Liftlog 1000: Title

Liftlog 1000
Fork Lift Truck

Weighing System
Installation and Calibration
User Guide
Title 1
LIFTLOG 1000 – INSTALLATION AND CALIBRATION
Electromagnetic Compatibility (EMC)

This product complies with European Council Directive 2004/108/EC when installed and used in accordance with the relevant
instructions.
Service and Technical Support

PLEASE CONTACT YOUR NEAREST DISTRIBUTOR or if unknown, contact the factory for further information.
RDS Technology Ltd, Cirencester Road, Minchinhampton, Stroud, Glos, GL6 9BH, United Kingdom
Ph: +44 (0)1453 733300 : Fax: +44 (0) 1453 733311 : EMAIL: info@rdstec.com
Our policy is one of continuous improvement and the information in this document is subject to change without notice.
Check that the software reference matches that displayed by the instrument.
This manual refers to Software Issue: GC114 Iss01 rev00
Document Number : S/DC/500-10-795 :
Issue : 1.01
Issue Date 29.9.15
Source file: \UK795110.DOCX
© Copyright RDS Technology Ltd 2015
2
Information on Disposal for Users of Waste Electrical & Electronic Equipment

This symbol on the product(s) and / or accompanying documents means that the electronic component(s) of this product should
not be mixed with general household waste at end of life.
RDS mobile machinery electronics are exempt from European WEEE recycling regulations. Regardless, we recommend that
wherever our products are used, the various elements (electrical or otherwise), are disposed of responsibly at their end of life. If
you wish to discard our products, then we advise that if unsure, you contact your local area authority / recycling centre for advice
on the correct method of disposal.
Disposing of our products correctly will help save valuable resources and prevent any potential negative effects on human health
and the environment, which could otherwise arise from inappropriate waste disposal. Penalties may be applicable for incorrect
disposal of waste, in accordance with your national legislation.
3
1. INTRODUCTION 6
1.1 Important Information 6
1.2 Important Safety Precautions ! 6
1.3 System Overview 7
1.4 Parts List : Ref. Kit P/LIFTLOG/1000 8
1.5 Hydraulic Fitting Kits (standard unless otherwise specified) 9
1.6 Hydraulic Fitting Kits (options) 11
2. INSTALLATION 12
2.1 Drop Valve / Pressure Sensor 12
2.1.1 Flow Rate Adjustment............................................................................................................................................................... 14
2.2 Reference Sensor 15
2.2.1 Weighing Height without Reference Sensor ............................................................................................................................. 16
2.3 Head Unit 17
2.4 Electrical 18
2.4.1 Junction Box .............................................................................................................................................................................. 18
2.4.2 Power Supply ............................................................................................................................................................................ 19
2.4.3 Printer ....................................................................................................................................................................................... 19
2.4.4 Electrical Connections ............................................................................................................................................................... 20
2.5 Diagnostics 21
4
3. CALIBRATION 22
3.1 Setup Menu 22
3.2 “Full Setup Wizard” 23
3.3 Technician Level Settings 24
3.3.1 Home Screen Functions ............................................................................................................................................................ 24
3.3.2 Logging Options ........................................................................................................................................................................ 24
3.3.3 Port Setup ................................................................................................................................................................................. 27
3.3.4 Language / Keyboard region ..................................................................................................................................................... 27
3.3.5 Instrument ID ............................................................................................................................................................................ 27
3.3.6 Job No. / Ticket No. ................................................................................................................................................................... 28
3.3.7 Save to USB ............................................................................................................................................................................... 28
3.3.8 Load from USB .......................................................................................................................................................................... 29
3.3.9 Overload Log ............................................................................................................................................................................. 30
3.4 Factory Level Settings 31
3.4.1 ‘Auto’ Weight Calibration ......................................................................................................................................................... 31
3.4.2 Calibration Factors .................................................................................................................................................................... 32
3.4.3 Linear Compensation Factors ................................................................................................................................................... 32
3.4.4 Sensor Setup ............................................................................................................................................................................. 33
3.4.5 Overload Alarm Setup ............................................................................................................................................................... 34
3.4.6 Error Log ................................................................................................................................................................................... 35
3.4.7 PIN ............................................................................................................................................................................................ 35
3.4.8 Software Reset .......................................................................................................................................................................... 35
5
1. Introduction
1.1 Important Information
NOTE: FITTING, CALIBRATION AND MAINTENANCE MUST ONLY BE UNDERTAKEN BY A TRAINED INSTALLER. ANY ATTEMPT BY
UNQUALIFIED PERSONNEL TO INTERFERE WITH OR ALTER THE INSTALLATION OR SETUP OF THE SYSTEM, MAY RESULT IN
DAMAGE TO THE MACHINE, PERSONAL INJURY OR POSSIBLE DEATH!
This manual provides general guidelines that will enable the experienced installer to adapt the system successfully to the
majority of machine makes and models. If you are in any doubt regarding an installation detail for a particular machine, then
further technical guidance and specific installation detail is available from RDS Technology. Log in the website, or contact the
RDS Service and Support Department at the factory.
RDS Technology Ltd does not accept responsibility for faulty operation of the system or consequential damage, as a result of poor
workmanship of installation, or any aspect of component installation that does not comply with the requirements for correct
operation as stated in this manual. The installer is responsible to ensure proper fitting.
1.2 Important Safety Precautions !

In addition to observing site safety requirements, before working on the machine always :-
 Make sure that the Attachment is down on the floor, and all pressure is released from the hydraulic system, before slackening
off any hydraulic coupling
 Prevent the machine from being accidentally started while working on it e.g. remove the ignition key, place a warning notice
in the cab etc.
 Keep other persons in the vicinity of the machine fully aware of your immediate intentions during installation and initial
calibration.
6
1.3 System Overview

The Liftlog 1000 is a weighing system designed for use principally on counterbalance fork lift trucks. It measures, displays and
records the net or gross weight lifted, normally based on sensing the lift system hydraulic pressure. Normally, a weighing start
point is established by use of a magnetic Reference position sensor fitted on the lift mast. Without the reference sensor
however, the weighing cycle can be started at any lift height (while still allowing the load sufficient height to drop while
weighing).
Indicator Indicator
Junction Box External Alarm
Cable
(optional)
Reference Remote Weigh Button
Sensor and/or Remote Enter
Switch (optional)
Magnet
Power Supply
Drop Valve
+ Pressure Sensor
T-piece
Triggering the weighing cycle operates a solenoid on a custom, flow-regulated valve, causing the lift cylinder(s) to drop at a
controlled rate while the hydraulic pressure is measured and averaged over the sampling period. The weight is then displayed
either as a gross weight, or if a tare value has been set, then the net weight can be displayed.
7
1.4 Parts List : Ref. Kit P/LIFTLOG/1000
Item Part No. Description Qty

Standard
1 K/DROP/VALVE Kit - Drop Valve
2 K/G-CAN/SCR/PRT Kit - Touchscreen Protection 1
3 K/INSTRUMENT Kit - Power Supply 1
4 K/LIFTLOG/REF Kit - Reference Sensor 1
5 K/LOAD/COMP/250 Kit - 250 bar Pressure Sensor 1
6 K/RAM/MOUNT/KIT Kit - “RAM” Mount Kit 1
7 S/AC/411-1-005 Junction Box 1
8 S/CB/410-1-026 Display Unit Cable 1
9 S/CBL/TIE/005 Cable Tie – 370mm 5
10 S/F724-003 Cable Tie – 6” 2
11 S/FSNR/940221 ¼” BSP “Dowty” Seal 1
12 S/HU/435-1-001 Head Unit 1
# S/DC/500-10-787 Terminator Label 1
# S/DC/500-10-794 Quick reference Guide 1
# S/DC/500-10-795 Installation and Calibration Manual 1
# S/DC/500-10-796 Operation Manual 1
# K/VHL/INST/053 3/8” BSP High Pressure Hose Kit 1
# K/VHL/INST/055 ½” Low Pressure Hose Kit 1
Optional:
# Kit - Remote Enter Switch 1
# Kit - Remote Weigh Button 1
# Kit - External Alarm 1
8
1.5 Hydraulic Fitting Kits (standard unless otherwise specified)

Unless specified otherwise, the following kits are supplied as standard with the main kit (ref. fig.1 overleaf)
Item Part No. Description Qty
Pressure Circuit (Cylinder Return circuit – Feed to Drop Valve)
K/VHL/INST/053 3/8” BSP High Pressure Hose Kit 1
1 S/HY/500-9-099 3/8” BSPF – 3/8”BSPF Hose, 250bar, 1M 1
2 S/HY/500-9-100 ¼” BSPF – 3/8” BSPM Adaptor 1
3 S/HY/500-9-101 3/8”BSPM – 3/8” BSPM Adaptor 1
4 S/HY/500-9-102 3/8” BSP “Dowty” Seal 1
5 S/FSNR/940221 ¼” BSP “Dowty” Seal 1
# K/VHL/INST/005 Tapped Port Kit (ref section 1.6 for alternatives) 1
Return to Tank Circuit

K/ VHL/INST/055 ½” Low Pressure Hose Kit 1
6# S/HY/500-9-103 ½” Hose, 25 bar, 2.5M 1
7 S/HY/500-9-101 3/8”BSPM – 3/8” BSPM Adaptor 1
8 S/HY/500-9-102 3/8” BSP “Dowty” Seal 1
9 S/HY/500-9-104 3/8” BSPM – 3/8” BSPF Elbow 1
10 S/HY/500-9-105 ½” BSPF Hosetail 1
11 S/FIXING/084 13 – 20mm Hose Clip 4
K/ VHL/INST/056 1/2” Low Pressure Tee Kit (ref section 1.6 for alternatives) 1
12 S/HY/500-9-106 ½” BSPM Hosetail 3
13 S/HY/500-9-107 3/8” BSPF Equal Tee 1
# Not illustrated.
9
Fig 1: Hydraulic Components Fit as required for either

LP Tank Return
‘P’ or ‘T’ ports
9
12
11
8 7
13
10 12
12
4 Lift Cylinder
return line
3
1 2 5
10
1.6 Hydraulic Fitting Kits (options)

Pressure Circuit (Cylinder Return circuit – Feed to Drop Valve)
The correct tee fitting kit should have been specified and supplied for the particular machine. Unless otherwise specified, the
system is supplied with kit K/VHL/INST/005 to drill and tap a 1/8” BSP port at a suitable point in the lift cylinder return circuit.
Return to Tank Circuit

In addition to the standard ½” Hose kit supplied, the correct tee fitting kit should have been specified and supplied for the
particular machine, to tee this hose into the hose returning to the hydraulic tank. Unless otherwise specified, the system is
supplied with kit K/VHL/INST/056 to suit a ½” bore tank return.
The optional LP tee kits are:
K/ VHL/INST/057 ¾” Low Pressure Hose Kit
K/ VHL/INST/058 1” Low Pressure Hose Kit
K/ VHL/INST/059 1-1/4” Low Pressure Hose Kit
K/ VHL/INST/060 1-1/2” Low Pressure Hose Kit
NOTE: Low pressure Hose kits are rated to 25 bar.
11
2. Installation
2.1 Drop Valve / Pressure Sensor
Before mounting the valve, fit the pressure sensor to the
valve body using the ¼” “Dowty” seal washer supplied. Solenoid 4-20mA
Pressure Sensor
Wherever possible, choose a mounting position where it will
be afforded the best protection from the elements. The valve
can be mounted in any orientation, but leaving the flow
adjustment screw accessible.
The drop valve pressure port marked 'P' (Pressure) should be
connected into the lift cylinder return line at a suitable
location, using the appropriate fittings (figure 1).
Lift
The drop valve return port marked 'T' (Tank) should be Cylinder
connected into the hydraulic tank return line from the spool return
valve block, using the appropriate fittings (Figure 1).
NOTE: Use PTFE sealing tape for low pressure fittings.
Flow
adjuster To tank
12
Typical Drop Valve installation
Drop
valve
Tee - lift cylinder

return line to
pressure port 'P'
Tee - return port 'T'
to tank return line
13
Route the pressure sensor lead and solenoid lead back to

the Terminator.
Cable tie at regular intervals following the existing wiring
loom where possible.
Ref. 2.4.4 for wiring connections.
2.1.1 Flow Rate Adjustment

The drop rate may need to be adjusted depending on the particular machine. With the solenoid connected and the head unit
powered up, press the weigh button to energize the solenoid and observe the rate of drop. Slacken the locking nut and turn the
adjuster screw in or out to decrease or increase the drop rate (i.e. approximately 15cm or 6” over the 5 second sampling period).
NOTE: Drop rate can be set with empty forks, since the drop valve keeps the flow rate constant under varying pressure.
14
2.2 Reference Sensor

The Reference sensor kit automatically enables the weigh button when the load reaches the weighing position.
Assemble the sensor to the bracket allowing it to project at
least 15mm from the face of the bracket.
Lift the forks to the desired weighing position.
Thoroughly clean the area where the sensor bracket and
magnet are to be positioned, and both the magnet and
bracket mounting face, using a degreasing solvent.
It is recommended to attach the magnet to the hanger
carriage where shown, using theself-adhesive pad supplied.
The position of the bracket determines the weighing height
when the magnet is directly opposite the sensor.
Two M6 mounting holes are provided on the bracket.
However, it is recommended wherever possible to avoid
drilling and tapping, and to attach the bracket to the side of
the mast using the self-adhesive pad supplied.
Allow 10mm clearance between the sensor and the magnet.
NOTE: The centre portion of the self-adhesive pad S/AC/500-4-155 is to attach the magnet, while the remainder is to attach the sensor
bracket. The adhesive can be applied in temperatures down to -10°C.
15
Cable-tie the sensor lead to the bracket where shown.

Connect the sensor extension lead and route in conduit back
to the Terminator.
Cable tie at regular intervals and following the existing wiring
loom where possible.
2.2.1 Weighing Height without Reference Sensor

The system can also be operated without a reference sensor.
In this case it is recommended to apply suitable markers on
the mast to indicate when the weighing position is reached.
16
2.3 Head Unit

Mount the head to the front panel with the RAM mount as
shown.
NOTE: The head unit can also be mounted off the ROPS pillar using a
“U” Clamp kit (optional
The head unit is dust-tight and splash-resistant, however it is
not rated for constant outdoor use.
For use in an outdoor environment, it is recommended to
mount the unit within a suitable secondary enclosure or
cover (not provided), so that it is afforded adequate
protection from rain and moisture.
Route the head unit cable back to the Terminator. Coil excess
cable next to the Terminator.
17
2.4 Electrical
2.4.1 Junction Box
The Junction Box or "Terminator" as it is also known, provides
for connecting the 18-core head unit cable, all sensors and
the power supply.
The Terminator is not sealed. It must be located where it will
be protected from EXCESSIVE MOISTURE AND DIRT
Cable-tie the cables entering the end of the box to the PCB.
The Base Moulding can be mounted using the screws
provided, or can be left in-line with the cables.
Connect the head unit lead onto the PCB header
The red wire on the 10-way plug goes to pin "R" on the PCB
connector.
The orange/blue wire on the 8-way plug goes to pin "O/B" on
the PCB connector.
Locate the cable grommet onto the moulding, and cable-tie
the head unit lead onto the moulded cable saddle to provide
strain relief.
NOTE: Cable-tie the cables entering the end of the box to the PCB.
18
2.4.2 Power Supply

NOTE: The Weightroller Precise operates from an 8 to 30VDC supply, however the solenoid on the drop valve is 12V. Therefore a suitable
voltage dropper must be fitted on vehicles using supply voltages above 12V.
The Terminator is fitted with a varistor for protection from voltage transients, and a power-on LED. The head unit has an integral
On-Off switch, but is normally powered on via the ignition circuit.
Using the power lead provided, connect from a switched live point not exceeding 24V (e.g. from the ignition circuit) to the
terminals marked POWER IN 0V and POWER IN+V.
If you inadvertently have the power supply connections reversed, nothing will work. The head unit has reverse polarity protection
and will not be damaged. The LED on the Terminator PCB will not light if the 0V and +V connections are reversed.
If the instrument does not power up when you switch the ignition on, then:
(a) check you have connected to a suitable point on the vehicle electrical system as described above.
(b) If (a) is OK but the LED is not lit, check the polarity is correct.
(c) If the LED is lit but the head unit does not come on, check that the 18-way connector is properly connected.
Once all is OK, clip the lid on the Terminator. To remove the lid, squeeze the sides of the base inward to release the clips.
2.4.3 Printer
Connect the printer lead onto the 4-way connector ('marked COM 2') in the terminal box. This lead also provides the printer
power supply.
Locate the cable grommet onto the moulding, and cable-tie the head unit lead onto the moulded cable saddle to provide strain
relief.
19
2.4.4 Electrical Connections

Route sensor leads inside conduit back to the junction box. Cable-tie the conduit securely to existing hydraulic lines or conduits.
Connect the wires according to the label on the junction box lid :
Input / Output Wire Terminator Connection

Colour
Pressure Sensor (on Blue 10 "P1"
Drop valve) Brown 4 "P1 +V"
Drop Valve Solenoid Blue 16 “DROP VALVE 0V”
Brown 6 “DROP VALVE + (BROWN)”
Reference Sensor Blue 13 "0V"
Brown 20 "REF SENSOR (BROWN)"
Remote Enter Blue 14 "REMOTE ENTER 0V (BLUE)"

Switch Brown 9 "REMOTE ENTER SIG (BROWN)"
Remote Weigh Blue 15 “WEIGH BUTTON 0V (BLUE)”
Button Brown 18 “REMOTE WEIGH BUTTON (BROWN)”
External Alarm Blue 13 “0V”
Brown 5 “EXTERNAL ALARM +VE (BROWN)”
Power Supply Blue 12 “POWER IN 0V (BLUE)”

Brown 1 “POWER IN +V (BROWN)”
20
2.5 Diagnostics
Press and select the “Diagnostics” screen from the
Setup menu “P1” = Pressure Sensor output in mA and
corresponding pressure (1 bar = 14.9psi)
The diagnostics screens provide a visual indication of the
system inputs and status.
If you experience a problem with the weighing system, with
this screen displayed, you can verify the correct operation of
the various components.
Press to freeze the real-time graphical display for the
pressure sensor and supply voltage.
NOTE: If you wish, you may take a snapshot of the screen (or any
other screen for that matter). Insert a USB stick and briefly Supply voltage
press the On-Off switch (the left hand rubber end piece of the UK794-280.JPG
indicator). A file <ALPHAxx.BMP> will then be saved. Pressure

Sensor output
graph
“REF” = Reference Sensor status

“REM” = Remote Enter Switch status
“ENT” = Remote Weight Enter Button status
21
3. Calibration
3.1 Setup Menu
Press to access the Setup menu. There are three calibration levels.
Operator Units Ref. Op. Manual
Time and Date “
Brightness “
Volume “
Calculator “
Nudge “
Diagnostics 2.5
Press and enter PIN (default = 4084) to access Technician Level UK796-300.JPG
Technician Home Screen Functions 3.3.1

Logging Options 3.3.2
Port Setup 3.3.3
Language 3.3.4
Keyboard 3.3.4
Instrument ID 3.3.5
Job Number 3.3.6
Ticket Number 3.3.6
Save to USB 3.3.7
Load from USB 3.3.8 UK796-310.JPG
Overload Log 3.3.9
22
Press and enter PIN (default = 4084) to access Factory Level.

Factory Full Setup Wizard 3.2
Calibration 3.4.1
Sensor Setup 3.4.4
Overload 3.4.5
Error Log 3.4.6
PIN 3.4.7
Software Reset 3.4.8
UK796-320.JPG
3.2 “Full Setup Wizard”

The “Full Setup Wizard” routine appears if the instrument is being setup for the first time, e.g. on installation, or if the software
has been updated.
Language Technician 3.3.4
Units Operator Ref. Op. Manual
Home Screen Functions Technician 3.3.1
Logging Options “ 3.3.2
Sensor Setup Factory 3.4.4
Overload “ 3.4.5
Brightness Operator Ref. Op. Manual
Volume “ “
Instrument ID Technician 3.3.5
Time / Date Operator Ref. Op. Manual
Calibration Factory 3.4.1
NOTE: If you do not wish to proceed with “Full Setup Wizard” routine, then press to return to the main operating screen, and then
press to select the Setup menu. To setup “manually”, please refer to the following sections if required.
23
3.3 Technician Level Settings

Select then to access the Technician Level Menu (default PIN = 4084).
3.3.1 Home Screen Functions

Select the functions that you wish to appear on the main
operating screen.
UK796-330.JPG
3.3.2 Logging Options

Setup for logging output to any of the following:
 Printer - (RDS ICP 300 printer or other printer)
 Data - (CSV output to modem / datalogger)
 SD – (CSV output to SD card)
 USB – (CSV output to USB stick)
NOTE: All logging options can be set to operate simultaneously.
UK796-340.JPG
24
Printing
Printer COM Port ---- Printing deactivated
COM 1 Select the Com Port to which the printer is connected.
COM 2 If connecting a printer other than an RDS "ICP300" printer, check the
settings in "Port Setup" match the printer specification.
Print Mode Short Load by Load Prints a summary of the last job cleared (a).
Long Load by Load Prints a summary of the last job cleared + space for customers Name
and Address (b).
Lift by Lift Prints a summary of the last job cleared + individual lift totals (c)
Auto Print On / Off On - Automatically prints as selected above, after a job is cleared.
Off – Allows manual printing only (press to access the print
menu).
ICP 300 On / Off On – Uses ICP300 protocol / character set
(a) (b) (c)
25
Output to Data Logging device

Data COM Port ---- COM port deactivated – no data output.
COM 1 Select the Com Port to which the datalogger is connected.
COM 2 Check the settings in "Port Setup" match those required by the
datalogging device.
Print Mode Off No data output
Load by Load Automatically outputs a line of data each time a job is cleared, as csv
string type ‘R’ (Load Record) , and adds it to a default file called
<TOTALS.CSV> e.g.
R,ID1, Job No.,Time, Net Weight, Tare Weight, Store Name, Reference
Lift by Lift Automatically outputs a line of data for each lift as csv string type ‘L’
(Individual Lift), and adds it to a default file called <TOTALS.CSV> e.g.
L,ID1, Job No.,Time, Net Weight, Tare Weight, Store Name, Reference
Output to SD Card / USB

The same CSV data string can also be output to the SD card
and/or USB stick as per the “Print Mode” setting above.
UK796-340.JPG
26
3.3.3 Port Setup

Press to edit RS232 Port settings. The default settings are suitable for the RDS "ICP300" printer.
The default settings for "COM 1" and "COM 2" are:
Status: Enabled / Disabled
Baud Rate: 1200 / 2400 / 4800 / 9600 / 19200
Parity: 'N' (None) / 'E' (Even) / 'O' (Odd)
Handshaking: RTS_OFF / RTS_ON
3.3.4 Language / Keyboard region

Select the language / regional keyboard option from the list. If the required language is not pre-installed, .HEX files for
alternative languages (including the appropriate keyboard option) may be available and can be uploaded via a USB memory stick.
3.3.5 Instrument ID
Programme up to 5 lines of text (18 characters per line) that appear as the heading of each Printout. Press to edit each line
e.g.
Machine ID
Company Name
Address
Postcode
Tel No. etc
NOTE: Only Line 1 will appear on a printout or in comma-delimited ASCII data output via the logging options "Data", "SD" and "USB".
27
3.3.6 Job No. / Ticket No.

Edit the Job No. (the number incrementing with each load cleared). The instrument will then increment from that number until it
is edited again.
Edit the Ticket No. (the number incrementing with each printout made). The instrument will then increment from that number
until it is edited again.
3.3.7 Save to USB

Insert the USB stick and select "Save to USB". The options are;
“All as HEX”
This saves all user-defined settings, calibration settings and Store
descriptions to a .HEX file. This allows you to 'clone' another head unit with
an identical setup.
The default file name is "'AL10ALL.HEX'". Press and rename the file if
desired. Press "Ent" on the screen keyboard to download the data (or "Esc"
to quit).
UK796-350.JPG
“Settings as HEX”
This saves only the calibration settings, Sensor setup and most user settings made in the 'Setup' menu. Store descriptions, Store
text references and the Instrument ID will not be included.
The default file name is "Al10Nvm.HEX". Press and rename the file if desired. Press "Ent" on the screen keyboard to
download the data (or "Esc" to quit).
NOTE: You must include the file extension ".HEX”, otherwise the file will not be read when subsequently attempting to upload to another
instrument.
28
“All text”
This saves the Store descriptions, Store references for all Stores and the “Instrument ID” text. This file does not include
calibration settings.
The default file name is "Strings.txt". Press and rename the file if desired. Press "Ent" on the screen keyboard to download
the data (or "Esc" to quit). .
3.3.8 Load from USB

Insert the USB stick and select "Load from USB". The options are;
"All Config. and Calib"
Loading ALL Settings:
All settings are contained in a .HEX file with the default name 'AL10ALL.HEX'.
It is either a file with the factory default settings, or is a file that has been
saved from an existing instrument (ref section ), in which case it will
include all user-programmed calibration settings and store names etc.
UK796-360.JPG
The information contained within the file will be checked to ensure it is
compatible with the current software, before being loaded directly into
memory.
Select the appropriate .HEX file from the list displayed and press to
upload. A complete software .HEX file will take 2-3 minutes to upload.
29
Load Calibration Settings only

Calibration settings are contained in a .HEX file with the default name "Al10Nvm.HEX".
These settings include calibration settings, Sensor setup and most user settings made in the 'Setup' menu.
NOTE: Calibration settings do not include store names, store references and “Instrument ID”, which can be uploaded separately from
.TXT files.
Typically you may have a number of .HEX files for different machines (named accordingly), saved from previously installed
instruments. Select the appropriate .HEX file from the list displayed and press to upload.
"Text"
Load the Store descriptions, Store references for all Stores and the “Instrument ID” text. This file does not include calibration
settings
Select the "Strings.txt" file from the list displayed and press to upload.
3.3.9 Overload Log

This screen displays the last 10 overload events. After the 10th overload, the
oldest log entry is deleted.
An overload is logged when the overload pressure limit (3.4.5) is exceeded for
longer than the “Overload Log Delay” time programmed in the Sensor Setup
menu. An overload is logged whether or not the load is weighed.
Press to export via USB.
Press to print out.
UK796-370.JPG
30
3.4 Factory Level Settings

Select then to access the Factory Level Menu (default PIN = 4084).
3.4.1 ‘Auto’ Weight Calibration

1. From the “Calibration“ screen, select ‘Auto’ and press .
2. Zero weigh – Lift the empty forks to the weighing position and press .
The zero point is calculated and displayed as a % of maximum pressure.
3. Enter the known weight of the calibration load. This should ideally be near
the maximum weight capacity in order to calculate the most accurate
calibration factor. UK796-380.JPG
4. Lift the calibration load to the weighing position and press .

5. The new calibration factors are calculated and stored in memory. All the
weight calibration factors can be viewed or manually edited by selecting
‘Manual’ from the “Calibration” screen.
UK796-390.JPG
31
3.4.2 Calibration Factors

1. From the “Calibration“ screen, select ‘Manual’ and press .
‘Zero’ This value is the % of full pressure at zero weight.
‘Cal Factor’ This value enables the calculation of weight
from the % pressure.
This figure can be manually edited if the displayed weight differs from the
actual weight.
For example: If the displayed weight is 1% more than the actual weight,
then reduce the cal. factor by 1% and vice versa. UK796-400.JPG
However, if enabled via the “Sensor Setup” screen, it is recommended to use the “Nudge” function instead (ref. Operation
manual).
3.4.3 Linear Compensation Factors

Normally there is a linear relationship in the calculation of weight
from the sensor signal. However, the relationship can become
non-linear above a certain weight threshhold.
If it is found that the weighing accuracy gets progressively worse
above a certain weight, then you can enter a correction factor to Correction
compensate for the error. Displayed factor
Weight
It is a process of trial and error to establish a suitable factor (+/-
%).
Sensor signal
32
“Correct from Weight” - “Wf” on graph.

“Correct to Weight” - “Wt” on graph.
The range over which the correction factor is applied.
“% Correction” - Correction applied between 'Wf' and 'Wt' on
graph.
UK796-400.JPG
3.4.4 Sensor Setup

Press to edit settings requiring a numeric entry.
“Reference Sensor” If fitted, the reference sensor only enables the weigh
button to operate at the weighing position.
“Drop Sample Time” The time after pressing the weigh button and the
“Sample Start Delay”, during which the weight is
sampled and averaged.
“Sample Start Delay” The time after pressing the weigh button, before the
solenoid activates and weight sampling commences.
This allows the hydraulic pressure to stabilize prior to UK796-410.JPG
the sampling period and improves accuracy.

“Overload Log Delay” The time that the pressure is detected to be constantly over the “Overload Level” before logging an
overload event.
“Overload Smoothing” This helps to prevent unnecessary overload events being logged due to inadvertent pressure transients,
caused for example by sudden lifting or other movement.
33
“Secure >0< Key” If enabled, PIN entry is required to access the zero routine on the main operating screen (the PIN is the
current factory level PIN as displayed on the “PIN” screen).
“Enable Nudge” Enable the Nudge function.
“Auto Add Delay” The time after weight sampling before the weight is automatically added to the weight total.
Press to exit the “Sensor Setup” screen.
3.4.5 Overload Alarm Setup

“Enabled” The overload function may be disabled if desired, in which case
the “load bar” will not be displayed on the main operating
screen.
“Max Capacity” The weight at which overload occurs. Either,
(i) Select "Max Capacity" and then press to manually program
in the weight units (kg, lbs), or,
(ii) Do an "Autocal". Load the forks to the maximum that is still safe to
lift, (keeping the forks low to the ground in case the machine
UK796-420.JPG
overbalances). Press and then to set the overload
threshold.
"Overload Zero" The overload zero point (% pressure with empty forks) saved from
the Auto Weight calibration routine (3.4.1).
NOTE: The Overload Alarm function is not a safety device!
UK796-430.JPG
34
3.4.6 Error Log

Logs the time and date of all error faults e.g. “P1” pressure sensor. This information can be cleared, printed, or saved to SD card /
USB stick.
3.4.7 PIN
You can change the factory default “Technician” menu PIN , and the “Factory” menu PIN.
NOTE: If the “Secure >0< Key” setting is enabled via “Sensor Setup”, then the “Factory” menu PIN is also that entered to access the “Set
Zero” routine on the main operating screen.
3.4.8 Software Reset

Resets all setup / calibration values and settings to the factory default settings.
Before doing a software rest, it is recommended to create a backup file of the above via the “Save to USB” screen in the Setup
menu, and save “All to HEX” (3.3.7).
35
Issue Ref. Date Description

1.0 4.8.15 Original issue
1.1 29.9.15 Ref. CRQ 6658
36

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Liftlog 1000

Fork Lift Truck

Installation and Calibration

Electromagnetic Compatibility (EMC)

Service and Technical Support

Information on Disposal for Users of Waste Electrical & Electronic Equipment

1.2 Important Safety Precautions !

1.3 System Overview

1.4 Parts List : Ref. Kit P/LIFTLOG/1000

Item Part No. Description Qty

1.5 Hydraulic Fitting Kits (standard unless otherwise specified)

Return to Tank Circuit

Fig 1: Hydraulic Components Fit as required for either

1.6 Hydraulic Fitting Kits (options)

Return to Tank Circuit

NOTE: Low pressure Hose kits are rated to 25 bar.

Typical Drop Valve installation

Tee - lift cylinder

Route the pressure sensor lead and solenoid lead back to

2.1.1 Flow Rate Adjustment

2.2 Reference Sensor

Cable-tie the sensor lead to the bracket where shown.

2.2.1 Weighing Height without Reference Sensor

2.3 Head Unit

2.4.2 Power Supply

2.4.4 Electrical Connections

Input / Output Wire Terminator Connection

Remote Enter Blue 14 "REMOTE ENTER 0V (BLUE)"

Power Supply Blue 12 “POWER IN 0V (BLUE)”

indicator). A file <ALPHAxx.BMP> will then be saved. Pressure

“REF” = Reference Sensor status

Technician Home Screen Functions 3.3.1

Press and enter PIN (default = 4084) to access Factory Level.

3.2 “Full Setup Wizard”

3.3 Technician Level Settings

3.3.1 Home Screen Functions

3.3.2 Logging Options

(a) (b) (c)

Output to Data Logging device

Output to SD Card / USB

3.3.3 Port Setup

3.3.4 Language / Keyboard region

3.3.6 Job No. / Ticket No.

3.3.7 Save to USB

3.3.8 Load from USB

Load Calibration Settings only

3.3.9 Overload Log

3.4 Factory Level Settings

3.4.1 ‘Auto’ Weight Calibration

4. Lift the calibration load to the weighing position and press .

3.4.2 Calibration Factors

3.4.3 Linear Compensation Factors

“Correct from Weight” - “Wf” on graph.

3.4.4 Sensor Setup

the sampling period and improves accuracy.

3.4.5 Overload Alarm Setup

3.4.6 Error Log

3.4.8 Software Reset

Issue Ref. Date Description

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