Avery Weigh-Tronix ZK840 User manual

ZK840
Checkweighing Application
User Instructions
AWT35-501671
Issue AA

ZK840_checkweigh_app_u_en_5016771.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 © 2017 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
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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.

ZK840 Checkweigh 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
FCC and EMC declarations of compliance ........................................................................ 8
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 ........................................................................................... 11
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 ............................................................................................................................. 14
Checkweighing application .............................................................................................. 14
Overview ................................................................................................................... 14
Checkweighing modes .............................................................................................. 14
Performing checkweighing operations ...................................................................... 17
Checkweighing with PLU database active ................................................................ 18
QA messaging ........................................................................................................... 18
Average checkweighing ............................................................................................ 18
Chapter 4 Error messages ...................................................................................................................... 19
Printing errors .................................................................................................................. 19
‘Copying to or from USB’ errors ....................................................................................... 19
BSQ errors ....................................................................................................................... 19
Accumulation errors ......................................................................................................... 19
Chapter 5 User menu ...............................................................................................................................20
User menu ....................................................................................................................... 20
About menu ...................................................................................................................... 22
Audit menu ....................................................................................................................... 23
Chapter 6 Supervisor menu .................................................................................................................... 24
CONFIG key .................................................................................................................... 25
System key ................................................................................................................ 26

4 ZK840 Checkweigh Application User Instructions
PLU key ..................................................................................................................... 27
APP key ..................................................................................................................... 29
DBASE key ......................................................................................................................30
EDIT key .................................................................................................................... 31
IMPORT key ............................................................................................................. 31
EXPORT key ............................................................................................................. 31
RESET key ................................................................................................................ 31
Totals key ......................................................................................................................... 31
Battery key ....................................................................................................................... 31
PLU setup ........................................................................................................................ 32
PLU ADD softkey ...................................................................................................... 32
PLU EDIT softkey ...................................................................................................... 35
PLU DELETE softkey ................................................................................................ 35
Chapter 7 Print formats ........................................................................................................................... 36

ZK840 Checkweigh 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 QUALIFIED SERVICE
PERSONNEL FOR SERVICE.

6 ZK840 Checkweigh 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 Checkweigh 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

8 ZK840 Checkweigh Application User Instructions
General information and warnings
1.7 FCC and EMC declarations of compliance
United States
Canada
European Countries
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own
expense.
This digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio
Interference Regulations of the Canadian Department of Communications.
Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de
la Classe A prescrites dans le Règlement sur le brouillage radioélectrique edicté par le ministère des Communications du Canada.
WARNING: This is a Class A product. In a domestic environment, this product may cause radio interference in which the user may be
required to take adequate measures.

ZK840 Checkweigh 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 Checkweighing application. See Chapter 3
for information about the Checkweighing 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 Checkweigh 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 sets the lives weight as the target weight.
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 Checkweigh Application User Instructions 11
2.5 Adjusting screen contrast
2.5 Adjusting screen contrast
To adjust the screen contrast press and hold the middle 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.
2.8 Menu access and navigation
The menus used to configure the ZK840 are accessed with passwords. See User menu
on page 20 and Supervisor menu on page 24 for passwords and information on the
menus. This section is to introduce you to the general information about menus.

12 ZK840 Checkweigh Application User Instructions
Introduction
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 Checkweigh 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 startup screen similar to the one
below.
With the Checkweigh application active the screen shows the user name and time and
date in the top line. Below that is the current weight. Below that is the bargraph 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.
PLU key Use this key to recall a PLU 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.
TARGET key Use this key to enter variables for checkweighing.
The screen above shows the default screen in the checkweighing application. There
are other screens you can choose which enable or disable various functions such as:
the PLU database screen size and an averaging function. See the menu item
Application Mode under APP key on page 29.

14 ZK840 Checkweigh Application User Instructions
Operating Instructions
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 formats on page 36 to see the available
default print formats.
3.3 Checkweighing application
3.3.1 Overview
This application offers the following functions:
lTolerance or limits mode of checkweighing
lPositive or reverse Checkweighing with Auto Tare
lPLU database
lAverage Checkweighing
lBasic Pack run counter
lSimple QA messaging
lData capture
Each is explained in the following sections.
3.3.2 Checkweighing modes
Tolerance mode
There are two modes of checkweighing that can be chosen in the Supervisor menu on
page 24: Tolerance mode and Limits mode.
In Tolerance mode you set a target weight, high and low tolerances and minimum and
maximum points. See Figure 3.1.
Figure 3.1 Tolerance mode
Min. point (Tol)
Low Tol. High Tol.
Max point (Tol)
Ta r g e t
Accept OverUnder

ZK840 Checkweigh Application User Instructions 15
3.3 Checkweighing application
Limits mode
In Limits mode you don’t set a target weight. You set a high limit and low limit for your
acceptable weight range and a minimum and maximum point. See Figure 3.2.
Figure 3.2 Tolerance mode
Reverse checkweighing
Reverse checkweighing involves placing a full container on the scale, taring the entire
weight and removing material until the weight is in the accept window. Turn on the Auto-
tare feature in the Supervisor menu on page 24 so the scale will automatically zero and
make the scale ready for the next weighment.
Setup in Tolerance mode
1. In Tolerance mode, press the Target softkey to view or change the available
settings. These define how the bar graph reacts.
The following screen is displayed:
Packrun Allows you to track the quantity checked.
Target Target weight (Can be set by pressing the SAMPLE
key with a weight on the scale. It can also be set or
modified here, if desired.)
Min. point (Tol)
Low Limit High Limit
Max point (Tol)
Accept OverUnder
If you are using the database in reverse checkweighing, be sure to enter the target
weight as a negative value.

16 ZK840 Checkweigh Application User Instructions
Operating Instructions
High / Low Tol Sets the upper and lower edge of the accept window
away from the target point.
Target wt. + High tol. = upper weight of accept window
Target wt. - Low tol. = lower weight of accept window
Max / Min points Sets the bar graph start and stop points.
Target wt. + High tol. + Max. point = upper bar graph
limit
Target wt. - Low tol. - Min. point = lower bar graph limit
2. Highlight an item in the Checkweigh Tolerance Mode screen, press the Enter
( softkey and enter a value in the screen that appears, such that the bar
graph reacts in the way desired for your operation. Press the Enter key to
accept the value and return to the Checkweigh Tolerance Mode screen.
3. Repeat the process for all the items in the Checkweigh Tolerance Mode
screen. When finished, press the Esc softkey to return to the startup screen.
Note that the High / Low Tol and the Max / Min points are values defining a range,
not the actual weights that trigger the bar graph positions. For example:
lTarget = 3kg
lHigh and low tolerance = 0.5kg
lMax and min. points = 0.25 kg
If 3kg is the target weight and you want the high and low tolerances to be
0.5kg above and below that, set 0.5kg as the value, not 3.5kg and 2.5kg.
The same holds true for the Max/Min points. If you want the bar graph to
top out at 5kg, set the Max point to 1.5kg.
Setup in Limits mode
1. In Limits mode, press the Target softkey to view or change the available
settings. These define how the bar graph reacts.
The following screen is displayed:
Packrun Allows you to track the quantity checked.
High / Low Limits Sets the upper and lower edge of the accept window.
High Limit = upper weight of accept window
Low Limit = lower weight of accept window

ZK840 Checkweigh Application User Instructions 17
3.3 Checkweighing application
Max / Min points Sets the bar graph start and stop points.
High Limit + Max. point = upper bar graph limit
Low Limit - Min. point = lower bar graph limit
2. Highlight an item and press the Enter ( softkey to enter a value for that item.
Press the Enter key to accept the value and return to the setup screen.
3. Repeat the process for all the items and when finished, press the Esc softkey
to return to the startup screen.
3.3.3 Performing checkweighing operations
Here is an example of a checkweighing procedure in Tolerance mode. Procedures are
basically the same in Limits mode except for the bar graph function in relation to target
weight.
In this example values are set as follows:
lPackrun = 6
lTarget = 3kg
lHigh and low tolerance = 0.5kg
lMax and min. points = 0.25 kg
1. Once the tolerance and target settings are set as shown above, place the object
to be weighed on the scale …
The weight is shown and the bar graph shows Under, Over or Accept.
See the note below.
2. Remove the weight and weigh the next item. As each item is weighed it will be
under the target, on target or over the target. When a packrun is complete,
Packrun Complete, is briefly displayed and a report is sent to a connected
device.
3. Keep repeating the procedure until finished with your items.
The display will show a running total of the packrun at the bottom of the display.
Once the total is reached the scale will print the total quantity packed.
Press and hold the Print key to clear Packrun totals and restart the counter back to 0.
There is a setting in the Supervisor menu on page 24 called Packrun Print. If this is
set to Accept, only the weighments seen in the Accept window will be counted. If set
to Under/Over/Accept it will print all stable checkweigh readings.

18 ZK840 Checkweigh Application User Instructions
Operating Instructions
3.3.4 Checkweighing with PLU database active
If the PLU database is enabled in the Supervisor menu on page 24, a PLU softkey
appears on the startup screen. Use this key to recall a stored PLU. See PLU setup on
page 32.
Recalling a PLU sets target and tolerances automatically. They can be viewed but not
changed in normal operating mode. The PLU must be updated in the supervisor menu.
3.3.5 QA messaging
QA messaging is set up in the supervisor menu. See the Extend key on page 28.This
is designed to display a custom message on a screen.
Each PLU can have a different message. The scale will display the custom message
(1 line of data) until you press any key. You can set a timer to display the message after
the set time has elapsed. This is ideal for reminding users to make regular sample
checks
3.3.6 Average checkweighing
Average Checkweighing is a mode of operation you can choose in the Supervisor
menu. See APP key on page 29. This can be uses with or without the database. Below
is the startup screen when you are in this mode.
The graph, pointed out in the illustration above, shows the result of a rolling average of
the last 100 (default) weighments. This displays the average weight reading along with
the highest & lowest recorded weight seen in that buffer window. You can set the
number of weighments being averaged from 5 to 1000. A visual line shows you if the
average is above or below the current target point.
UCL stands for Upper
LCL stands for Lower
Press the PrtStat softkey to print statistical data when required.

ZK840 Checkweigh Application User Instructions 19
4.1 Printing errors
4 Error messages
In order to complete the weighing process, a number of conditions must be met. The
following messages may appear which may prevent completion of the weighing
sequence.
4.1 Printing errors
Timeout Something interfered with the printing process. Check
connections and retry.
Print Error Something interfered with the printing process. Check
connections and retry.
Print Aborted Something interfered with the printing process. Check
connections and retry.
Print Failed Something interfered with the printing process. Check
connections and retry.
4.2 ‘Copying to or from USB’ errors
Failed to Copy File Something interfered with the copy process. Check USB
device.
Can’t Close database Software error. Restart indicator.
File Not Found File doesn’t exist. Create the database.
4.3 BSQ errors
BSQ Error Communications error
BSQ XCAL BSQ Calibration Mismatch Error - cell that is connected to
the scale is not the cell that was calibrated. X = scale
number.
4.4 Accumulation errors
FAILED RTZ ERR Scale must return to zero between accumulations.
NO COUNT ERR Count is not a positive number when you try to
accumulate. Count must be a positive value to
accumulate.

20 ZK840 Checkweigh Application User Instructions
User menu
5 User menu
The ZK840 three user accessible menus:
lUser menu - Use to set Time, Date, Site ID, check Seal status and check
Archive information.
lAbout menu - Use to see information on the software, firmware, application,
serial number, options, ethernet and downloads
lAudit menu - Use this to check and/or print the calibration and configuration
counters.
The password for these menus is 111. Follow these steps to access and use these
menus.
1. Press and hold the SETUP key until …
The password entry screen appears, shown below:
2. Key in 111 and press the Enter ()key…
This screen is displayed:
The bold box around the center image means that is the highlighted
menu item.
3. Use the Left and Right keys to highlight the menu you want to enter and press
the Enter ( ) key. Below are the explanations for these menus.
5.1 User menu
When the User menu is selected, these choices appear:
Time Date Site ID Seal Archive