modules on page 15.

1. Access the User Management menu as explained on p age 16 using password

111.

2. Press the Down Arrow softkey as necessary to highlight Audit Trail Counter.

3. Press the Enter softkey.

The audit count is displayed.

Figure 6.4 Sample Audit Count

4. Press the Esc softkey to exit to normal operating mode.

24 FLSC 05 w/FLI 225 Instrument Service Manual

7 Diagnostics Manager Module

The Diagnostics Manager module is available when you access the Diagnostics
Management menu, the Supervisor Management menu or the Ad min Management

menu, however, this section assumes the individual is entering password 911. For more
information on how to access the menus, see Overview of the Menus and Modules on

page 15.

1. Access the Diagnostics Mana gement module as explained on page 16 using
password 911.

2. Press the Enter softkey.

The Diagnostics Manager module is displayed as shown in Figure 7.1.

Figure 7.1 Screen 1 (left) and 2 (right) of Diagnostics Mana ger

3. Press the Up or Down Arrow softkey to highlight an option.

4. Press the Enter softkey to select the highlighted option.

5. Test the option as necessary.

6. After completing the diagnostics, press the Esc softkey to return to the
Diagnostics Management menu accessed in step 1.

7.1 Communications

Select Communications from the Diagnostics Manager module to perform a
loopback test to help identify a possible faulty communications port.

The instrument displays the available communications ports.

Figure 7.2 Communications Test Screen

1. Press the Up or Down Arrow softkeys as necessa ry to highlight the port
(Com2, Com3) you need to test.

FLSC 05 w/FLI 225 Instrument Service Manual 25

2. Connect transmit and receive with a tight fitting jumper connection.

69

51

or

Figure 7.3 Sample Connector with Jumper

3. Press the Enter softkey

One of the following messages displays.

Figure 7.4 Loopback Test Passed (left) or Failed (right)

A failed loopback test may indicate a problem with the connection.

4. Press the Esc or Enter softkey once you have completed the test to return to the

list of communications ports.

5. Press the Esc softkey to return to the Diagnostics Manager module.

Test Handshaking

You can also perform a loopback test on COM 3 to verify that handshaking is working
properly. For information on enabling handshaking, see Handshake on page 65

1. To test Handshaking, you must also jumper CTS and RTS.

2. Perform the communications test as described on page 25.

You will get a message indicating PASS or FAIL for both the loopback
and the handshaking test. A failed test for either may indicate a problem
with the connection tested.

3. Press the Esc softkey to return to the Diagnostics Manager module.

26 FLSC 05 w/FLI 225 Instrument Service Manual

7.2 Keypad

7.3 Display

7 Keypad

1. Select Keypad from the Diagnostics Manager module to test the function of
each key.

2. Press the Enter softkey.

The instrument prompts you to press a key.
During the Keypad Test, the name of the key will display while it is

pressed. If you press and hold the key, the function will remain onscreen
until you release the key.

3. Press the On / Off key to exit the test and return to Diagnostics Manager.

1. Select Display from the Diagnostics Manager. The screen will flash the model
name in standard display followed by inverse (highlighted) and finally a solid
black screen and will repeat until F1 or F4 is pressed.

2. Press the Enter softkey.

3. Press either the F1 or F4 key to end the test and return to the Diagnostics
Manager module.

7.4 Analog Option Card

The Analog Option Card test is not available on the FLSC 05 digit al system. Refer to
the appropriate service manual for the QT LTSC or QTLTS.

7.5 Digital Carriage

Selecting Digital Carriage from the Diagnostics Manager let s you vie w the status of
the FLJ 100 digital Jbox and the scaled counts.

1. Access the Diagnostics Mana gement module.

2. Press the Up or Down Arrow softkey as necessary to highlight
Digital Carriage

Figure 7.5 Test Screens

FLSC 05 w/FLI 225 Instrument Service Manual 27

3. Press the Enter softkey.

7.5.1 FLJ 100 Status

1. Select FLJ 100 Status from the FLJ 100 module to help determine if there is a

2. Press the Enter softkey to view the status of the junction box.

The FLJ 100 module is displayed.

Figure 7.6 FLJ 100 Module

problem with the digital junction box.

The following screen is displayed.

Figure 7.7 Sample FLJ 100 Status Screens (Wired on left, Wireless on right)

7.5.2 View FLJ 100 Counts

1. From the FLJ 100 module, press the Down Arrow softkey as necessary to
highlight View FLJ 100 Counts.

2. Press the Enter softkey to display the Scaled Counts. Any reference to right,
left, forward, backward, top or bottom is from the driver’s point of view.

3. Press the ZERO key to zero the counts.

When weight is applied to a corner (for example, bottom left), the counts
for that cell should increase. When the weight is moved to another
corner, the counts for the new location should be similar.

Figure 7.8 Sample FLJ 100 Counts

28 FLSC 05 w/FLI 225 Instrument Service Manual

7.6 Inputs

The Inputs test checks if the remote input is working properly.

1. Begin with the input connected and in its default setting (off or on).

2. From the Diagnostics Manager screen, press the Up or Down Arrow sof tkey

3. Press the Enter softkey.

4. The Inputs Test screen is displayed with the current setting for each available

5. Put the input device in the opposite setting (on or off).

6. Press the Esc or Enter softkey to return to the Diagnostics Manager module.

7.7 Seal Switch

This instrument has a Category 3 audit trail. For locations requiring a physical seal,
there is a seal switch located at S1 on the communications/power supply board.

7 Inputs

as necessary to highlight Inputs.

input.

The status of the input changes to reflect this difference.

Select Seal Switch from the Diagnostics Manager module to view the current status
(sealed or unsealed).

For information on sealing or unsealing the instrument, see Change Seal S tatus on
page 35.

7.8 Error Log Viewer

The Error Log Viewer can assist you in diagnosing problems with the FLI 225
instrument or the FLSC 05 system by showing you a list of dates when errors occurred.

By default, FLSC communications errors and Drift errors are disabled. See
Diagnostics Tools on page 78.

1. Select Error Log Vi ewer from the Diagnostics Manager module.

The Error Log is displayed.

Figure 7.9 Sample Error Log

FLSC 05 w/FLI 225 Instrument Service Manual 29

2. Press the Up or Down Arrow softkey as necessary to highlight the entry you
wish to see.

3. Press the Enter softkey.

The details for that entry are displayed.

Figure 7.10 Sample Error Log Record

4. Press the Esc or Enter softkey to return to the Error Log Viewer.

5. Press the Esc softkey to the Diagnostics Manager module.

The following errors may be logged if enabled.

Table 7.1 Error Codes and Definitions

Error Definition

UNDERLOAD ERROR The weight on the carriage has gone below the set negative% of capacity.

OVERLOAD ERROR The weight on the carriage has gone above the set positive% of capacity.

DRIFT ERROR Zero Tracking has removed an accumulated weight beyond the set% (positive or negative) of

capacity.

FLJ COMM ERROR Communication with the FLJ 100 or FLW 100 has been lost.
FLJ CHANGE ERROR An FLJ 100, FLW 100 or FLI 225 instrument has been changed.
FLJ CORNER ERROR Stored corner coefficients do not match between FLI 225 and FLJ 100 or FLW 100

FLJ ANGLE ERROR Stored angle coefficients do not match between FLI 225 and FLJ 100 or FLW 100.

30 FLSC 05 w/FLI 225 Instrument Service Manual

8 Supervisor Settings Module

The Supervisor Settings module is available when you access the Supervisor
Management menu or the Admin Management menu, however, this section assumes

the individual is entering password 1793. For more information on how to access the
menus, see Overview of the Menus and Modules on page 15.

1. Access the Supervisor Management module as explained in Accessing and
Exiting the Menus on page 16 using password 1793.

2. Press the Enter softkey.

The Supervisor Settings module is displayed as shown in Figure 8.1.

Figure 8.1 Supervisor Settings Module

3. Press the Up or Down Arrow softkey to highlight an option.

8.1 Zero Band

4. Press the Enter softkey to select the highlighted option.

5. Configure the option as necessary.

6. After completing configurations, press the Esc softkey to return to the
Supervisor Management menu.

1. Select Zero Band from the Supervisor Settings module to view or change the
Zero Band value.

The current weight to which the instrument must return to reset all return
to zero (RTZ) functions such as print, tare clear and store transaction is
displayed.

2. Scroll in a value between 0 and the maximum capacity of the scale using the
Data Entry Procedure on page 13 as necessary.

3. Press the Enter softkey to accept the entry and return to the Supervisor
Settings module.

FLSC 05 w/FLI 225 Instrument Service Manual 31

8.2 Timeouts

Select Timeouts from the Supervisor Settings module to set the amount of time the
instrument will wait for a user to key in information before returning to the previous
screen as well as set a timer to shut the instrument down when left idle.

8.2.1 Prompt Timeout

By default, the prompt timeout is set to 15 seconds, however, you can set it for any
value between 0 and 120 seconds.

1. Select Prompt Timeout from the Timeouts screen.

2. Scroll in the timeout value in seconds using the data entry procedure.

Figure 8.2 Timeouts Screen

3. Press the Enter softkey once the value is correct

4. Press the Esc softkey to return to Supervisor Settings.

8.2.2 Shutdown Timer

By default, the shutdown timer is set to 4 hours. You can change the shutdown timer to
30 minutes, 1 hour, 2 hours, 4 hours, 10 hours or turn it off.

1. Select Shutdown Timeout from the Timeouts screen.

2. Select the value from the available options.

3. Press the Enter softkey to accept the value and return to the Timeouts
screen.

4. Press the Esc softkey to return to Supervisor Settings.

The instrument returns to the Timeouts screen.

32 FLSC 05 w/FLI 225 Instrument Service Manual

8.2.3 Identification

Select Identification from the Supervisor Settings module to enter reference
information for the installation site, forklift, scale and device as shown.

Installation ID

1. Select Installation ID from the Identification module.

2. Use the data entry procedure to scroll in the location where the scale is

3. Press the Enter softkey.

8 Timeouts

Figure 8.3 Identification Module

primarily used

The information is stored and the instrument returns to the Identification
module.

Fork Lift ID

1. Select Forklift ID from the Identification module.

2. Use the data entry procedure to scroll in any information to help identify the
forklift (such as a serial number).

3. Press the Enter softkey.

The information is stored and the instrument returns to the Identification
module.

Scale ID:

1. Select Scale ID from the Identification module.

2. Use the data entry procedure to scroll in the identification number (such as a
serial number, carriage type, etc.) for the scale.

3. Press the Enter softkey.

The information is stored and the instrument returns to the Installation
module.

Set Device Serial Number:

1. Select Device Serial Number from the Identification module.

2. Use the data entry procedure to scroll in the serial number for the device that
is connected to the instrument (such as a printer or scanner).

3. Press the Enter softkey.

The information is stored and the instrument returns to the Installation
module.

FLSC 05 w/FLI 225 Instrument Service Manual 33

9 Setup Manager Module

The Setup Manager module is only available when you access the Admin
Management menu (password 522). For more information on how to access the

menus, see Overview of the Menus and Modules on page 15.

1. Access the Admin Management module as explained on page 16 using
password 522.

2. Press the Enter softkey.

The following screens are displayed.

Figure 9.1 Screen 1 (left) and 2 (right) of Setup Manager

3. Press the Up or Down Arrow softkey to highlight an option.

4. Press the Enter softkey.

5. Make all necessary changes.

6. Press the Esc softkey to return to Admin Management when finished.

The Setup Manager module contains the following items:
Calibrate Select Calibrate to set gravity compensation, set zero,

set span, perform corner and angle calibration. See
Calibrate the FLSC 05 with FLI 225 on page 36 for details.

Scale Select Scale to configure the various components of:

Units, Settings, Filter, Motion/AZT, Ranges and System.
See Scale on page 55 for details.

Communications Select Communications to configure the various

communications ports. SeeCommunications on page 64
for details.

Print Strings Select Print S trings to edit the print strings and con figure

the strings to print. See Print Strings on page 66 for
details.

Application Selection Select Application Selection to choose the application:

Classic w/Print, Classic w/Accum or Expanded. See

App Selection on page 72

Country Code Select Country Code to pick the area, NA (North

America) or EU (European Union) where the instrumen t is
used. See Country Code on page 73 for details.

Miscellaneous Select Miscellaneous to set up the inputs, reset the

system, run diagnostics or reset passwords. See

Miscellaneous on page 74 for details.

34 FLSC 05 w/FLI 225 Instrument Service Manual

9

Change Seal Status

The FLI 225 has a Category 3 audit trail. For locations requiring a physical seal, you
must unseal the instrument before accessing th e Admin Management menu.

1. Access the User Settings module using password 111.

2. Press the Up or Down Arrow softkey as necessary to highlight Seal Status.

3. Press the Enter softkey.

The current status (sealed or unsealed) is displayed.

Figure 9.2 Sample Seal Status Screen

4. If the status is unsealed, skip to step 8. Otherwise continue with the following.

5. Remove the back panel of the instrument.

6. Press the seal switch located at S1 on the communications/power supply
board.

The status changes from sealed to unsealed.

7. Replace the back panel.

8. Press the Esc or Enter softkey to return to the previous m odule.

The display returns to the User Settings screen.

9. Press the Esc softkey 2 times to exit to normal operating mode.

10. Access the Setup Manager module as explained on page 34.

11. After completing all change s in th e Setup Manager, reseal the instrument as
necessary. The steps for sealing the instrument are the same as for unsealing.

FLSC 05 w/FLI 225 Instrument Service Manual 35

9.1 Calibrate the FLSC 05 with FLI 225

The FLSC is a digital system. This section covers calibration procedures for the FLSC
with the FLI 225 instrument.

Before beginning any calibration procedure, please make sure you do the following:

l Determine if calibration is necessary. See page 37.
l Obtain a heavy duty pallet that will support the calibration weights.
l Put the pallet and weights on the forklift and drive it around to exercise the

scale.

l Make sure the forklift is level in all directions (front/back and left/right).
l Place the forks directly over the Weigh Bars.
l Gather all tools, weights and other supplies.

After completing the above steps, select Calibrate from the Setup modu le to access
the various calibration procedures as shown below.

Figure 9.3 Calibration Main Screen

Gravity compensation Gravity compensation is only done once, if necessary, when

the scale is put into service. For full details, see Gravity
Compensation on page 44.

Zero Select Zero to set the scale’s zero point. For full details, see

Zero on page 46.

Span Select Span to set the span. For full details, see Span on

page 46.

FLSC Calibration Select FLSC Calibration to perform corner calibration

(see Corner Calibration on page 48, and angle calibration (see
Angle Calibration on page 51.

QTLTSC Calibration This option is not available for the FLSC. See the appropriate

service manual for details.

View Live Weight Select View Live Weight to view a live weight reading

without exiting the menus.

l When finished with calibration, press the Esc softkey to return to the top of

the Setup Manager screen.

l Press the Esc softkey again to return to the Admin Management menu.

36 FLSC 05 w/FLI 225 Instrument Service Manual

9 Calibrate the FLSC 05 with FLI 225

For Span Calibration:

NTEP/Handbook 44 requires that the scale be calibra ted to at least 50% of the scale’s
rated capacity. A minimum of 12.5% or 1000 lb. (whichever is greater) of the scale’s
rated capacity in certified test weights is required for calibration. If you do not ha ve 50%
of capacity in certified weight available, you will need to use the Substitution test
method (Buildup Calibration) to reach the require d amount of weight. This weight must
include the required certified weight.

For Angle (16 Point) Calibration:

When performing the Angle Calibration, you will actually need two known weight
values; full weight and half weight. Full weight (span weight) does NOT need to be
equal to the full capacity of the scale. Half weight must be equal to 50% of the full weig ht
value. For example, if you used 2000 lbs for full weight (span weight), you will need to
use 1000 lbs for half weight.

For complete scale calibration, follow your local weights and measures
requirements.

9.1.1 Determining if Calibration is Needed (NA)

Calibration of the FLSC 05 with FLI 225 may be required when:

l The system fails one of the following calibration tests
l A Weigh Bar is replaced
l The FLI 225 is replaced
l The FLJ 100 is replaced

Calibration Test Method 1 (NA)

Calibration Test 1 uses 1000 pounds of certified test weight to establish if the
Avery Weigh-T ro nix legal-for-tr ade forklif t sca le requir es recalibr ation. If the displaye d
weight is anything but 1000 pounds, follow the instructions for the indicated calibration

procedure.

This recommendation is subject to local Weights and Measurements regulations.

1. Configure the indicator to display in 5 lb divisions. See page 58.

2. Disable Automatic Zero Tracking ( AZT). See page 60.

3. Position the forks centered over the Weigh Bars.

4. Place a sturdy pallet on the forks.

5. With the forks raised, press the ZERO key to zero the scale.

FLSC 05 w/FLI 225 Instrument Service Manual 37

6. Place 1000 lb in the center of the pallet.

If the system fails this test, perform a Zero and Span operation as
explained on page 46 using a minimum of 500 lb for the span weight
before continuing with step 7.

7. Place 1000 lb on each of the corners in succession, noting the weight reading
for each corner.

Figure 9.4 Weight on corners

If the system fails this test, perform the Corner calibration as explained
on page 48 using a minimum of 500 lb for the span weight before
continuing with step 8.

8. Place 1000 lb in the center of the pallet.

9. Tilt the mast forward and note the weight reading.

10. Tilt the mast back and note the weight reading.

If the system fails either step 9 or step10, perform the 16 point Angle
Calibration as explained on page 51 using a minimum of 2000 pounds
for the span weight.

11. Upon completion, recon figure the in dicator to 5 lb divisions and AZT - ON.

Calibration Test Method 2 (NA)

Calibration Test 2 uses a 500 pound certified test weight to establish if the
Avery Weigh-Tronix legal-for-trade forklift scale requires recalibration. The allowable
variance in all instances is ±1 pound. Therefore, any weight reading between 499.0 and

500.8 lb is acceptable.

This recommendation is subject to local Weights and Measurements regulations.

1. Configure the indicator to display in 0.2 lb divisions. See page 58.

2. Disable Automatic Zero Tracking ( AZT). See page 60.

3. Position the forks centered over the Weigh Bars.

4. Place a sturdy pallet on the forks.

5. With the forks raised, press the ZERO key to zero the scale.

6. Place 500 pounds in the center of the pallet.

If the system fails this test, perform a Zero and Span operation as
explained on page 46 using a minimum of 500 pounds for the span
weight before continuing with step 7.

38 FLSC 05 w/FLI 225 Instrument Service Manual

9 Calibrate the FLSC 05 with FLI 225

7. Place 500 pounds on each of the corners in succession, noting the weight
reading for each corner.

Figure 9.5 Weight on corners

If the system fails this test, perform the Corner calibration as explained
on page 48 using a minimum of 500 pounds for the span weight before
continuing with step 8.

8. Place 500 pounds in the center of the pallet.

9. Tilt the mast forward and note the weight reading.

10. Tilt the mast back and note the weight reading.

If the system fails either step 9 or step10, perform the 16 point Angle
Calibration as explained on page 51 using a minimum of 2000 pounds
for the span weight.

11. Upon completion, recon figure the in dicator to 5 lb divisions and AZT - ON.

FLSC 05 w/FLI 225 Instrument Service Manual 39

9.1.2 Determining if Calibration is Needed (EU)

For systems with EU configuration, calibration of the FLSC 05 with FLI 225 may be
required when:

l The system fails one of the following calibration tests
l A Weigh Bar is replaced
l The FLI 225 is replaced
l The FLJ 100 is replaced

Calibration Test Method 1 (EU)

Calibration Test 1 uses 500 kilograms of certified test weight to establish if the
Avery Weigh-T ro nix legal-for-tr ade forklif t sca le requir es recalibr ation. If the displaye d
weight is anything but 500 kilograms, follow the instructions for the indicate d calibration
procedure.

This recommendation is subject to local Weights and Measurements regulations.

1. Configure the indica tor to display in 2 kg divisions. See page 58.

2. Disable Automatic Zero Tracking ( AZT). See page 60.

3. Position the forks centered over the Weigh Bars.

4. Place a sturdy pallet on the forks.

5. With the forks raised, press the ZERO key to zero the scale.

6. Place 500 kg in the center of the pallet.

If the system fails this test, perform a Zero and Span operation as
explained on page 46 using a minimum of 500 kg for the span weight
before continuing with step 7.

7. Place 500 kg on each of the corners in succession, noting the weight reading
for each corner.

If the system fails this test, perform the Corner Calibration as explained
on page 48 using a minimum of 500 kg for the span weight before
continuing with step 8.

8. Place 500 kg in the center of the pallet.

9. Tilt the mast forward and note the weight reading.

10. Tilt the mast back and note the weight reading.

If the system fails either step 9 or step10, perform the 16 point Angle
Calibration as explained on page 51 using a minimum of 1000 kilograms
for the span weight.

11. Upon completion, recon figure the indicator to 2 kg divisions and AZ T - ON.

40 FLSC 05 w/FLI 225 Instrument Service Manual

9 Calibrate the FLSC 05 with FLI 225

Calibration Test Method 2 (EU)

Calibration Test 2 uses 200 kilograms of certified test weight to establish if the
Avery Weigh-Tronix legal-for-trade forklift scale requires recalibration. The allowable
variance in all instances is ±0.4 kg. Therefore, any weight readin g betwe en 19 9.0 and

200.8 kg is acceptable.

This recommendation is subject to local Weights and Measurements regulations.

1. Configure the indicator to display 0.2 kg graduations. See page 58.

2. Disable Automatic Zero Tracking (AZT). See page 60.

3. Position the forks centered over the Weigh Bars.

4. Place a sturdy pallet on the forks.

5. With the forks raised, press the ZERO key to zero the scale.

6. Place 200 kilograms in the center of the pallet.

If the system fails this test, perform a Zero and Span operation as
explained on page 46 using a minimum of 200 kg for the span weight
before continuing with step 7.

7. Place 200 kilograms on each of the corners in succession, noting the weight
reading for each corner.

If the system fails this test, perform the Corner Calibration as explained on
page 48 using a minimum of 200 kg for the sp an weight before continuin g
with step 8.

8. Place 200 kilograms in the center of the pallet.

9. Tilt the mast forward and note the weight reading.

10. Tilt the mast back and note the weight reading.

If the system fails either step 9 or step10, perform the 16 point Angle
Calibration as explained on page 51 using a minimum of 10 0 0 kilog r am s
for the span weight.

11. Upon completion, reconfigure the indicator to 2 kg divisions and AZT - ON.

After Replacing a Weigh Bar

If a Weigh Bar is replaced, perform one o f the precedin g calibration tests to determine
if calibration of the system is required. For information on replacing a Weigh Bar, see

Replacing Weigh Bars on the FLSC 05 Carriage on page 82.

FLSC 05 w/FLI 225 Instrument Service Manual 41

After Replacing the FLI 225

Calibration information is stored in both the junction box (FLJ 1 00) and the instr ument.
If the FLI 225 is replaced, you can retrieve the stored calibration information from the
junction box.

1. After connecting the FLI 225 to the system, power the instrument on.

The following screen is displayed.

Figure 9.6 FLJ 100 Coefficient Mismatch Screen 1

If the screen in Figure 9.6 does not display on p ower up, the FLI 225 tha t is connected
to the system was set to Factory Defaults. Calibration information will automatically
be uploaded from the junction box. Proceed to one of the calibration tests.

2. Press the No softkey.

The second option is displayed.

Figure 9.7 FLJ 100 Coefficient Mismatch Screen 2

3. Press the Yes softkey to retrieve the stored calibration coefficient information
from the junction box.

For instruments with EU configuration, selecting No for both options will lock the
instrument to prevent weighing until calibration has been completed. The instrument
will display dashes and display the message, “Calibration Required.”

The parameters are saved and the instrument returns to normal
operating mode.

4. Press the ZERO key if the weight displayed is not zero.

5. Proceed to one of the calibration tests on pages 38 through 41.

42 FLSC 05 w/FLI 225 Instrument Service Manual

9 Calibrate the FLSC 05 with FLI 225

After Replacing the FLJ 100

Calibration information is stored in both the junction box (FLJ 1 00) and the instr ument.
If the FLJ 100 is replaced, you can retrieve the stored calibration information from the
instrument.

This option is not available for instruments with EU configuration. The instrument will
display dashes and the message, “Calibration Required.” You must recalibrate the
system.

1. After connecting the FLI 225 to the system, power the instrument on.

The following screen is displayed.

Figure 9.8 FLJ 100 Coefficient Mismatch Screen 1

If the screen in Figure 9.8 does not display on power up, the FLJ 100 that is
connected to the system was set to Factory Defaults. Calibration information will
automatically be uploaded from the FLI 225. Proceed to one of the calibration tests.

2. Press the Yes softkey to retrieve the stored calibration coefficient information
from the FLI 225.

The parameters are saved and the instrument returns to normal
operating mode.

3. Press the ZERO key if the weight displayed is not zero.

4. Proceed to one of the calibration tests on pages 38 through 41.

FLSC 05 w/FLI 225 Instrument Service Manual 43

9.1.3 Gravity Compensation

1. Select Gravity Compensation from the Calibrate list.

2. Press the Enter softkey.

The Gravity Compensation list appears.

Calculate Local g Factor

Instructions for calculating the local gravity factor continue from the previous section.
In order to calculate the gravity factor, you will need the latitude and altitude for the

destination.

Figure 9.9 Gravity Compensation Menu

If you know the local gravity factor, continue with Key in Known Gravity Factor.

3. Select Calculate Local g Factor.

The instrument prompts you to enter the local latitude.

Figure 9.10 Calculate Local Gravity Screen 1

4. Scroll in the local latitude using the data entry procedure.

44 FLSC 05 w/FLI 225 Instrument Service Manual

9 Calibrate the FLSC 05 with FLI 225

5. Press the Enter softkey.

The instrument prompts you to enter the local altitude.

Figure 9.11 Calculate Local Gravity Screen 2

6. Scroll in the local altitude in feet using the data entry procedure.

7. Press the Enter softkey.

The instrument calculates the gravity factor.

Figure 9.12 Calculate Local Gravity Screen 3

8. Press the Esc or Enter softkey to return to the G rav it y Co mp ens at io n lis t.

9. Press the Esc softkey to return to the Calibrate screen.

Key in Known Gravity Factor

If you know the gravity factor for the place of installation, you can sav e se ve ra l steps.

1. From the Gravity Compensation Menu, select Key In/View Local g Factor.

The current gravity factor is displayed.

Figure 9.13 Gravity Factor Key-in Screen

2. Scroll in the new gravity factor as necessary, using the data entry procedure.

3. Press the Enter softkey to accept the new gravity factor and return to the
Gravity Compensation list.

4. Press the Esc softkey to return to the Calibrate Menu.

FLSC 05 w/FLI 225 Instrument Service Manual 45

9.1.4 Zero

1. Place all deadload (pallets, chains, etc.) on the forks.

2. Select Zero from the Calibrate screen.

3. Remove all weight from the scale (except deadload) and press the Enter
softkey.

The screen will change and may briefly show a weight value other than
zero while processing.

Figure 9.14 Zero in Process

The zero value is stored after processing.

4. Press the Enter or Esc softkey to return to the Calibrate screen when
prompted.

9.1.5 Span

1. Select Span from the Calibrate menu.

2. Using the data entry procedure, scroll in the calibration weight if other than the
default.

Figure 9.15 Key in Calibration Weight

The Cal Weight value (span weight value) is the known weight you will use when
prompted to “apply load” during calibration.

46 FLSC 05 w/FLI 225 Instrument Service Manual

9 Calibrate the FLSC 05 with FLI 225

3. Apply the correct load to the scale.

The load must be equal to the value entered in on step 2.

Figure 9.16 Span Weight Applied

4. After all the weight is loaded and the scale has stabilized, press the Enter
softkey.

The screen will change and may briefly show a weight value other than
the weight keyed in on step 2 while processing.

5. Press the Enter or Esc softkey when prompted.

9.1.6 FLSC Calibration

Select FLSC Calibration from the Calibrate screen and the following screen is
displayed.

Corner Calibration: helps the Weigh Bars work together. If you will be

Figure 9.17 Span in Process

The span value is stored after processing.

Span calibration is complete and the instrument returns to Calibrate.

Figure 9.18 FLSC Calibration Screen

performing an Angle Calibration, you must first perform a

Corner Calibration.

Angle Calibration: provides the most accurate weight reading when the lo ad

is pitched forward or backwards or when it is rolled right or
left which may occur in normal forklift operation

FLSC 05 w/FLI 225 Instrument Service Manual 47

Corner Calibration

Corner calibrate the system using a known weight (minimum 10% capacity - maxim um
40% capacity) in each corner of the pallet in succession.

Select Corner Calibration from the FLSC Calibration screen.

The Corner Calibration screen is displayed.

Figure 9.19 Corner Calibration Screen.

The four corner points are stored in Set/View Corner Points and are define d as :

Table 9.1 Corner Points Defined

Point Description

Pt 1: Right Rear Place weight on the rear, right corner of the pallet.
Pt 2: Left Rear Place weight on the rear, left corner of the pallet.
Pt 3: Left Front Place weight on the front, left corner of the pallet.
Pt 4: Right Front Place weight on the front, right corner of the pallet.

Any reference to Right, Left, Forward or Backward is from the driver’s point of view.

Pt 1: Right Rear

1. Select Set/View Corner Points from the Corner Calibration menu.

The Set/View Corner Points screen is displayed with Pt 1: Right Rear
highlighted.

Figure 9.20 Set/View Corner Points Screen

2. Press the Enter softkey.

48 FLSC 05 w/FLI 225 Instrument Service Manual

9 Calibrate the FLSC 05 with FLI 225

3. Place weight on the rear, right corner of th e pallet.

Figure 9.21 Corner Calibration Point 1

The instrument displays both the live and the most recent stored raw
count values for the cells.

Figure 9.22 Sample Live and Stored Counts

4. Wait for coun ts to stabilize

The last two or three digits of the “Live” counts value will continue to fluctuate.

5. Press the Store softkey.

The instrument stores the counts and returns to the Set/View Corner
Points screen.

6. Remove the weight (except for the deadload).

Pt 2: Left Rear - Pt 4: Right Front

The instructions for points 2 through 4 are the same as those for point 1 and are
described in this section. The instructions continue from the previous section.

7. From the Set/View Corner Points screen, press the Down Arrow softkey to
highlight the next point (Pt 2: Left Rear, Pt 3: Left Front, etc.)

8. Press the Enter softkey.

The instrument displays the live and stored raw count values for the
cells.

FLSC 05 w/FLI 225 Instrument Service Manual 49

9. Place the corner weight on the pallet in the position that corresponds to the
point.

Figure 9.23 Weight Position for Points 2 through 4

10. Wait for counts to stabilize.

11. Press the Store softkey.

The instrument stores the counts and returns to the Set/View Corner
Points screen.

12. Repeat steps 7 through11 until completing Pt 4: Right Front.

13. After completing all four points, press the Esc softkey to return to the Corner
Calibration screen.

14. Proceed to Fit Corner Points.

Fit Corner Points

After completing the corner calibration, you must fit the points.

1. Select Fit Corner Points from the Corner Calibration screen.

2. Press the Yes softkey to fit the corner points.

The screen displays Fit Complete and displays a weight.

3. Press the Esc or Enter softkey to return to the Corner Calibration menu.

If you select No when prompted “Are you Sure?” the fit is not performed and the
instrument returns to the Corner Calibration screen.

4. Press the Esc softkey to return to the FLSC Calibration menu.

5. Proceed to Angle Calibration or press the Esc softkey 2 times to return to the
Setup Manager module.

50 FLSC 05 w/FLI 225 Instrument Service Manual

9 Calibrate the FLSC 05 with FLI 225

Angle Calibration

1. Select Angle Calibration from the FLSC Calibration screen to display the
following:

Figure 9.24 Sample Angle Calibration Screen

Change Cal Weight

If you need to change the Cal Full Weight value (the span weight value) or the Cal Half
Weight value, follow these instructions before continuing with the angle calibration.

The Cal Half Weight value must be equal to 50% of the Cal Full Weight value.

1. Select Cal Full Weight from the Angle Calibration module.

2. Scroll in the new value using the data entry procedure.

3. Press the Enter softkey.

The instrument returns to the Angle Calibration menu.

4. Select Cal Half We ight from the Angle Calibration module.

5. Repeat steps 2 and 3.

The instrument returns to the Angle Calibration menu.

6. Proceed to Set/View Angle Points.

Set/View Angle Points

The Set/V iew Angle Points section is where the values for the angle points are sto red.

Figure 9.25 Set/View Angle Points Screen 1

FLSC 05 w/FLI 225 Instrument Service Manual 51

The sixteen points are defined in the table below.

Table 9.2 Explanation of Sixteen Points

Points 1 - 5 Points 6 - 10 Points 11 - 15 Point 16

No Weight Half Weight Full Weight Half Weight

Level Level Level
Roll Left (~ 5°) Roll Left (~ 5°) Roll Left (~ 5°)
Roll Right (~5°) Roll Right (~5°) Roll Right (~5°)

Level
Pitch Forward Pitch Forward Pitch Forward
Pitch Backward Pitch Backward Pitch Backward

Any reference to Right, Left, Forward or Backward is from the driver’s point of view . In
the illustration below, 1 is level, 2 is roll left, 3 is roll right, 4 is level, 5 is pitch
backwards and 6 is pitch forward.

Use ramps to facilitate rolling the forklift. See Making a Ramp for Tilting the
Forklift on page 79.

No Weight (Points 1-5)

1. Place all deadload (pallets, chains, etc.) on the forks.

52 FLSC 05 w/FLI 225 Instrument Service Manual

9 Calibrate the FLSC 05 with FLI 225

2. Select point 1 from the Set/View Angle Points screen.
The instrument displays both the live and the most recent stored raw

count values for the scale pitch and roll as well as for the current weight.

Figure 9.26 Sample Counts Pt 1

The last two or three digits of the “Live” counts value will continue to fluctuate.

3. Press the Store softkey.
The instrument stores the value and returns to the

Set/View Angle Points screen.

4. Press the Down Arrow softkey to highlight Pt 2 No Wt Roll Left.

5. Press the Enter softkey.

6. Roll the forklift 5 degrees to the left.

7. Press the Store softkey.
The instrument stores the value and returns to the

Set/View Angle Points screen.

8. Press the Down Arrow softkey to highlight Pt 3 No Wt Roll Right.

9. Roll the forklift 5 degrees to the right.

10. Press the Store softkey.
The instrument stores the value and returns to the

Set/View Angle Points screen.

11. Press the Down Arrow softkey to highlight Pt 4 No Wt Pitch Forward.

12. Press the Enter softkey.

Always return the lift truck and forks to a level condition before proceeding to the next
step. For example, do not tip both forward and to the side during any step in the
procedure.

13. Tilt the forks 5 degrees forward.

14. Press the Store softkey.
The instrument stores the value and returns to the

Set/View Angle Points screen.

FLSC 05 w/FLI 225 Instrument Service Manual 53

15. Press the Down Arrow softkey to highlight Pt 5 No Wt Pitch Back.

16. Press the Enter softkey.

17. Tilt the forks back 5 degrees.

18. Press the Store softkey.
The zero points are complete and you can move on to half weight.

Half Weight (Points 6-10)

The process of acquiring the half weight values is the same as described in the
previous section except you will use the half weight value. It is assumed that points 1
through 5 have been set.

1. With the deadload on the forks, load 50% of the full weight on to the forks.

2. Perform all five half weight calib ration poin ts as prompted. T he proced ure is

the same as described in No Weight (Points 1-5) on page 52.

3. Proceed to the section on full capacity.

Full Weight (Points 11-15)

The process of acquiring the full weight values is the same as described in the p revious
sections except you will use the full weight value. It is assumed that points 1 through
10 have been set.

1. Add sufficient weight until reaching the full weight value.

2. Perform all five full weight calibration points as prompted. The procedure is the

same as described in No Weight (Points 1-5) on page 52.

3. Proceed to the final sectio n.

Half Weight Level (Point 16)

After completing all points with the fu ll weight on the forks, the FLI 225 prompts yo u for
one final point.

1. Remove 50% of the weight.

2. Press the Down Arrow softkey to select Pt 16 Half Weight Level.

3. Press the Enter softkey.

4. Level the forks.

5. Press the Store softkey.
The instrument returns to the Set/View Angle Points screen.

6. Press the Esc softkey.

7. Proceed to the Fit Angl e Points section.

54 FLSC 05 w/FLI 225 Instrument Service Manual

9 Scale

Fit Angle Points

After performing an angle calibration, you must fit the angle points.

1. From Angle Calibration, press the Down Arrow softkey to highligh t Fit Angle

Points.

2. Press the Yes softkey to accept.
The current weight is displayed along with the Fit Index value.

If you select No when prompted “Are you Sure?” the fit is not performed and the
instrument returns to the Angle Calibration menu.

3. Press the Enter or Esc softkey to return to Angle Calibration.

4. Press the Esc softkey to return to FLSC Calibration.

5. Press the Esc softkey to return to Calibrate.

6. Press the Esc softkey to return to the top of the Setup Manager module.

7. Select another item from the Setup Manager or press the Esc softkey to

return to the top of the Admin Management menu.

9.2 Scale

1. Select Scale from the Setup Manager module and the following is displayed.

Figure 9.27 Scale Module Pages 1 and 2

2. Select the item to configure from the Scale mod ule.

3. When finished changing the scale properties, pr ess the Esc softkey to return

to the top of the Setup Manager screen.

4. Press the Esc softkey to return to the top of the Admin Management screen.

5. Press the Esc softkey to exit and return to normal operating mode.

FLSC 05 w/FLI 225 Instrument Service Manual 55

9.2.1 Units

Select Units to configure the calibration, display or custom units.

Figure 9.28 Units Screen

l CalibrationSelect Calibration to pick lb or kg for the calibration unit of

measure.

l lbSelect lb to turn lb on or off.
l kg Select kg to turn kg on or off.
l CustomSelect Custom to create and define a custom unit of measure.

To create a custom unit of measure, such as a ton, follow these steps:

1. Select Custom from the Units screen.
The Custom menu displays.

Figure 9.29 Custom Units Menu

2. Select Custom Unit =.

3. Press the Up or Down Arrow softkey to select On.

4. Press the Enter softkey.
The change is made and the instrument returns to the Custom module.

5. Select Custom Name =.

6. Scroll in a new name for the custom unit of m easure using th e Data Entry

Procedure on page 13.

7. Press the Enter softkey.
The change is made and the instrument returns to the Custom module.

8. Select Custom Cal Wt = 0 from the Custom module.

9. Press the Enter softkey.

56 FLSC 05 w/FLI 225 Instrument Service Manual

9 Scale

10. Scroll in the value for the calibration weight.

Cal Wt is the amount of weight needed to make one custom unit. For example, if
creating a custom unit for tons, the Cal Wt is 2000 (2000 lbs = 1 ton) and the Cal Un it
is 1.

11. Press the Enter softkey.
The change is made and the instrument returns to the Custom module.

12. Select Custom Unit Wt = 0 fr om the Custom me nu.

13. Scroll in the value for the custom unit weigh t.

14. Press the Enter softkey.
The change is made and the instrument returns to the Custom module.

Creation of the custom unit is complete.

15. Press the Esc softkey to return to Units menu.

16. Press the Esc softkey (again) to return to the Scale module.

9.2.2 Settings

1. Select Settings from the Scale Module and the following screen is displayed.

Figure 9.30 Settings Module with Defaults

2. After defining the settings, press the Esc softkey to exit and return to the Scale

Module.

Each item is explained below.

Capacity

By default, the capacity is 5000 lb.

1. From the Settings screen, select Capacity.

2. Scroll in the new capacity using the Data Entry Procedure on page 13.

3. Press the Enter softkey to accept and return to Settings.

FLSC 05 w/FLI 225 Instrument Service Manual 57

Division

By default, the number of divisions is set to 5 lb.

1. From the Settings screen, select Divisions =.

2. Press the Up or Down Arrow softkey to scroll through the available divisions

and highlight the value.

3. Press the Enter softkey to set the division size and return to Settings.

Carriage Type

1. From the Settings screen, select Carriage Type to select the type of scale

carriage attached to the FLI 225 instrument. Choose from:

FLSC WIRED (default) refers to the FLSC carriage with the standard
interface cable connecting it to the FLI 225 instrument. This is an all digital
system.

FLSC WIRELESS refers to the FLSC carriage with the optional FLW 100
radio interface to the FLI 225. This is an all digital system.

QTLTSC refers to the analog QTLTSC carriage. This is an analog scale
with angle sensing for legal-for-trade operation and an interface cable to
the FLI 225.

QTLTS refers to the analog QTLTS carriage. This is an analog scale with
an interface cable to the FLI 225.

9.2.3 Filtering

2. Press the Enter softkey to accept the choice and return to Settings.

Filtering is used to counteract vibration of the scale.

1. Select Filter from the Scale module to display the Filter screen.

Figure 9.31 Filter Module with Defaults

2. After defining the settings, press the Esc softkey to exit and return to the Scale

Module.

Averages

1. Select Averages from the Filter module.

2. Scroll in a value between 1 and 128. This is the number of weight readings per

second to average for the weight display value. The default value is 96.

3. Press the Enter softkey to accept the change and return to the Filter screen.

58 FLSC 05 w/FLI 225 Instrument Service Manual

9 Scale

Filter Type

1. Select Filter Type = from the Filter module.

2. Select from the available filtering options. Filter2 is the default setting.

None means no filtering.
Filter1 filtering is slower response to weight in a longer time period with

improved accuracy.
Filter2 filtering is faster response to weight in a short time.

3. Press the Enter softkey to accept and return to the Filter screen.

Constant

If you turn filtering on, you need to set the Constant. Typical valu es are between 1 and
10 (default = 4). Set the number low for small vibration problems and higher for more
dampening effect.

1. Select Constant from the Filter Module.

2. Press the Up or Down Arrow softkey to choose a number between 0 and 10.

3. Press the Enter softkey.

Threshold

The purpose of the Threshold is so the instrument will respond quickly to large weight
changes. Threshold is the amount of weight change, in calibr ation units, beyond wh ich
the filter will be temporarily disabled. For example, if you set this to 10 lbs, a weight
change over 10 pounds occurring during the sample time (½ sec. in our example) will
disable the filter until the weight change during the sample time drops below 10 lbs.

1. Select Threshold from the Filter Module.

2. Scroll in the value in calibration units using the data entry procedure

3. Press the Enter softkey to return to the Filter screen.

9.2.4 Motion/AZT

1. Select Motion/AZT from the Scale module to display the following screens.

The constant is stored and the instrument returns to the Filter screen.

(Default = 3).

Figure 9.32 Motion/AZT Screens

2. After defining the settings, press the Esc softkey to exit and return to Scale.

FLSC 05 w/FLI 225 Instrument Service Manual 59

Motion (div) =

1. Select Motion (div)= from the Motion/AZT module.

2. Press the Up or Down Arrow softkeys to highlight the appropriate number of

divisions (1 - 10). The default setting is 3.

3. Press the Enter softkey.
The change is made and the instrument returns to Motion/AZT module.

Motion (sec) =

1. Select Motion (sec)= from the Motion/AZT module.

2. Press the Up or Down Arrow softkeys to highlight the appropriate number of

seconds. The default setting is 1.

3. Press the Enter softkey.
The change is made and the instrument returns to the Motion/AZT

module.

AZT (div) =

1. Select AZT (div) from the Motion/AZT to display the list of divisions. The

default setting is 3.

2. Press the Up or Down Arrow softkey to select the appropriate number of

divisions from the list. This division size defines a range above and below
zero. When the weight is within this range for the number of seconds set in
AZT (sec), 50% of the weight will be zeroed.

The change is made and the instrument returns to Motion/AZT.

AZT (sec) =

1. Select AZT (sec)= from the Motion/AZT module.

2. Press the Up or Down Arrow softkey to highlight the appropriate number of

seconds. The default setting is 1.

3. Press the Enter softkey.
The change is made and the instrument returns to Motion/AZT.

To disable AZT, set AZT (div) and AZT (sec) to zero.

60 FLSC 05 w/FLI 225 Instrument Service Manual

Motion Blanking

1. From the Motion/AZT module, press the Up Arrow softkey one time to select

Motion Blanking.

2. Select either Off or On. The default setting is Off.

If Motion Blanking is enabled, the instrument will show dashes if there is motion on
the scale.

9.2.5 Auto Tare Clear

Setting Auto T are Clear to ON means if tares are enabled, they will clear automatically
when the gross weight returns to zero. The default setting for this is OFF. For
information on enabling tares, see Enable or Disable Keys on page 77.

1. Select Auto Tare Clear = Off from the Scale module.

9 Scale

The change is made and the instrument returns to page 2 of the Motion/
AZT screen.

9.2.6 Ranges

2. Select either On or Off.
The change is made and the instrument returns to page 2 of the Scale

module.

1. Select Ranges from the second page of the Scale Module to display these

screens.

Figure 9.33 Sample Ranges Module

2. Select the range you wish to change from the Ranges Module. Refer to the

appropriate table for available ranges and default values for your country
code.

3. Scroll in the new value using the data entry procedure. For Center of Zero,

choose from the 2 available options. See Table 9.3 or Table 9.4 for the valid
ranges and defaults.

4. Press the Enter softkey to accept the entry and return to the Ranges module.

FLSC 05 w/FLI 225 Instrument Service Manual 61

5. Press the Esc softkey to return to the previous menu.

Table 9.3 Ranges NA Configuration

Range Name Details Valid Range Default

Over/Under

Basis =

Overload (%)

Underload (%)

Zero Range (%)

Center of Zero

Zero Band

Auto Print (%)

Zero Drift (%)

Choose how the instrument determines an Over or Under
condition. Choose either percentage or divisions.

This is the allowable percentage over maximum capacity.
Any weight beyond this will cause the instrument to record
an overload condition.

This is the allowable percentage below minimum capacity.
Any weight, in the negative direction, beyond this weight will
cause the instrument to record an underload condition.

This is the amount of weight you can zero off. Zeroing off
weight reduces the scale capacity by the amount of weight
zeroed off.

This affects how the zero indication will operate. Any weight
within ± of your choice for the zero point will cause the
display to show the center of zero annunciator >0<.

This determines how close to ‘actual’ zero the measured
weight must be for the instrument to recognize an empty
scale with no load.

Entering a value greater than 0 enables autoprint. Entering a
value of 100 would require overloading the scale to print and
is NOT recommended.

This allows you to set a warning level as a percentage of
scale capacity. If the deadload weight change exceeds this
percentage, an error message is displayed.?

Percent or

Division

Percent

(%)

0-105 105

0 - 105 20

0 - 100 100

0.25 - 0.50
divisions

0.25

divisions

0 - 5000 lbs 50 lbs

0 - 100 0

0 - 100 2

62 FLSC 05 w/FLI 225 Instrument Service Manual

9 Scale

Table 9.4 Ranges EU Configuration

Range Name Details Valid Range Default

Over/Under

Basis =

Choose how the instrument determines an Over or Under
condition. Choose either percentage or divisions

Overload (div) This is the allowable amount over maximum capacity. Any

weight beyond this will cause the instrument to record an
overload condition.

Underload (div) This is the allowable amount below minimum capacity. Any

weight, in the negative direction, beyond this weight will
cause the instrument to record an underload condition.

Zero Range (%) This is the amount of weight you can zero off. Zeroing off

weight reduces the scale capacity by the amount of weight
zeroed off.

Center of Zero This affects how the zero indication will operate. Any weight

within ± of your choice for the zero point will cause the
display to show the center of zero annunciator >0<.

Zero Band This determines how close to ‘actual’ zero the measured

weight must be for the instrument to recognize an empty
scale with no load.

Auto Print (%) Entering a value greater than 0 enables autoprint. Entering a

value of 100 would require overloading the scale to print and
is NOT recommended.

Zero Drift (%) This allows you to set a warning level as a percentage of

scale capacity. If the deadload weight change exceeds this
percentage, an error message is displayed.?

Percent or

Division

Division

0-100 9

0 - 250 250

0 - 100 100

0.25 - 0.50
divisions

0.25

divisions

0 - 5000 lbs 50 lbs

0 - 100 0

0 - 100 2

FLSC 05 w/FLI 225 Instrument Service Manual 63

9.3 Communications

The Communications Module allows you to configure the settings for the available
COM ports. For information on how to test communications ports, refer to chapter 7,

Diagnostics Manager Module.

When connected to a digital junction box, COM 1 will automatically be configured and
will not be accessible.

1. Select Communications from the Setup Module to display the
Communications module.

Figure 9.34 Communications Module

2. Select the appropriate port.

The configurable options are displayed.

Figure 9.35 Com Port Screens 1- 3

3. Configure the port as necessary. See configuration options on the following
pages.

4. After configuring the port(s), press the Esc softkey to exit and return to the
Setup Module.

64 FLSC 05 w/FLI 225 Instrument Service Manual

9 Communications

Mode

Select Mode and the following list appe ars. Select one and press th e Enter sof tkey to
activate it and return to the previous scree n. Enquire is the default value.

l Print Key Choose Print Key to send a print string out the

COM port to a connected printer or serial device
when the PRINT key is pressed.

l Enquire Choose Enquire to configure the instrument to

respond to a single character such as ASCII 05
sent from a remote device.

l Extended Enquire This is currently under development.
l Scanner Choose Scanner to configure the COM port to

interface with a bar code scanner.

l FLJ 100 Choose FLJ100 to configure the COM port to

use the FLJ 100 radio.

l SMA Choose SMA to configure the COM port to use

the Level 1 command / response protocol from
the Scale Manufacturer’s Association. See SMA
Protocol on page 100 for a list of available
commands and the corresponding results.

l Broadcast Choose Broadcast to continually output

(broadcast) data from the instrument to a
peripheral device.

l Remote Display Choose Remote Display to configure the COM

port for use with the FLR 100 remote display.

Baud

Select Baud to choose from the available baud rates: 300, 1200, 2400, 4800. 96 00,
19200, 38400, 57600, 1 15200. Select one and press the Enter sof tkey to activate it and
return to the previous screen. The default is 9600.

Data Bits

Select Data Bits to choose either 7 or 8. Select one and press the Enter softkey to
activate it and return to the previous screen. The default is 8.

Parity

Select Parity to choose from None, Odd or Even. Select one and press the Enter
softkey to activate it and return to the previous screen. The default is None.

Stop Bits

Select Stop Bits and choose either 1 or 2. Press the Enter softkey to activate it and
return to the previous screen. The default is 1.

Handshake

Handshaking is available on COM 3 only . Select this option and choose None, Xon/Off
or Hardware. Press the Enter softkey to accept it and return to the previous screen.
The default is None.

FLSC 05 w/FLI 225 Instrument Service Manual 65

Polling Character

Select Polling Character to set the character to which the instrument will respond.
Scroll in a value for a single HEX decimal (HEX) character (1 - 255). Press the Enter
softkey to accept the entry and return to the previous screen. The default setting is 5.

Leading Zero

Select Leading Zero and choose either On or Off. If you turn this item on, a leading
zero will appear in weight fields when sent through the COM port. The default value is
Off.

Update Rate =

Select Update Rate = and choose 1, 2, 5 or 10 updates per second. The default is 1.
Make your selection and press the Enter sof tkey to accept it an d return to the previous
screen.

9.4 Print Strings

Select Print Strings from the Setup Manager module to customize what information
is included on reports, transaction records, etc. using up to 10 print strings and defining
which strings to print. The following screen is displayed.

Figure 9.36 Print Strings Module

After making the changes to the print strings, press the Esc softkey to return to the

Setup Manager module.

If you change the Application type, the print strings will return to their default settings.

66 FLSC 05 w/FLI 225 Instrument Service Manual

9.4.1 Print String Editor

1. Select Print String Editor from the Print String screen to display the list of
available print strings.

2. Select the string you need to change.

9 Print Strings

Figure 9.37 Print String Editor (page 1 of 3)

The configurable options for the selected print string are displayed.Refer
to the figure and table below to help you move around the edito r.

Figure 9.38 Sample Print String Detail with Configuration Keys

FLSC 05 w/FLI 225 Instrument Service Manual 67

Table 9.5 Print String Configuration Screen and Keys Defin ed

Reference

#

Description or Function

1 Press the TARE key to insert a character where the cursor is located.

When prompted, press the Yes softkey to insert a new character or press the No
softkey for the option to delete the current character.

2 Press the PRINT key to send the current print string details to a printer or other

peripheral.

3 Press the SELECT key to move to the previous character. This does NOT delete the

previous character.
4 Press the ZERO key to move to the next character.
5 Press the Enter softkey (F4) to accept the entry and return to the list of strings.
6 Press the Down Arrow softkey (F3) to scroll down through the HEX and DEC values.
7 Press the Up Arrow softkey (F2) to scroll up through the HEX and DEC values.
8 Press the Esc softkey (F1) to disregard changes and return to the list of strings.
9 Current Token

10 HEX value for the current token
11 Decimal equivalent of the HEX value.
12 Current character
13 Location of the End of String character
14 Current String

The changes are made and the instrument returns to the previous
screen. Refer to the table of available print tokens as necessary.

68 FLSC 05 w/FLI 225 Instrument Service Manual

Table 9.6 Print Token List

Dec HEX Token Application

128 0x80 GWT Gross Weight
129 0x81 NWT Net Weight
131 0x83 SAT Semi-Auto Tare
132 0x84 UN Units
135 0x87 ID Scale Serial Number
136 0x88 TIM Time
137 0x89 DAT Date
151 0x97 GTO Gross Accumulator
153 0x99 STO Net Accumulator
162 0xA2 DIS Remote Display Status
170 0xAA VER Software Version Number
173 0xAD WST Weight Steady
200 0xC8 DSP Print Displayed Weight
208 0xD0 DBF Database Field:

1 = ID#
2 = Scale/Carriage ID
3 = Device ID
4 = Site ID
5 = Forklift ID

6 = Operator ID
215 0xD7 NULL Null Token
216 0xD8 ACT Send the active value (G=gross,

N=net, T=Tare)
229 0xE5 PAC Pitch Angle Counts
230 0xE6 RAC Roll Angle Counts
231 0xE7 PAD Pitch Angle Degrees Value
232 0xE8 RAD Roll Angle Degrees Value
233 0xE9 HRW High Resolution Weight Value
250 0xFA SOC Start of CCITT CRC-16 Checksum
251 0xFB EOC End of CCITT CRC-16 Checksum
252 0xFC CRC CCITT CRC-16 Checksum Value
253 0xFD HEX Following character will be

transmitted by value.
254 0xFE TEX Token extender for future

development.
255 0xFF EOS End of String

9 Print Strings

The ASCII characters are shown on the Chart of ASCII Characters on page 70.

FLSC 05 w/FLI 225 Instrument Service Manual 69

Chart of ASCII Characters

70 FLSC 05 w/FLI 225 Instrument Service Manual

9.4.2 Strings to Print

1. Select Strings to Print from the Print Strings screen to display the following

2. Select the mode to which you will assign the print string(s).

9 Print Strings

screen.

Figure 9.39 Strings to Print Screen

The current print strings and the order they are sent are displayed.

Figure 9.40 Sample Strings to Print for Print Key

3. Select the step you wish to change.
A list of available print strings is displayed.

Figure 9.41 Available Print Strings (page 1 of 3)

4. Select one of the available print strings to add th e string to the mo de and

return to the previous screen.

Figure 9.42 Updated Strings to Print Screen

5. Repeat steps 2 through 4 until complete.

6. Press the Esc softkey 3 times to return to the Setup Manager module.

FLSC 05 w/FLI 225 Instrument Service Manual 71

9.5 App Selection

1. Select App Selection from the Setup Manager module to display the

App Selection module.

Classic w/Print With the FLI 225 set to this mode, you can weigh and print. There

Classic w/Accum Along with the print function, you can accumulate transactions and

Expanded Expanded mode builds on the Classic w/Accumulator mode and

2. Select the application that best suits your customer’s needs.

Figure 9.43 App Selection module

is no accumulate function.

print them later or print accumulator reports.

activates the ID, Pallet and Oper softkeys.

3. If prompted to default the prin t strings, press th e Yes softkey to set the print

strings back to their defaults or press the No softkey to keep any changes
made to the print strings.

Selecting No does not prevent you from changing the application.

The change is made and the instrument returns to the previous screen.

72 FLSC 05 w/FLI 225 Instrument Service Manual

9.6 Country Code

Select Country Code and choose between NA, North America, or EU, European
Union, for the FLI 225 location of operation. This will set the necessary defaults for each
location.

Changing a global setting will override any changes made previously to an item’s
value. The reverse is also true. If you make a change to an item’s value, it will
override the setting which was made in Country Code.

The following table shows the factory default settings for the FLI 225, for each region.

Gravity Compensation 9.8043 9.8043
Calibration Unit lb kg
Enabled Unit(s) lb kg
Weight Capacity 5000 lb 2500 kg
Weight Division 5 lb 2 kg
Calibration Full Weight 4000 lb 2000 kg
Calibration Half Weight 2000 lb 1000 kg
Gross Zero Band 50 lb (10 divisions) 20 kg (10 divisions)
Over/Under range basis percentage divisions
Over range 105% 9 divisions (i.e. 2518 kg)
Under range 20% 250 divisions (i.e.-500 kg)
Zero range 100% 2%
Auto print range 0% (disabled) 0% (disabled)
Separator decimal point decimal point
Time format 12 hr (4:00 PM) 24 hr (16:00)
Date format MM/DD/YYYY DD/MM/YYYY

9 Country Code

Table 9.7 Default Settings by Region

Setting N orth America (NA) Default Europe (EU) Defaults

FLSC 05 w/FLI 225 Instrument Service Manual 73

9.7 Miscellaneous

1. Select Miscellaneous from the Setup Module to display the Miscellaneous

module.

2. Select an item from the Miscellaneous module.

3. Make any necessary changes to the item(s).

4. After making the changes, press the Esc softkey to exit and return to the

Setup Module.

9.7.1 Inputs

Figure 9.44 Miscellaneous Module

1. Select Inputs from the Miscellaneous module to display the Inputs screen.

Figure 9.45 Default Inputs Screen

2. From the Inputs screen, select either Input 1 or Input 2.
The remote input options for the input are displayed.

Figure 9.46 Input Options

3. Select the option you wish to assign to the selected input.
The change is made and the instrument returns to the Inputs module.

4. Repeat steps 2 and 3 if enabling a second input.

74 FLSC 05 w/FLI 225 Instrument Service Manual

5. Press the Esc softkey to return to the Miscellaneous module.

6. After you have finished configuring all the options, press the Esc softkey 2

7. Power off the instrument and disconnect from the power source.

8. Remove the back panel.

9. Remove the plug from the g land.

10. Run the cable leads for your in put(s) throug h the gland.

11. Route the cable leads to TB4 on th e comm unications board. TB4a and TB 4b

9.7.2 Reset System

1. Select Reset System from the Miscellaneous module to display the following

9 Miscellaneous

more times to return to normal operating mode.

correspond to Input 1. TB4c and TB4d correspond to Input 2. (Refer to the
block diagrams and technical illustrations for more information.)

screen:

Figure 9.47 Reset System Screen

l Reset All Accumulators clears the accumulators but all other settings will

remain.

l Reset Configuration sets all configuration settings EXCEPT calibration

back to factory defaults (including Country Code and Print Strings).

l Reset Entire System will set the instrument back to ALL factory default

settings, including calibration information.

2. Select the type of reset you wish to perform.

CAUTION: Do not reset anything unless you sure about your decision!

3. Press the Yes softkey to confirm and reset the selected options.
The selected parameters are reset and the instrument reboots in normal

operating mode.

Pressing the No softkey will abort the reset procedure and the instrument will return to
the Reset System module.

FLSC 05 w/FLI 225 Instrument Service Manual 75

9.7.3 Passwords

1. Select Passwords from the Miscellaneous module to access the Passwords

screen.

Figure 9.48 Passwords Screen

2. Select the password you wish to change from the list.
The current password for that option is displayed.

3. Scroll in the new password using the Data Entry Procedure on page 13.

4. Press the Enter softkey to accept the new password and return to the

Passwords module.

9.7.4 Display

CAUTION: Changing the default Admin password is not recommended as you
will not be able to access the menus if it is lost or forgotten.

1. Select Display from the Miscellaneous module to access the Display screen.

Figure 9.49 Display Screen

2. Select Update Rate (Hz) = to a ccess the list of availa ble update ra tes.

3. Change the update rate to 1, 2, 5 or 10 Hz as necessary. The default is 5.
The change is made and the instrument returns to the Display screen.

4. Select Separator = from the Display screen to display the available options

(decimal point or comma).

5. Select the decimal separator as necessary.
The change is made and the instrument returns to the Display screen.

6. Press the Esc softkey to return to the Miscellaneous module.

76 FLSC 05 w/FLI 225 Instrument Service Manual

9.7.5 Time / Date

1. Select Time / Date from the Miscellaneous module to configure the way the

2. Select Time Format to change the way time is displayed as necessar y.

3. Select either 12 Hours (a.m and p.m) or 24 Hours display.

4. Press the Esc softkey to return to the Miscellaneous module or press the Up

9 Miscellaneous

time and date display.

Figure 9.50 Time and Date Screen.

The change is made and the instrument returns to Time / Date.

or Down Arrow softkey as necessary to set the date format.

5. From the Tim e / Date screen, select Date to change the way dates are

displayed.

6. Select either MMDDYYYY (2 digit month, 2 digit day, 4 digit year) or

DDMMYYYY (2 digit day, digit month, 4 digit year). The default setting for
North America is MMDDYYYY.

The change is made and the instrument returns to Time / Date.

7. Press the Esc softkey to return to the Miscellaneous module.

9.7.6 Enable or Disable Keys

1. Select Key Enable from the Miscellaneous module to display the list of

available keys.

Figure 9.51 Key Enable Module Defaults

2. Select the key you wish to enable or disable.

3. Select either On (enable) or Off (Disable) as necessary.
The change is made and the instrument returns to the previous screen.

4. Press the Esc softkey to return to the Miscellaneous module.

FLSC 05 w/FLI 225 Instrument Service Manual 77

9.7.7 Diagnostics Tools

1. Select Diagnostics from the Miscellaneous module to display the list of

diagnostics tools that can be enabled or disabled.

2. Select the option you wish to enable or disable.

The Over Trigger and Under Trigger values are shown for re fe rence o nly and ca n not
be changed in this module. The values shown reflect the ranges set in section

9.2.6 .

3. Select On (enable) or Off (disable) as necessary.

Figure 9.52 Diagnostics Screens

The changes are made and the instrument returns to the Diagnostics
module.

4. Press the Esc softkey to return to the Miscellaneous module.

78 FLSC 05 w/FLI 225 Instrument Service Manual

10 Making a Ramp for Tilting the Forklift

10 Extras

10.1 Making a Ramp for Tilting the Forklift

Table 10.1 Ramp board dimensions

Board H W L (in inches)

A 0.5 in / 12.7 mm 8 in / 203.2 mm 24 in / 609.6 mm
B 0.5 in / 12.7 mm 8 in / 203.2 mm 22 in / 558.8 mm
C 0.5 in / 12.7 mm 8 in / 203.2 mm 20 in / 508.0 mm
D 0.5 in / 12.7 mm 8 in / 203.2 mm 18 in / 457.2 mm
E 0.5 in / 12.7 mm 8 in / 203.2 mm 16 in / 406.4 mm
F 0.5 in / 12.7 mm 8 in / 203.2 mm 14 in / 355.6 mm

Ramps are constructed of 1/2” plywood. Total height is 3 inches (76.2 mm).

FLSC 05 w/FLI 225 Instrument Service Manual 79

10.2 Calculating New Lift Capacity

No scale installed

Scale installed

l A = Forklift Capacity in pounds
l B = Inches from front wheel center line to fork face
l C = Inches from fork face to truck rating point

(usually 24")

l D = Weight of scale in pounds
l E = Inches from front wheel center line to

carriage face

l F = Inches from carriage face to scale

center of gravity (CG)

l G = J + K (inches from carriage face to rear

face of load)

l H = Inches from fork face to new truck

rating point

l J = Thickness of fork
l K = Thickness of scale

You must have the ID plate on the forklift updated stating the new lifting capacity and
center of gravity information. Always comply with your local rules and regulations. A
calculation formula is provided below.

It is the customer’s responsibility to contact their forklift manufacturer / distributor with
this information to obtain the new ID plate.

The FLSC forklift scale comes in an ITA Class II (16” high, 5,000 lb) model. This model
comes in several widths for cleat type carriages. From Table 10.2, select the width that
meets the dimensions of the forklift carriage. Use the weights, dimensions and the
following formula to calculate the net lifting capacity of your forklift with a scale
attached.

Refer to the figure below for the dimensions.

Figure 10.1 Formula & Dimensions for Calculating New Lift Capacity

80 FLSC 05 w/FLI 225 Instrument Service Manual

10 Resistance Test for FLSC Weigh Bars

10.2.1 Class II 5,000 lb Models

Table 10.2 Class II dimensions

Width Weight "D" DIM "F" DIM “K”

30.0" 319 lb 2.0" 4.0

32.0" 339 lb 2.0" 4.0

34.0" 346 lb 2.0" 4.0

36.0" 365 lb 2.0" 4.0

37.0" 369 lb 2.0 4.0

38.0" 373 lb 2.0" 4.0

40.0" 396 lb 2.0" 4.0

42.0" 404 lb 2.0" 4.0

10.3 Resistance Test for FLSC Weigh Bars

Perform these resistance checks to test the FLSC 05 Weigh Bars. With the meter set
on the appropriate ohms scale, check the following values between the color coded
wires on the section of the cord connected to the Weigh Bar or the corresponding pin
out for the connector. See Figure 10.2.

Figure 10.2 Weigh Bar connector

The electrical connections of the FLSC Weigh Bar can be verified by measuring the
resistances listed below:

Pins Wires Reading Tolerance in Ohms

1 to 2 ORG to RED _____________ 996 to 1004 (1000)
3 to 4 YEL to BRN _____________ 998 to 1002 (1000)
6 to 7 GRN to BLK _____________ 1074 to 1087 (1080)
7 to 8 BLK to BLU _____________ 1047 to 1053 (1050)
1 to 6 ORG to GRN _____________ 785 to 795 (790)
2 to 6 RED to GRN _____________ 785 to 795 (790)
1 to 7 ORG to BLK _____________ 785 to 795 (790)
2 to 7 RED to BLK _____________ 785 to 795 (790)
3 to 8 YEL to BLU _____________ 798 to 802 (800)
4 to 8 BRN to BLU _____________ 798 to 802 (800)
3 to 7 YEL to BLK _____________ 748 to 752 (750)
4 to 7 BRN to BLK _____________ 748 to 752 (750)

All pins or wires to the metal of the Weigh Bar are to measure >500 mega ohms. Pin
9 (shield, bare wire) to all other pins or wires are to measure >500 mega ohms.

FLSC 05 w/FLI 225 Instrument Service Manual 81

10.4 Replacing Weigh Bars on the FLSC 05 Carriage

10.4.1 Disassembly of the Carriage

Tools needed for replacement of a Weigh Bar:

l Minimum 12 inch/pounds torque wre nc h
l Minimum 65 foot/pounds torque wrench
l 5/32 and 3/8 hex Allen
l 6 Weigh Bar bolts, part # 17704-5929
l 3/4" or 1" socket drive
l 1 1/2” socket
l adapter for torque wrench to fit 1/2” socket
l 7/16 socket
l 3/4" socket
l 1/2"socket
l multiple 3/32" cable ties
l side cutters
l Medium strength thread-locking compound.
l another person and/or chain hoist--this disassembly and reassembly

procedure is a two person task

Jam nuts are torqued to 500 ft/lbs so removal requires extra force and caution. Use a
3/4" or 1" drive socket and the method described below to secure the scale for
disassembly/assembly.

1. Leave the forks on the scale with a loaded pallet on them.

2. Remove the lower hooks and disconnect th e scale interface cable.

3. With a helper, block the back of the forks with a wedge shaped piece of wood

while lowering the carriage so the scale will tilt forward when lowered.

4. Lower the scale so that it disengages from the forklift carriage.

5. Back the forklift away from the scale. This leaves the scale in an upright

position with easy access to the nuts and stability for providing the 500-ft lb.
torque required.

82 FLSC 05 w/FLI 225 Instrument Service Manual

10 Replacing Weigh Bars on the FLSC 05 Carriage

Cable egress guard

bolts, 7/16”

Jbox guard bolts,

7/16” (recessed)

6. Remove the cable egress guard by re moving the bo lts shown in Figure 10.3.

Figure 10.3 Bolts to remove

7. Remove the junction box g uard by rem oving the bolts pointed out in Figure

10.3.

8. Remove the junction box r etainer plate bolts, shown in Figure 10.4, and

remove the retainer plate.

Figure 10.4 Junction box retainer plate and bolts

9. Disconnect all the conne ctors from the junction box.

FLSC 05 w/FLI 225 Instrument Service Manual 83

10. Through the front of the carriage, remove the two recessed, hex screws (5/32”)

that hold the cable shields in place. See Figure 10.5.

Figure 10.5 Recessed cable shield screws

Step 8 is very important. Do not att empt to s epa rate t he t wo halv es of t he scale
without removing the two screws indicated in Figure 10.5. Damage will result.

11. Loosen the jam nuts. Jam nuts are torqued to 500 ft/lbs so removal requires

extra force and caution. Use a 3/4" or 1" drive socket. The weight of the pallet
on the forks will allow you to loosen the nuts without excess movement of the
carriage.

12. Once the jam nuts are loosened, place the carriage back on the forklift,

remove the wedges under the forks and remove the pallet from the forks.

13. Remove the forks and lower the scale carriage onto the edge of a sturdy pallet

and back the forklift away.

14. With assistance from other people or a hoist, lower the scale onto its front face

on the pallet.

15. Remove the jam nuts and the harde ned wa shers from the Weigh Bars.

16. With assistance from other people or a hoist, remo ve the rear car riage plate

from the front carriage plate, being careful not to damage the Weigh Bar
cables.

17. Clip and remove the cable ties securing the cable leading from the Weigh Bar

being replace.

18. Use a 3/8 Allen wrench and socket d rive r to remove the Weigh Bar bolts from

the Weigh Bar being replaced and discard the bolts.

19. Remove the Weigh Bar.

84 FLSC 05 w/FLI 225 Instrument Service Manual

10.4.2 Reassembly

Labeling the Cable from the Top Weigh Bars on the FLSC 05

To assure proper cable connection, when you replace a top Weigh Bar be sure to af fix
the FRONT label included in the Weigh Bar kit to the cable near the 9-pin connector.
See Figure 10.6.

Top Weigh Bars connect to the front two 9-pin connectors in the FLJ 100 junction box.
Front being the farthest away from the driver’s position. See Figure 10.7 for an
illustration of how the Weigh Bars should be connected to the FLJ 100.

10 Replacing Weigh Bars on the FLSC 05 Carriage

Figure 10.6 FRONT label shown in position.

Figure 10.7 FRONT label positions and FLJ 100 illustration. (View from below)

All directions are from the driver’s point of view with the scale mounted on the forklift.

With the top Weigh Bars labeled FRONT, reassemble the carriage by reversing the
disassembly steps. Pay close attention to the following notes:

1. Place the new Weigh Bar in position and check its rotation orientation. Be sure

the cable exit point matches the Weigh Bar you’re replacing, as shown in Figure

10.8.

2. You must replace the Weigh Bar bolts with new ones during reassembly. The

part number for 5000 lb Class II carriages is 17704-5929. See the note on
page 90.

FLSC 05 w/FLI 225 Instrument Service Manual 85

3. Make sure the Weigh Bar cables are positioned correctly and cable tie them to

Cable routing on the left side of the carriage.

‘Left side’ is from driver’s perspective.

Cable routing on the right side of the carriage.

‘Right side’ is from driver’s perspective.

each other and the cable guard in a fashion similar to the one shown in Figure

10.8.

Figure 10.8 Cable routing and cable ties

4. Be sure to cable tie the cables to the shield in a way that prevents the cables

from contacting the Weigh Bar bolts. See Figure 10.9.

Figure 10.9 Space must exist between the cable and the bo lt and sh ield

86 FLSC 05 w/FLI 225 Instrument Service Manual

10 Replacing Weigh Bars on the FLSC 05 Carriage

5. Make sure the cables are secured a nd will not get pinche d when the car riage

is reassembled.

6. Torque each of the Weigh Bar bolts to 65 foot pounds. Start at the top then go

to the bottom bolt. Always tighten opposites. Follow the pattern shown in
Figure 10.10.

Figure 10.10 Weigh Bar bolt tightening pattern

7. Using a hoist and strap or plenty of ma npower, slowly lower the back of the

carriage over the front, lining up the Weigh Bars with their associated holes in
the back plate. Be sure to keep the Weigh Bar cables and ends positioned so
they are not pinched as the two pieces are brought together. The cables
should exit the shields at the notches in the carriage. See Figures 10.11 and

10.12.

Figure 10.11 Joining the carriage halves

FLSC 05 w/FLI 225 Instrument Service Manual 87

Figure 10.12 Cable exit from shield

8. Install the hardened washers and jam nuts on the end of the Weigh Bar and

tighten the nuts finger tight. See Figure 10.13.

Figure 10.13 Hardened washer and jam nut

9. With help, stand the carriage assembly up on the pallet and move the cable

shields, between the carriage halves, with your fingers until the tab on each
corner of each shield engages in the holes in the back carriage plate.

Step 9 is important to avoid damaging the cab le shield and f or pro per f unction
of the scale.

88 FLSC 05 w/FLI 225 Instrument Service Manual

10 Replacing Weigh Bars on the FLSC 05 Carriage

Top Weigh Bar connectors

10. Place the screws thro ugh the rece sse d h oles, sh own in Figure 10.5, to attach

the cable guards to the carriage back plate. Tighten the screws.

11. Tighten the jam nuts to 50 ft pounds.

12. Attach all Weigh Bar cables to the junction box as shown in Figure 10.14. The

top Weigh Bars are attached to the connectors closest to the front plate of the
scale carriage.

13. Attach the interface cable. Route the cable as shown in F igure 10.15. T he

Figure 10.14 Weigh Bar cables attached to junction box.

photo shows the exit path if the cable is exiting at the top center or on the right
side of the carriage. The drawn line shows the cable routing if you want th e
cable exit on the left side of the carriage. Pay close attention that the cable is
routed between the Weigh Bar connectors and under the standoff.

Figure 10.15 Interface cable routing

14. Attach the jbox retainer plate to the standoffs and tighten the two bolts.

15. Place the scale carriage on the forklift, add the forks and pick up a loade d

pallet.

16. With a helper, block the back of the forks with a wedge shaped piece o f wood

while lowering the carriage so the scale will tilt forward when lowered.

17. Lower the scale so that it disengages from the forklift carriage.

FLSC 05 w/FLI 225 Instrument Service Manual 89

18. Back the forklift away from the scale. This leaves the scale in an upright

position with easy access to the nuts and stability for providing the 500 ft lb.
torque required.

19. Tighten the jam nuts to 500 ft lbs. See Optional Scanner Connection below.

Also see the note on page 90.

20. Replace the cable egress and jbox g uards.

21. The scale is now ready to be reinstalled on the forklift.

10.4.3 Tightening Procedure

To tighten the jam nut to 500 ft/lbs you can use two techniques:
One: Buy a 500 ft/lb torque wrench and use this to torque the nut.
Two: Torque the nut to 50 ft/lbs and then with a 3/4" or 1" drive socket turn the nut

1/6th of a turn. This will be very close to 500 ft/lbs. See the Figure 10.16.

Use medium strength thread-locking compound on all threaded hardware including
the jam nut.

Figure 10.16 Jam nut tightening procedure

90 FLSC 05 w/FLI 225 Instrument Service Manual

10 Installing the FLW 100 Wireless Carriage Option

1

2

3

4

5

10.5 Installing the FLW 100 Wireless Carriage Option

The FLW 100 wireless carriage option allows you to operate the scale with no wire
between the carriage and instrument. The kit parts for this installation are shown in
figure 10.17.

Figure 10.17 Optional FLW 100 kit

The kit is made up of these parts:

1 Carriage transceiver
2 FLI 225 instrument transceiver
3 Battery guard
4 Battery pack
5 Battery charger

See FLI 225 Instrument Parts List & Options on page 107 for a more detailed list of
available parts.

The kit is pre-configured at the factory. If you choose to change the setup, you must
configure the radio using a PC with the FLW 100 Updater program (part number
AWT30-500095) installed. Instru ctions for this sof twa re are included with the progra m
and are outside the scope of this manual.

FLSC 05 w/FLI 225 Instrument Service Manual 91

Y o u can insta ll the kit without removing the carriage from the for klift but you may find it

Cable egress guard

bolts, 7/16”

Jbox guard bolts,

7/16” (recessed)

easier if the scale carriage is removed. Follow these steps to install the FL W 100 option.

1. Remove the cable egress guard by removing the bolts shown in figure 10.18.

Figure 10.18 Bolts to remove

2. Remove the junction box g uard by rem oving the bolts pointed out in figure

10.18.

3. Remove the junction box r etainer plate bolts, shown in figure 10.19, and

remove the retainer plate.

Figure 10.19 Junction box retainer plate and bolts

4. Disconnect the interface cable fro m the jun ction box a nd from the back of the

FLI 225.

5. Clip all cable ties and remove the interface cable from the forklift.

92 FLSC 05 w/FLI 225 Instrument Service Manual

10 Installing the FLW 100 Wireless Carriage Option

6. Place the cables from the carriage transceiver through the back slot in the rear

carriage plate. See figure 10.20.

Figure 10.20 Installing carriage transceiver

7. Press the transceiver into the slot. About 1 inch of the housing will extend

outside the carriage plate. Place the two supplied screws and brass washers
into the holes on each side of the transceiver to firmly hold it in place. See
figure 10.21.

Figure 10.21 Carriage transceiver and hold down bolts an d wash ers

8. Pass both connectors down and between the ca rriage plates.

FLSC 05 w/FLI 225 Instrument Service Manual 93

9. Route the interface connector to the junction box and plug the conn ector in.

Power cable from transceiver.

Cable guide plate.

Follow the path shown in figure 10.22.

Figure 10.22 Interface cable routing

10. Replace the junction box retainer plat e and fasten with the two bolts removed

previously.

11. Replace the cable egress guard and tighten the two bolts. Reference figure

10.18.

12. Run the power cable from the transceiver d own the right side of th e carriage

and cover it with the cable guide plate shown in figure 10.23.

94 FLSC 05 w/FLI 225 Instrument Service Manual

Figure 10.23 Cable guide plate (rear view of carriage)

13. Bolt the cable guide plate in place with the two supplied bolts.

14. Replace the junction box guard and tighten the two bolts through the access

holes in the front plate of the carriage. Reference figure 10.18.

10 Installing the FLW 100 Wireless Carriage Option

Cable tie

15. Cable tie the power cable at the bottom of th e guide pla te as show n in figure

10.24.

Figure 10.24 Cable tie at bottom of the cable guide plate

16. Place the battery guard o n the back plate o f the carria ge and place th e two

supplied bolts through the recesses, shown in figure 10.25, through the battery
guard holes and into the threaded holes in the carriage back plate. Tighten to
hold the battery guard firmly in place.

Figure 10.25 Battery guard recessed bolts

17. The power cable should exit the battery gu ard as shown in figur e 10.26.

Figure 10.26 Power connector exiting battery guard

FLSC 05 w/FLI 225 Instrument Service Manual 95

18. Peel the backing from the sponge rubbe r pieces and place as shown in figure

10.27. These will help lift the battery pack out when the thumb catch is
released.

Figure 10.27 Sponge rubber strips

19. Connect the battery to the power cable and loop the cable inside the channel.

Tuck the cable and connectors inside this channel.

20. Place the recessed end of the battery pack into the channel and snap the other

end down until the latch snaps shut. figure 10.28 shows the battery pack in
place.

Figure 10.28 Battery pack in place (view from the back of the carriage)

96 FLSC 05 w/FLI 225 Instrument Service Manual

10 Installing the FLW 100 Wireless Carriage Option

21. Connect the instrument transce iver to the interface con nector on the back of

the FLI 225 instrument. See figure 10.29.

Figure 10.29 Instrument transceiver installed on the FL I 225

Y our wireless carriag e system is now installed. There are some settings to make in th e
FLI 225 instrument to configure it for wireless function. Ask your service representative
to perform this configuration.

10.5.1 Charging the Battery

1. To charge the battery re lease the catch as shown in figure 10.30.

Figure 10.30 Battery pack catch release

FLSC 05 w/FLI 225 Instrument Service Manual 97

2. Lift the battery out as shown in figure 10.31 and disconnect the ba ttery pack

Green Scanner TXD
Black Ground
Red +5VDC

from the power cable.

Figure 10.31 Lifting out the battery pack

Plug the battery pack into the supplied charger and charge for 8 to10 hours to fully
charge the pack.

10.6 Optional Scanner Connection

The FLI 225 instrument can be equipped with an optional bar code scanner. Run the
cable (part number AWT25-500570) through the Gland Access in the back plate and
connect the leads to one of the available COM ports. See the system block diagram for
location of COM ports. Connect the DB-9 connector to the scanner.

The COM port must be configured for scanner operation. See Communications on
page 64 for instructions on configuring the COM port.

Figure 10.32 Scanner Cable and Color Codes

10.7 RM-200 Connection

The RM-200 (part number AWT05-500691) allows the FLI 225 to perform a variety of
communications functions wirelessly . These functions can be configured depending on
customer needs. If the RM-200 serial cable has a DB-9 connector, you must remove it
and expose the leads in order to connect it to an available COM port on the FLI 225.

1. Disconnect the FLI 225 from the power source and the rest of the scale system.

2. Remove the back plate.

98 FLSC 05 w/FLI 225 Instrument Service Manual

10 RM-200 Connection

Red TXD
Green RXD
Orange Power
Black Ground
Yellow RTS
Brown CTS

To FLI 225

3. Run the cable through the gland acce ss in the ba ck plate.

4. Connect the leads to TB3 (COM 2). Se e the system block diag ram on page

103 for location of COM ports.

5. Replace the back plate.

6. Tighten the strain relief as necessary.

7. Connect the FLI 225 to the scale system.

8. Reconnect the power.

9. Configure the COM port accord ing to the function required . See

Communications on page 64.

FLSC 05 w/FLI 225 Instrument Service Manual 99

10.8 SMA Protocol

The following table shows the SMA communication commands supported and the
corresponding results. Refer to www.scalemanufacturers.org for complete details.

Table 10.3 SMA protocol

Command Sent to Indicator Result

<LF>W<CR> Weight returned if no motion. Dashes displayed if motion on scale.
<LF>P<CR> Weight returned if no motion. Dashes displayed if motion on scale.
<LF>Z<CR> Scale zeros itself if no motion. Dashes displayed if motion on scale.
<LF>T<CR> Scale tares itself and returns G or N weight if no motion. Dashes displayed if motion on scale.
<LF>T<xxxxxx.xxx><CR> Scale attempts to take the <xxxxxx.xxx> data as the tare weight and returns G or N weight if no

motion. Dashes displayed if motion on scale.
<LF>M<CR> Returns the tare weight if no motion. Dashes displayed if motion on scale.
<LF>C<CR> Clears the tare weight if no motion. Dashes displayed if motion on scale.
<LF>U<uuu><CR> Sets the unit of measure label to uuu Example: lb_ ( _ =space) Works for lb or kg only, not

custom units
<LF>D<CR> Runs scale diagnostics and sends diagnostic message
<LF>A<CR> Sends the SMA compliance level. See note at left.
<LF>B<CR> 1st B sent returns manufacturer

2nd B sent returns model software #

3rd B sent returns the software revision level

4th B sends an END

5th or more sends a ?
<LF>U<CR> Toggles the units of measure if no motion. Dashes displayed if motion on scale.
<LF>I<CR> Sends the SMA compliance level as SMA:compliance level / revision level

100 FLSC 05 w/FLI 225 Instrument Service Manual