Avery Weigh-Tronix ZK840 User manual

ZK840
Picklist Application
User Instructions
AWT35-501768
Issue AA

ZK840_picklist_app_u_en_501768.book
Avery Weigh-Tronix is a trademark of the Illinois Tool Works group of companies whose ultimate parent company is Illinois Tool
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specification, design, price or conditions of supply of any product or service at any time.

ZK840 Picklist Application User Instructions 3
Table of Contents
page
Table of Contents ...................................................................................................................................... 3
Chapter 1 General information and warnings ......................................................................................... 5
About this manual ..............................................................................................................5
Text conventions ......................................................................................................... 5
Special messages ....................................................................................................... 5
Installation .......................................................................................................................... 5
Safe handling of equipment with batteries .................................................................. 6
Wet conditions ............................................................................................................. 6
Routine maintenance ......................................................................................................... 6
Cleaning the machine ........................................................................................................ 7
Training .............................................................................................................................. 7
Sharp objects ..................................................................................................................... 7
Chapter 2 Introduction .............................................................................................................................. 9
Front panel keys .............................................................................................................. 10
Softkeys ........................................................................................................................... 10
Annunciators .................................................................................................................... 10
Powering up a ZK840 indicator ........................................................................................ 10
Adjusting screen contrast ................................................................................................. 11
Touch screen calibration .................................................................................................. 11
Web access .....................................................................................................................11
Menu access and navigation ........................................................................................... 12
Escaping or exiting from a menu ............................................................................... 12
Chapter 3 Operating Instructions ........................................................................................................... 13
Power up .......................................................................................................................... 13
Setting User name, time and date ............................................................................. 13
Key functions ............................................................................................................. 13
Printing ............................................................................................................................. 13
Picklist application ............................................................................................................ 14
Application overview .................................................................................................. 14
Performing a picklist operation .................................................................................. 15
Creating a PLU entry ....................................................................................................... 16
Creating an Assembly ...................................................................................................... 19
Assembly process choices ........................................................................................ 23
Features .................................................................................................................... 23
Chapter 4 Error messages ...................................................................................................................... 25
Printing errors .................................................................................................................. 25
‘Copying to or from USB’ errors ....................................................................................... 25
BSQ errors ....................................................................................................................... 25
Accumulation errors ......................................................................................................... 25
Chapter 5 User menu ...............................................................................................................................26
User menu ....................................................................................................................... 26
About menu ...................................................................................................................... 28
Audit menu ....................................................................................................................... 29
Chapter 6 Supervisor menu .................................................................................................................... 30
CONFIG key .................................................................................................................... 31
System key ................................................................................................................ 32
PLU key ..................................................................................................................... 33

4 ZK840 Picklist Application User Instructions
APP key ..................................................................................................................... 34
DBASE key ......................................................................................................................35
EDIT key .................................................................................................................... 36
IMPORT key ............................................................................................................. 36
EXPORT key ............................................................................................................. 36
RESET key ................................................................................................................ 36
Totals key ......................................................................................................................... 36
Battery key ....................................................................................................................... 37
Chapter 7 Print and barcode formats .................................................................................................... 38
Barcodes .......................................................................................................................... 39

ZK840 Picklist Application User Instructions 5
1.1 About this manual
1 General information and warnings
1.1 About this manual
This manual is divided into chapters by the chapter number and the large text at the top
of a page. Subsections are labeled as shown by the 1.1 and 1.1.1 headings. The
names 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.
1.1.1 Text conventions
Key names are shown in bold and reflect the case of the key being described. If a key
has a dual function it may be referred to by its alternate function.
Displayed messages appear in bold italic type and reflect the case of the displayed
message.
Annunciator names appear as italic text and reflect the case of the annunciator.
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 information or the relative
level of hazard.
1.2 Installation
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.
NO USER SERVICEABLE PARTS.REFER TO Q U A LIFIED SERVICE
PERSO N N EL FO R SERVICE.

6 ZK840 Picklist Application User Instructions
General information and warnings
1.2.1 Safe handling of equipment with batteries
1.2.2 Wet conditions
Under wet conditions, the plug must be connected to the final branch circuit via an
appropriate socket / receptacle designed for washdown use.
Installations within the USA should use a cover that meets NEMA 3R specifications
as required by the National Electrical Code under section 410-57. This allows the unit
to be plugged in with a rain tight cover fitted over the plug.
Installations within Europe must use a socket which provides a minimum of IP56
protection to the plug / cable assembly. Care must be taken to make sure that the
degree of protection provided by the socket is suitable for the environment.
1.3 Routine maintenance
Always isolate the indicator from the power supply before starting any routine
maintenance to avoid the possibility of electric shock.
CAUTION: Danger of explosion if battery is incorrectly replaced. Replace only
with the same or equivalent type recommended by the manufacturer. Dispose
of used batteries according to the manufacturer’s instructions.
ATTENTION: Il y a danger d'explosion s'il y a remplacement incorrect de la
batterie, remplacer uniquement avec une batterie du même type ou d'un type
équivalent recommandé par le constructeur. Mettre au rebut les batteries
usagées conformément aux instructions du fabricant.
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.

ZK840 Picklist Application User Instructions 7
1.4 Cleaning the machine
1.4 Cleaning the machine
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.
To avoid the risk of RSI (Repetitive Strain Injury), place the machine on a surface which
is ergonomically satisfactory to the user. Take frequent breaks during prolonged usage.
1.6 Sharp objects
Do not use sharp objects such as screwdrivers or long fingernails to operate the keys.
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
Spray the cloth when using a proprietary
cleaning fluid
Spray any liquid directly on to the display windows

ZK840 Picklist Application User Instructions 9
2 Introduction
The ZK840 is a fully programmable indicator which, when attached to a BSQ digital
scale base, creates a highly accurate counting and weighing system. With custom
programming the indicator and its touch-screen graphic display can perform many
other functions. This manual applies to the Picklist application. See Chapter 3 for
information about the Picklist application.
The indicator, shown in Figure 2.1, requires 100 VAC - 240 VAC, 50 or 60 Hz or 9-
36VDC. The indicator has two full duplex RS232 ports, two USB host ports, Ethernet
port, one Micro SD slot, three logic level inputs with configurable functions, three
setpoint outputs and an expansion card slot for 1 of 2 option cards:
l802 Wireless card
l5V Analog scale card
Other options available are a stack light kit for visual confirmation of outputs, two
columns for mounting the indicator above the BSQ base, battery packs and scanners.
The ZK840 allows five bases to be used (one local BSQ base, two remote BSQ bases
and two analog platforms). Other base combinations are available.
See the Specification literature for a full list of specifications.
For information on the BSQ bases please refer to the manuals for the BSQ line.
Figure 2.1 shows the front panel of the ZK840 indicator. The front panel consists of the
keys and the graphic display.
Figure 2.1 ZK840 front panel
ZK840
T HE CO UN TI NG
FEATURE IS NOT LEGAL
FOR TRADE
SETUP ZERO
TARE
SAMPLE
Never press a key with anything but your finger. Damage to the overlay may result if
sharp or rough objects are used.

10 ZK840 Picklist Application User Instructions
Introduction
2.1 Front panel keys
The keys and their functions are listed below.
2.2 Softkeys
Softkeys are the key images that appear at the bottom of the display. Their functions
change to suit the situation. In this manual, when you are instructed to press a
particular softkey, the text will name the function and then show the image appearing
on the softkey. For example: Press the UP ( ) softkey.
2.3 Annunciators
On screen you will see various annunciators. Below are the annunciators and what
they mean.
Motion - This appears when the indicator senses scale motion.
Center of Zero - This appears when the scale is in the zero window.
Scale - If multiple scales are attached and active, this annunciator shows
which scale’s information is being displayed.
W1 Weight Range 1 - For multi-range operation, this shows which weight
range the weight is in. May also be W2 or W3.
PT Appears when a Preset Tare is active.
2.4 Powering up a ZK840 indicator
The indicator is always active as long as power is received. Power must be 100-240
VAC with a frequency of 50 or 60 Hz, or 9-36 VDC.
The SAMPLE key can be used to perform custom application
functions.
Press the TARE key to perform a pushkey tare function or with zero
weight on the scale press the TARE key to enter a known tare. To
clear a tare, press and hold the TARE key.
Press the ZERO key to zero the display.
The SETUP key can be used to perform custom application
functions. It can also be used to access the password entry screen
for menu access.
Press the PRINT key to print the configured information through the
configured port. A long key press will print and clear the Count totals.
Press the SCALE key to switch the display between different
connected scale bases.
SAMPLE
TARE
ZERO
SETUP
SCL#1

ZK840 Picklist Application User Instructions 11
2.5 Adjusting screen contrast
2.5 Adjusting screen contrast
To adjust the screen contrast press and hold the PRINT ( ) key on the left side of the
ZK840 and repeatedly press the SAMPLE key to increase contrast or the TARE key to
decrease the contrast. You may need to press the key many times until the change is
visible.
2.6 Touch screen calibration
If you need to calibrate the touchscreen, press and hold the top key on the left side of
the ZK840 on powerup and the touch calibration screen appears. Follow the prompts
to calibrate the screen.
2.7 Web access
The ZK840 can be accessed from a web browser. This allows you to access basic
functions of the scale, such as zero, print, and tare.
You must have the scale connected to the internet and when you enter the IP address
of your scale in the browser address bar, the following screen will appear allowing
access to the scale.

12 ZK840 Picklist Application User Instructions
Introduction
2.8 Menu access and navigation
The menus used to configure the ZK840 are accessed with passwords. See User menu
on page 26 and Supervisor menu on page 30 for passwords and information on the
menus. This section is to introduce you to the general information about menus.
Press and hold the SETUP key to access the password entry screen, shown below.
Enter the password for the menu you want and press the Enter key. On-screen
prompts often guide you as you move through the menus.
When icons are on screen the bold box around an icon means it is the highlighted icon.
See the example below.
When a text list appears on screen, the highlighted item is shown by a green bar over
the text. See the example below.
Press the UP ()orDOWN ( ) softkey to move the highlight and then press the
Enter ( ) softkey to accept the highlighted choice. Press Esc to return to the previous
screen without making a change.
2.8.1 Escaping or exiting from a menu
In any menu you will have either UP or ESC softkeys.
To exit any menu, if there is an ESC softkey, use it until it disappears then use the UP
softkey until you are asked if you want to save any changes or not. Highlight your
choice and press Enter ( ) to accept.
The indicator will reboot and return to the startup screen.
User AboutAudit
Highlighted icon

ZK840 Picklist Application User Instructions 13
3.1 Power up
3 Operating Instructions
3.1 Power up
The indicator can be powered by one of the battery options on the BSQ scale or by AC
power supply. If the battery option is used, there is a power key on the rear of the scale.
Press and hold the key until the screen lights up. If AC power is used, when the power
is on, the indicator is on.
When the indicator is powered up, you will see a start screen similar to the one below.
With the Picklist application active, the screen shows the user name and time and date
in the top line. Below that is the current weight. Below that are the Assembly number
and description and active softkeys.
3.1.1 Setting User name, time and date
Touch the User area of the screen and a keyboard pops up so that you can enter your
desired user name. Press Enter ( ) to accept. The user name will remain active until
changed or deleted.
Touch the time and date area and enter the requested data, i.e. Year, month, etc.
3.1.2 Key functions
Below are short descriptions of three softkeys’ functions.
RECALL key Use this key to recall an Assembly number from the database.
UNITS key Use this key to change unit of measure.
SELECT key Use this key to scroll through the active display values. By default
they are: Gross, Net and Tare.
3.2 Printing
Press the PRINT key when there is no scale motion. What is printed is typically
controlled by the custom program. See Print and barcode formats on page 38 to see
the available default print formats.

14 ZK840 Picklist Application User Instructions
Operating Instructions
3.3 Picklist application
3.3.1 Application overview
This application leads through picking a list of items identified by PLU (Piece Look Up)
numbers into an assembly. By using weight (or counts), you verify that all items in an
assembly have been added to the package.
The PLU and the Assembly numbers are stored in the internal database memory. The
items in the database are created and managed using the Supervisor menu, password
1793. See Creating a PLU entry on page 16 and Creating an Assembly on page 19 for
directions on these processes.
There are two ways you can perform the picking and packing of an assembly. You can
pick items and place them in a box on the scale or have the box sitting next to the scale.
See Assembly process choices on page 23 for instructions on how to enable the Auto-
tare function which is needed if you’re filling the box on the scale.
The internal database can hold approximately 1000 Assemblies/PLUs. The microSD
card can hold up to 3500 Assemblies/PLUs.
If the PLU has a piece weight it is a counted item, otherwise it is a weight-based item.
For a hand-add item, set the target value and tolerances to 0.


A hand-add item cannot be the first PLU in an assembly.

ZK840 Picklist Application User Instructions 15
3.3 Picklist application
3.3.2 Performing a picklist operation
Assume there is an assembly and its associated PLUs already in the database for
assembling the parts for a three drawer cabinet. The package consists of two sides, a
top, bottom, back, three drawers, a hardware pack, a hex key and a set of instructions.
Each of these items are a separate PLU item.
1. To select an assembly press the RECALL softkey shown on the powerup
screen below:
The following screen is displayed:
2. Type in the Assembly ID you want to assemble and press the Enter softkey …
If the entry is wrong you will see the message Assembly Not Found and
then the screen returns to startup screen.
If the assembly exists in the database, the indicator will show a screen
similar to the one shown below with the ASSY# and Description shown
below the weight display:
Enter softkey

16 ZK840 Picklist Application User Instructions
Operating Instructions
3. Begin the assembly by pressing the Start softkey …
This will initiate a print out on the printer and the active assembly # is
shown on the top line as shown below:
The current active Assembly and the bar graph are displayed.
Also shown is the list of PLU parts that need to be fulfilled. The bargraph
move for each highlighted part as they are added to the scale. Each part
can be weight or count based. You can also have a hand-add item such
as a business card which must have target and tolerances set to 0.
Each step can have validation features turned on to reduce operator
error. See Supervisor menu on page 30.
4. Place the item on the scale. If acceptable the bargraph will be in the middle
range. Press the NEXT key to step to the next item in the list. At this point an
item string is sent to the report printer.
When all PLU items have been completed an additional complete string is sent to the
report printer. If you press and hold the PRINT key, the sub-total transactions will be
printed and cleared but the grand total transactions will increment by one every time
this assembly is made. The grand total can only be cleared in the Supervisor menu.
3.4 Creating a PLU entry
Creating a PLU consists of two parts:
lDefine everything that will be in a PLU by configuring the database. This is
done when the database is created and is explained in the Supervisor menu
on page 30.
lTo create a new PLU entry in the database you follow the steps below.
5. Access the Supervisor menu using password 1793 and the password entry
procedure explained in Menu access and navigation on page 12.
A hand-add item cannot be the first PLU in an assembly.

ZK840 Picklist Application User Instructions 17
3.4 Creating a PLU entry
6. Press this key sequence to access the database and start adding new PLUs:
DBASE>EDIT>PLU>ADD
These are the screens you will see in order as you progress through the
key presses listed above:
Press the EDIT
softkey to edit an
existing PLU.

18 ZK840 Picklist Application User Instructions
Operating Instructions
7. Key in an ID for the new PLU and press the Enter key. Below is an example of
a screen you will see:
8. Press BASIC and enter values for the items in the list that appears. By default
they are Description 1, Unit of Measure and Piece Weight. When finished
press the Esc key to return to the screen above. Press the Extend softkey and
fill in the items there and press the Esc key to return to the screen above.
9. From the screen in step 7, press the BACK softkey and repeat steps 7and 8
for all the PLUs you need to create.
10. When finished press the BACK softkey until you see this screen
11. Press the ASSY softkey to move to the next section, Creating an Assembly.

ZK840 Picklist Application User Instructions 19
3.5 Creating an Assembly
3.5 Creating an Assembly
Before creating the assembly, all the PLUs used in the assembly must be entered in
the database. See the previous section Creating a PLU entry on page 16.
1. If you are coming from the previous section’s step 11, you can press the ASSY
softkey then the ADD softkey and continue.

If you are starting from startup screen, access the Supervisor menu (password
1793) and press this softkey sequence from the Supervisor Setup screen:
DBASE>EDIT>ASSY>ADD …
You will see this screen:
Use this screen to give the assembly a name and description.
2. Select assembly and press the Enter ( ) softkey …
A text entry screen appears:
3. Key in an Assembly name and press Enter.
The name is saved and the screen returns to the previous one shown in
step 1.
4. Select description and repeat this process.
5. Sub transactions are a temporary total of the number of assemblies
completed. This can be cleared when an assembly is completed by pressing
and holding the PRINT key.

The grand transactions are a running total of the number of transactions. This
can only be cleared by selecting that item in this screen and entering a 0
value.

20 ZK840 Picklist Application User Instructions
Operating Instructions
6. Press Esc when you are finished and you are given a SAVE/ABORT choice,
shown below:
7. Highlight your choice and press the Enter ( ) key …
The ASSEMBLY SETUP screen is displayed, shown below.
8. Press the EDIT key to see a list of the Assemblies in the database, like the
example screen shown below:
There is a Filter softkey in this screen. If you have a large number of
Assemblies, press this key, key in first part of the Assembly’s name and
press the Enter key. Assemblies starting with those characters will be
listed and you can highlight the one you want and press the Enter ()
softkey to edit it following the steps below.

ZK840 Picklist Application User Instructions 21
3.5 Creating an Assembly
9. Select the assembly you want to edit and press the Enter ( ) key …
Following is an example of the screen you will see:
The name of the assembly is shown as well as the sub transaction and
grand transaction counts. These are both 0 since this is a new
assembly. This is the screen where you pick the PLUs that make up all
the parts of the assembly.
10. Highlight Assembly Items and press the Enter ( ) key …
The following is displayed:
Since there are no PLUs entered yet as part of this assembly there is
only a nil place holder.