Avery Weigh-Tronix FLSC 05 User manual

FLSC 05 Forklift Scale
with FLI 225 Instrument
Service Manual
original instructions
AWT 35-500234
Issue AK
CONFIDENTIAL

FLSC05_FLI225_s_en_500234.book
Avery Weigh-Tronix is a trademark of the Illinois Tool Works group of companies whose ultimate parent
company is Illinois Tool Works Inc (“Illinois Tool Works”). Copyright © 2013 Illinois Tool 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 dimensions of a three-dimensional 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 prior 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 Weigh-Tronix reserves the right to alter
without notice the specification, design, price or conditions of supply of any product or service at any time.

FLSC 05 w/FLI 225 Instrument Service Manual 3
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

4 FLSC 05 w/FLI 225 Instrument Service Manual
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

FLSC 05 w/FLI 225 Instrument Service Manual 5
Carriage Assembly Parts List .........................................................................................105
Exploded View of FLI 225 AWT05-500348 ....................................................................106
FLI 225 Instrument Parts List & Options ........................................................................107
Menu Maps ....................................................................................................................108

6 FLSC 05 w/FLI 225 Instrument Service Manual
Manual Revision History
Current
Issue Date Created Details of Changes
AA June 2008 Issue new manual
AB August 2008 Updated illustration of ramps on page 71. Corrected reference numbers / part numbers on
exploded view of carriage on pages 94-95. Updated Carriage Assembly drawing on p. 94.
Removedpartnumberforref1onp.95asthispart is NA. Corrected description of explodedview
on p. 96. Included additional notes on installing the wireless carriageon p. 82.
AC January 2009 Addedlabelstoshow relationshipbetween TB1(COM 1),TB2(COM3)TB3(COM2)andRS232
connections on page 91. Corrected part number AWT25-500013 to AWT25-500342 on page 95.
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.
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.
AF July 2010 Changed part number AWT20-500353 to AWT20-503844 and AWT20-500356 to AWT20-
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.
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 coypyrightstatement. Added“CONFIDENTIAL” to front page. AddedGrounding section
to chapter 10.

FLSC 05 w/FLI 225 Instrument Service Manual 7
1 General information and warnings
1.1 About This Manual
Thismanualisdividedinto chapters as shown bythechapternumberandthelargetext
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 the next subsection level
appear at the top of alternating pages 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
signalwordshavespecificmeanings toalertyoutoadditionalinformationortherelative
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.

8 FLSC 05 w/FLI 225 Instrument Service Manual
1.2 Installation
1.3 Routine Maintenance
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
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.
DANGER: RISK OF ELECTRICAL SHOCK. NO USER SERVICEABLE
PARTS. REFER TO QUALIFIED SERVICE PERSONNEL FOR SERVICE.
IMPORTANT: This equipment must be routinely checked for proper operation
and calibration. Application and usage will determine the frequency of
calibration required for safe operation.
Table 1.1 Cleaning DOs and DON’Ts
DO DO NOT
Wipedowntheoutsideofstandardproducts
withacleancloth,moistenedwithwaterand
a small amount of mild detergent
Attempt to clean the inside of the machine
Use harsh abrasives, solvents, scouring cleaners or
alkaline cleaning solutions

FLSC 05 w/FLI 225 Instrument Service Manual 9
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
1.7 FCC and EMC Declarations of compliance
European Countries
CAUTION: Do not attempt to operate the keypad with objects such as
screwdrivers or long fingernails as this may cause damage to the instrument.
This equipment has been testedand found to comply with the limits for a Class A digital device, pursuantto Part15 of theFCC 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.
WARNING: This is a Class A product. Ina domestic environment, this product maycause radio interference in which the user may be
required to take adequate measures.

10 FLSC 05 w/FLI 225 Instrument Service Manual

FLSC 05 w/FLI 225 Instrument Service Manual 11
1 FCC and EMC Declarations of compliance

12 FLSC 05 w/FLI 225 Instrument Service Manual
2 Introduction
TheFLSC05w/FLI 225 Instrument is a fully digital, legal-for-tradesystemforweighing,
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
of use. Transactions are not stored.
Classic Mode with Accumulate addstheability toaccumulatetotalsandgenerate
reports.
Expanded Mode allows the user to print and store totals but also
addsfeatures that set it apart from the two classic
modes.
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.
Figure 2.1 FLI 225 Front Panel.
Table 2.1 Key Definitions
Reference Key Name Key Function(s)
1TARE Tare the weighton the scale fornetweighing. Factory default for this key is
OFF. See Enable or Disable Keys on page 77
2STANDBY Turn the instrument on.
Put the instrument into standby mode.
3SELECT 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.
4PRINT Send data to a printer or other connected device. Store (save) transactions for future download, depending on configuration.
Access report menu in certain modes.
5ZERO Zero the instrument to compensate for minor weight changes.
Move to the right in data entry mode.

FLSC 05 w/FLI 225 Instrument Service Manual 13
2 Data Entry Procedure
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.
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
6F1 - F4 Collectivelycalledthesoftkey because their function changeswiththetitle.
Common softkeys (6a - 6d) are shown.
6a Esc softkey Abort a procedure or return to previous menu.
6b Up Arrow
softkey Scroll up from zero and then forward through the alphabet.
6c Down Arrow
softkey Scroll backwards from zero and then backwards through the alphabet.
6d Enter softkey Accept an entry.
Table 2.1 Key Definitions
Reference Key Name Key Function(s)
If you make a mistake, press the SELECT key to backspace and delete one character
or press the Esc softkey to abort.
Table 2.2 Definition of Annunciators
Annunciator Description
~The weight is in motion and is not stable.
>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.
–Indicates a negative weight.
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.

14 FLSC 05 w/FLI 225 Instrument Service Manual
2.4 FLR 100 Remote Display Option
Figure 2.2 shows the FLR 100 remote display option. This display canbe 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
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.
(Y) Indicates that the instrument is set to FLSC Wireless and is
communicating wirelessly with the carriage.
Y Indicates that the instrument is set to FLSC Wireless but wireless
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.
Table 2.2 Definition of Annunciators
Annunciator Description

FLSC 05 w/FLI 225 Instrument Service Manual 15
3 Overview of the Menus and Modules
The FLI 225 has four password protected menus. Each menu gives 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.
Thereareeightmodules and four of them appearin all fourmenus.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

16 FLSC 05 w/FLI 225 Instrument Service Manual
3.1 Accessing and Exiting the Menus
The procedure for accessing most of the menus is the same and is explained below.
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.
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.
The Admin Management menu may require unsealing the instrument. See Change
Seal Status on page 35 for details.
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.

FLSC 05 w/FLI 225 Instrument Service Manual 17
3 Overview of the Modules
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:
lTime (set the time)
lDate (set the date)
lDisplay Contrast (set the display contrast)
lSeal 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 part number
of the firmware. See chapter 5, About FLI 225 Module for more information.
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 Counter is available in all four menus and 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:
lCommunications (test Com1, Com2 or Com3)
lKeypad (test and identify keypad buttons)
lDisplay (test the display)
lAnalog Option Card (verify installation and operation of an analog card as
well as see analog counts as necessary)
lDigital Carriage (verify installation and operation of FLJ 100 as well as see
digital counts as necessary)
lInputs (test any inputs connected to the instrument)
lSeal Switch (check the state of the seal switch)
lError Log Viewer (view history of errors)
See chapter 7, Diagnostics Manager Module for more information.

18 FLSC 05 w/FLI 225 Instrument Service Manual
3.2.6 Supervisor Settings
This module is available in the Supervisor and Admin Management menus. It allows
you to view / change the following:
lZero Band (set gross zero band in calibration units)
lTimeout Settings (set timers)
lIdentification (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:
lCalibrate (calibrate the scale) including:
mGravity Compensation
mZero
mSpan
mFLSC Calibration (perform corner and angle calibration)
mView Live Weight
lScale (configure various scale metrology items) including:
mUnits (set calibration units, enable units of measure)
mSettings (configure capacity, divisions and carriage type)
mFilter (set various filtering components)
mMotion/AZT (configure motion and AZT)
mAuto Tare Clear (enable or disable auto tare clear)
mRanges (set ranges for overload, underload, zero range, center of zero,
zero band, auto print and zero drift)
lCommunications (configure various COM settings for COM 1, 2, 3)
lPrint Strings (Access the Print String Editor and configure Strings to Print)
lApp Selection (Choose the application for the instrument)
lCountry Code (Set instrument to either NA or EU default settings)
lMiscellaneous (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.

FLSC 05 w/FLI 225 Instrument Service Manual 19
4User Settings Module
TheUser Settings moduleis availablewhenyou enter any ofthepasswords,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.

20 FLSC 05 w/FLI 225 Instrument Service Manual
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.
Figure 4.4 Sample Display Contrast Screen
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.
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.