Avery Weigh-Tronix ZK840 User manual

ZK840
Counting Scale
User Instructions
AWT35-501613
Issue AA

ZK840_u_en_501613.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
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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 Counting Scale User Instructions 3
Table of Contents
page
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
Annunciators .................................................................................................................... 10
Powering up a ZK840 indicator ........................................................................................ 10
Menu access and navigation ........................................................................................... 11
Escaping or exiting from a menu ............................................................................... 12
Adjusting screen contrast ................................................................................................. 12
Touch screen calibration .................................................................................................. 12
Chapter 3 Operating Instructions ........................................................................................................... 13
Power up .......................................................................................................................... 13
Printing ............................................................................................................................. 13
Simple Weighing (no database active) ............................................................................ 14
Gross weighing .......................................................................................................... 14
Tare/Net weighing ..................................................................................................... 14
Counting .................................................................................................................... 15
Advanced operations ....................................................................................................... 16
Customizing screens ................................................................................................. 16
Database ................................................................................................................... 19
Accumulation ............................................................................................................. 20
Check counting .......................................................................................................... 20
Autobase switching ................................................................................................... 23
Chapter 4 Menus ...................................................................................................................................... 24
User menu ....................................................................................................................... 24
About menu ...................................................................................................................... 25
Audit menu ....................................................................................................................... 27
Chapter 5 Error messages ...................................................................................................................... 28
Printing errors .................................................................................................................. 28
‘Copying to or from USB’ errors ....................................................................................... 28
BSQ errors ....................................................................................................................... 28
Accumulation errors ......................................................................................................... 28
Chapter 6 Print formats ........................................................................................................................... 30
Chapter 7 Supervisor menu .................................................................................................................... 36
CONFIG key .................................................................................................................... 37
System key ................................................................................................................ 38
PLU key ..................................................................................................................... 39

4 ZK840 Counting Scale User Instructions
APP key ..................................................................................................................... 41
DBASE key ......................................................................................................................44
EDIT key .................................................................................................................... 45
IMPORT key .............................................................................................................. 45
EXPORT key ............................................................................................................. 45
RESET key ................................................................................................................ 45
Totals key ......................................................................................................................... 45
Battery key ....................................................................................................................... 45

ZK840 Counting Scale 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 Counting Scale 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 Counting Scale 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 Counting Scale 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 Counting Scale 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.
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 Counting Scale User Instructions
Introduction
2.1 Front panel keys
The keys and their functions are listed below.
2.2 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.
2.3 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 Counting Scale User Instructions 11
2.4 Menu access and navigation
2.4 Menu access and navigation
The menus used to configure the ZK840 are accessed with passwords. Press and hold
the SETUP key to access the password entry screen, shown below.
In general, a menu is made up of a group of top level items, sub levels under each of
those and lists of items to view or configure. There are variations on this theme.
Sometimes there may be no sub level or there maybe two sub levels before you get to
a list of items to set.
You will see on-screen lists with instructions on how to choose and set an item in each
menu list. On-screen prompts 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 or down arrow to move the highlight and then press the Enter key to
accept the choice. Press Esc to return to the previous screen without making a change.
The main menu is made up of the User, About and Audit menus. See Chapter 4for
complete information.
Note that the display shown above and throughout the manual is not proportional to
the actual screen. It is shortened vertically to save space on the page when practical.
User AboutAudit
Highlighted icon

12 ZK840 Counting Scale User Instructions
Introduction
2.4.1 Escaping or exiting from a menu
In any menu you will have either UP or ESC keys listed on-screen.
If ESC is listed use it until it disappears then use the UP key 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.
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.

ZK840 Counting Scale 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.
The Count application without the database is active by default. The screen shows the
user name and time and date in the top line. Below that is the current weight and the
count screen. Below that are the piece weight and active softkeys.
Click 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.
Click the time and date area and enter the requested data, i.e. Year, month, etc.
Below are short descriptions of three softkeys’ functions.
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, Tare, Count and Piece weight.
PCWT key Use this key to enter a known piece weight.
3.2 Printing
Press the PRINT key when there is no scale motion. What is printed is typically
controlled by the custom program. If accumulation function is configured, press and
hold the PRINT key and any accumulated counts will be printed and cleared.

14 ZK840 Counting Scale User Instructions
Operating Instructions
3.3 Simple Weighing (no database active)
The Count application is the default application when you power up the ZK840. You can
also do simple gross/tare/net weighing by following the instructions below.
First step - power up
The first step for all these instructions is to power up the scale by applying AC or DC
power. If DC power is being used with a BSQ base, a power key is on the back panel
of the scale. Press the key to power up the indicator. If AC power is used, when the unit
is plugged in it will power up immediately.
Second step - zero the scale
The next step is to zero the indicator if the display does not read 0 weight. Press the
ZERO key to zero the indicator.
3.3.1 Gross weighing
To weigh any object within the scales capacity, place the item on the scale …
The weight is displayed.
3.3.2 Tare/Net weighing
1. To perform a tare weighment, place the container to be tared on the scale and
press the TARE key …
The display shows the Net annunciator and the weight is tared from the
display.
2. Place the material to be weighed in the container …
The net weight is displayed.
3. Repeat steps 1and 2for a different sized container. Repeat step 2if the
containers are all the same weight.
4. To remove a tare weight, empty the scale, press and hold the TARE key.
To key in a known tare, remove all weight from the scale, press the TARE key and
enter the known tare weight using the keyboard that is displayed. Press Enter to
accept.

ZK840 Counting Scale User Instructions 15
3.3 Simple Weighing (no database active)
3.3.3 Counting
Simple counting
To perform a simple counting procedure, follow these steps:
1. Press the SAMPLE key …
The scale zeros itself and the following screen appears:
2. There are several actions you can take using the available keys (which can
vary depending on configuration of your indicator through the supervisor
menu):
Press the ABORT key to return to the start screen.
If enabled, press the S.Size key to change the sample size. Use the displayed
keypad to enter your desired sample size and press Enter.
If enabled, press the Acc% key to change the desired accuracy. Choose from
the choices displayed. The expected accuracy is based on the noise in the
zero acquired and the weight of the sample on the scale. The expected
accuracy can be improved by aborting and changing the environment and then
starting over, or by increasing the sample size and adding more parts.
If enabled, press the SMODE key to change the sample mode. Choices are
Dribble (default) or Bulk sampling. This is set in a password protected
Supervisor menu. Each type is defined below.
Dribble sampling definition:
When sample parts are being added to the scale they can be counted
out slowly or, in other words, dribbled onto the scale. A key press
(SAMPLE key) is needed to finish the sampling process. The piece
weight is calculated and the count is displayed.
Bulk sampling definition:
When sample parts are being added to the scale they must all be placed
on the scale at once, in other words, in bulk. If the sample is large
enough to meet the minimum weight requirements the piece weight is
calculated and the count is displayed with no extra key presses.
Since, by default, the scale zeroes itself when sampling, you need not tare the weight
of a container. Place it on the scale first and it’s weight will be zeroed when you begin
the sampling process. If this option is active, tare the weight of a container first, before
sampling. See R.Sample on page 43.

16 ZK840 Counting Scale User Instructions
Operating Instructions
3. Place the number of samples shown on the screen onto the scale: Current
sample size = 5 …
The following screen is displayed:
The screen shows the expected accuracy and requests you press the
SAMPLE key when ready.
4. Press the SAMPLE key …
The screen briefly shows that the sampling was successful and then
returns to the start screen with the new piece weight active and the
current count shown in the Count window.
5. Add more parts to be counted.
6. Clear the scale and weigh more parts of the same piece weight or sample new
parts that have a different piece weight.
3.4 Advanced operations
This section will explain scale operation using some of the options which are available
through the password protected Supervisor menu on page 36. Using this menu a
supervisor can alter the configuration of the ZK840. Alternate display layouts can be
chosen. Different keys can be shown. Different functions such as use of the database
and accumulation can be configured. This section will introduce and give examples of
how these advanced features can be used.
3.4.1 Customizing screens
There are screens which can be chosen in the supervisor menu to display different
information in various formats. Following are examples of these screens.

ZK840 Counting Scale User Instructions 17
3.4 Advanced operations
Split Screen w/o DB: Split screen without database. This screen shows the
weight on the left side and the counts on the right. User
and Time and Date are shown across the top of the
display. Piece weight is shown above the softkeys.
Softkeys appropriate to this option are displayed. The
database is disabled.
Split Screen w/ DB: Split screen with database. This screen shows the weight
on the left side and the counts on the right. User and Time
and Date are shown across the top of the display. Piece
weight is shown above the softkeys as well as other PLU
information. Softkeys appropriate to this option are
displayed. The database is enabled.
Large w/o DB: Large screen without database.This screen shows a large
count display and a small weight display below the count.
User and Time and Date are shown across the top of the
display. Softkeys appropriate to this option are displayed.
The database is disabled.

18 ZK840 Counting Scale User Instructions
Operating Instructions
Large w/ DB: Large screen with database.This screen shows a large
count display and a small weight display below the count.
User and Time and Date are shown across the top of the
display. Softkeys appropriate to this option are displayed.
The database is enabled.
Check w/o DB: Check counting screen without database. This screen
shows a large weight display with a bar graph beneath
that to show the status of the check counting operation,
i.e. Over, Under or Accept. User and Time and Date are
shown across the top of the display. Piece weight is
shown above the softkeys. Softkeys appropriate to this
option are displayed. The database is disabled.
Check w/ DB: Check counting screen with database. This screen shows
a large weight display with a bar graph beneath that to
show the status of the check counting operation, i.e. Over,
Under or Accept. User and Time and Date are shown
across the top of the display. Piece weight is shown above
the softkeys. Softkeys appropriate to this option are
displayed. The database is enabled.

ZK840 Counting Scale User Instructions 19
3.4 Advanced operations
Dual Check w/o DB: Count and Weight screen without database. This screen
shows a large count display over a small weight display
and a bar graph beneath that to show the status of the
check counting operation, i.e. Over, Under or Accept.
User and Time and Date are shown across the top of the
display. Softkeys appropriate to this option are displayed.
The database is disabled.
Dual Check w/ DB Count and Weight screen with database. This screen
shows a large count display over a small weight display
and a bar graph beneath that to show the status of the
check counting operation, i.e. Over, Under or Accept.
User and Time and Date are shown across the top of the
display. Softkeys appropriate to this option are displayed.
The database is enabled.
Check with No Graph Check counting with no graph showing. Can be useful
when using stack lights.
3.4.2 Database
When configured for using a database a PLU key appears on the display. Use this to
recall a specific PLU # which exists in the database. This makes active all the enabled
features of the product or item assigned to the PLU.

20 ZK840 Counting Scale User Instructions
Operating Instructions
For example the following information can be displayed: Part number, piece weight,
tare weight, Description 1, stock on hand, number of transactions and location. Other
data which is not displayed but which can be printed, if so configured are: Company
name, address, phone number, etc. For the full list see the Supervisor menu on page
36.
When the PLU is active, all associated tare weights, limits and tolerances are also
active.
3.4.3 Accumulation
When configured, you can accumulate multiple counts by pressing the ACCUM+ key.
You can subtract a count using the ACCUM- key. The accumulated count will be
displayed on the screen along with the number of transactions completed. The weight
must return to within the zero band before you can do another accumulation. An error
message will appear if not in the zero band when you press the ACCUM key.
To clear the accumulated counts and transactions, press and hold the PRINT key. The
totals print format will be printed and the totals are cleared from memory.
The totals are also cleared if the indicator is powered off or if a new piece weight sample
is taken.
3.4.4 Check counting
This configuration allows you to quickly count items to a preset number or range of
numbers. A bargraph shows the current comparison of counts to the desired count by
showing Under condition, Over condition or Accept condition. A moving line within the
Accept section of the bargraph will show even finer graduations as the count
approaches the center of the section. See the example shown later in the is section.
For example: If you are counting ball bearings into a box and want exactly 50 bearings,
you can set the low and high limit to 50 so the graph will show an Accept condition only
when 50 are in the box.
Auto Updating of the piece weight and tare weight:
If Plu Piece Weight Update and Plu Tare Update are set to ON (in the Supervisor
menu on page 44) and you have an active PLU, if you take a new sample to establish
a new piece weight, the display will ask if you want to save the new piece weight to
the PLU. If you do, the piece weight value is updated in the database. If you choose
not to update the PLU piece weight the, recalled PLU becomes inactive and the piece
weight value is used in the temporary PLU with the number 0.
If you establish a new tare, you are asked if you want to replace the tare value in the
active PLU. If you say YES, the new value is saved in the PLU and the new tare value
is active. If you say NO, the tare weight is active but the value is not saved in the PLU.
If a PLU is active, the accumulated total becomes Stock on Hand and the counts will
be added or subtract from this item in the database. Press and hold PRINT to clear
the transactions. This will not clear the total in Stock on Hand.