Genyx

System for the production of concrete

Onyma Srl Sistemi & Tecnologie

Via Albinoni, 61/65
41019 - Soliera (Modena) ITALY
 +39 059 850005
email: [email protected]
web: www.onyma.it

The information contained in this manual is subject to modification without notice.

No part of this manual may be reproduced in any form or by any electronic or mechanical
means without the written permission of ONYMA S.r.l. SISTEMI & TECNOLOGIE named hereafter
as the manufacturer.

Under no circumstances the manufacturer, its agents or its staff directors, manager
clerks can be held responsible towards the buyer or the user for any indirect, direct
or accidental damage (including loss of profit, interruption of work and similar)
following the use or improper use of the products described in this manual.

The guarantee relative to the products described in this manual consists in the manufacturer
undertaking to intervene during of any possible manufacturing faults.
The guarantee covers the repair or substitution of the faulty part in the ONYMA S.r.l.
SISTEMI & TECNOLOGIE premises in Soliera (MODENA - Italy). Transport of the guaranteed
parts from the buyer to the manufacturer or vice-versa will be at the buyer's expense.
If the intervention of the manufacturer's technical personnel should be necessary
in the buyers premises during the guarantee period this will be carried out free
of charge excluding traveling time and all relative expenses. In no case will faults
or breakages due to incorrect conservation, installation or manipulation be considered
covered by the guarantee..

The period of guarantee is reported on the contract of sale.

Genyx™
user manual v1.2
 Summary
Genyx .................................................................................................................................. 1
Welcome! ......................................................................................................................... 1
Main features ................................................................................................................... 1
Navigator - Main Menu ................................................................................................. 1
Data editing .................................................................................................................. 4
Filter function ................................................................................................................ 5
Find function ................................................................................................................. 6
Multiple selection mode ................................................................................................ 7
Definitions ..................................................................................................................... 8
Calculation method for compensating aggregate/water according to the moisture
percentage .................................................................................................................... 9
Water correction method.................................................................................................... 10
Automatic Error Compensation between fractions ............................................................. 11
Plant mimic..................................................................................................................... 12
Animated plant mimic ................................................................................................. 12
Commands on the plant mimic ................................................................................... 15
Meaning of icons and symbols showing operating parts of the plant .......................... 16
Dosage information - components .............................................................................. 17
Dosage information - meters ...................................................................................... 18
Scale/meter status symbols ........................................................................................ 19
Components batchers parameters ..................................................................................... 20
Scales/meters parameters ................................................................................................. 26
Aggregate moisture parameters ........................................................................................ 31
Mixer parameters ............................................................................................................... 35
Dry loading point parameters (truck mixer drip edge) ........................................................ 40
Belt conveyors parameters ................................................................................................ 44
Screw conveyors parameters ............................................................................................ 46
Skip parameters ................................................................................................................. 48
Stand-by hoppers parameters ........................................................................................... 50
Thermometer parameters .................................................................................................. 52
Wattmeter parameters ....................................................................................................... 55
Commands for plant status change ............................................................................ 59
Production ...................................................................................................................... 61
Components / Raw materials ...................................................................................... 61
Components exchange ............................................................................................... 65
Formulas..................................................................................................................... 68
Products ..................................................................................................................... 73
Clients......................................................................................................................... 75
Destinations/delivery sites .......................................................................................... 78
Trucks ......................................................................................................................... 81
Orders......................................................................................................................... 84
Production .................................................................................................................. 86
Automatic calculation of production fractions ..................................................................... 94
Delivery dockets (delivery notes) ................................................................................ 95
Batch reports .............................................................................................................. 99
Consumptions ........................................................................................................... 105
Statistics ................................................................................................................... 108
Suppliers................................................................................................................... 112
Raw materials reception ........................................................................................... 114

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Stock......................................................................................................................... 117
Files.............................................................................................................................. 120
Data storage ............................................................................................................. 120
System ......................................................................................................................... 122
Genyx configuration .................................................................................................. 122
Communication configuration ................................................................................... 127
Delivery Docket Printing Configuration ..................................................................... 129
Plant's Data configuration ......................................................................................... 147
Alarms History .......................................................................................................... 149
Language selection................................................................................................... 151
Reserved access - Operators ................................................................................... 151
Alarms .......................................................................................................................... 155
Alarms ...................................................................................................................... 155
Alarms: description ................................................................................................... 156
ATTACHMENT ............................................................................................................. 162
HYGROMETER GENERAL PARAMETERS (Click the hygrometer icon on the
desktop): ................................................................................................................... 162
SYSTEM PARAMETERS ......................................................................................... 163
HYGROMETER PARAMETERS IN FORMULA (click on the hygrometer button within
each individual recipe): ............................................................................................. 166

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Genyx
Welcome!

Main features
Navigator - Main Menu
Access to this function could be limited by operator's access rights.

For opening the Genyx Navigator, that is the main menu for accessing all functions, click on
in the bottom right corner of the plant mimic, or press and release the Alt key.

The navigator is divided in 3 main functional groups: Production, Files, System.

Production
Contains the functions that are commonly used for the automatic production.

(click on the icon of each function for more information)

The access icons in this group are ordered and connected via a logical information flow: following
the direction of the arrows, one can understand what information are necessary for operating each
function.
up

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Files
Contains backup and restore functions for the configuration parameters and the production data
generated by Genyx.

(click on the icon of each function for more information)

up

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System
Contains functions for configuring the Genyx according to the controlled plant, and for trimming the
behavior of the program to the user's needs.

(click on the icon of each function for more information)

up

Show quick access icons

Clicking on this icon, you can show/hide the quick access icons on the plant mimic.

(click on the icon of each function for more information)

The quick access icon group can be moved anywhere on the plant mimic, by moving the mouse
cursor on the top part of the icons group, between two icons, then finally clicking and dragging the
icons group in the desired position.
up

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Data editing
Inside any page containing data, you can always use the following functions (or some of them):
Confirm - Cancel - Print - Enable/Disable

Confirm and record the modifications

Click on (or in some cases on ) for recording (memorizing) the modifications made on
the data.
up

Cancel/discard the modifications

Click on for canceling the modifications made on the data.

up

Print data

Click on for printing the page containing the current data.

up

Enable/Disable
Some parameters or operating modes can be enabled/disabled, by means of "switches":

= disabled / no
= enabled / yes

or

= disabled / no

= enabled / yes

Click on the switch to change the mode.

up

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Filter function
The Filter function allows to display information referring to a specific group (i.e. containing a
specific name) within a list of entries.

Normally, inside the box Filter on? you have to enter the text to be used as match for the filter,
within the currently shown list (docket list, reports, etc.). For example, if you want to see only the
list entries containing the word "Test", type in "Test".

In some cases, it is necessary to select the element to be use as filter from a pre-defined list: in

this case, click on to open the selection list.

In some cases, you can also select a date or time frame for the filtering.

Click on the button (or in some cases on ) to apply the filter: if there are entries
matching the filtering criteria, they will be shown in the list.

If there are no entries matching the filtering criteria, the list will be empty.

For removing the active filter from the list, click on .

For exiting the filter setup page, click on .

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Find function
The Find functions allows to search an information inside a list.

Normally, inside the Find? entry you have to write the text to find inside the currently displayed
list (formulas, products, etc.).

In some cases, the value must be selected from a pre-defined list: in this case click on to
open the list with the available choices.

In other cases, it is also possible to select a date interval-time frame for limiting the search.

Click on to start the search: if the requested information is present inside the list, the

cursor will stop on the element containing the information. By clicking again on , the
search restarts looking for the next occurrence.

If the requested information cannot be found, the message Search ended! will be shown.

For restarting the search from the top of the list, click on .

For abandoning the search, click on .

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Multiple selection mode

It is possible to select more than one list entry at the same time.

- Multiple selection of contiguous entries: click on the first entry to be selected on the list, then

press the (shift/upper case) key, keep it pressed and click on the last entry to be
selected on the list. All selected entries will be highlighted.

- Multiple selection of non contiguous entries: click on the first entry to be selected on the list, then

press the key, keep it pressed and click on the next entry to be selected. Repeat the

operation while keeping the key pressed. All selected entries will be highlighted.

The multiple selection mode is useful, for example, for deleting many entries from a list in a single
operation.

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Definitions

Batcher
Device used to extract a component from its container (silo, hopper, tank), that is for dosing
a component. For example: pneumatic chute, motorized screw conveyor, pneumatic valve, etc.

Meter
Device used for measuring the dosed quantity of a component. For example: weighing scale, etc.

Moisture meter
Device used for measuring the moisture held by the aggregates. For example: various types of
sensors, probe with digital display, etc.

Cycle
When you want to carry out an automatic production which needs to be repeated cyclically, you
can define, other than the cubic meters to be produced (Delivery m3, referred to the single cycle),
the number of cycles for repeating the production of the requested cubic meters.
For example, if you define as cubic meters to be produced 3.00 and you specify 5 cycles, the total
production will be 5 x 3.00 = 15.00 cubic meters.

Note: the entry for the number of cycles is available only on pre-cast plants.

Fraction
When you want to carry out an automatic production which cannot be dosed in a single shot,
because of the limits set by the plant capacity, that is for any of the following reasons:
total quantity does not fit in the mixer capacity;
total quantity for each component group does not fit in the capacity of any of the
scales/meters;
total quantity for each component does not fit in the the maximum quantity
for components/batchers;
Genyx divides automatically the production in one or more fractions for falling back into the above
mentioned limits. Fractions can also be generated for every production cycle.
All fractions are of the same size and the balance, if any, is added to the first fraction. For example,
if you ask for 8.00 cubic meters and the plant has a 3.00 cubic meters mixer, the production is
automatically split in 3 fractions of 2.66 cubic meters (2.68 + 2.66 + 2.66 = 8.00 cubic meters).
Inside the automatic production page you can see the fractions automatically generated by Genyx
according to each single production request.

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Calculation method for compensating aggregate/water according to the

moisture percentage
Forewords: the moisture percentage held by the aggregates is detected referring to wet or dry
aggregate, according to the choice from the technological laboratory of the user. As a
consequence, it is necessary to calibrate the moisture sensors for automatic detection accordingly,
and setting up the Genyx properly from function Plant's data - Production in the System group.

Testing the moisture content with the drying method, the resulting moisture percentage is:
Percentage on the wet aggregate Percentage on the dry aggregate

where
U = moisture percentage held by the aggregate
Pu = weight of the wet aggregate sample
Pssa = weight of the dried aggregate sample, S.S.D. (Saturated, Surface Dry).

For a quantity of wet aggregate on which the moisture percentage is known, the actual quantity of
S.S.D. aggregate can be obtained:
Percentage on the wet aggregate Percentage on the dry aggregate

Vice versa, wanting to calculate the quantity of wet aggregate to be dosed, knowing the moisture
percentage and the S.S.D. quantity:
Percentage on the wet aggregate Percentage on the dry aggregate

Genyx uses the the above equations, according to the configuration, for calculating the theoretical
quantity to be dosed, starting from:
the aggregate requested quantity from the formula (thus S.S.D.)
the moisture percentage held by the aggregate.

Applying those equations to numerical examples, it is easily demonstrated that the two methods of
detection/calibration on the wet or dry aggregate lead to exactly the same result of compensation,
therefore they are equivalent.

Remember that any kind of moisture detection sensor always detects the moisture
absorbed by the aggregate as well. Keep this into consideration when calibrating the
sensor!

See also: dosed water correction method.

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Water correction method

The quantity of water to be dosed during automatic production is corrected, that is re-calculated, in
order to keep the Water/Cement ratio defined in the formula.

Specifically, as can be seen by analyzing the batch reports, the theoretical amount of water is re-
calculated for compensating:

- the aggregates moisture (defined in the formula as Saturated Surface Dry);

- possible dosage errors on the cement (affecting directly the Water/Cement ratio);

- possible dosage errors on components affecting the Water/Cement ratio for a specific % (i.e.
the "addings" component type);

- possible dosage errors on components containing a specific water % (i.e. the "additive"
component or "ice" component types).

The Water/Cement ration in the formula (for S.S.D. aggregates) is calculated like this

quantity of water type components + (quantities of components containing water x % water contained)
-----------------------------------------------------------------------------------------------------------------------------------------------------
quantity of cement type components + (quantities of addings type components x % of influence on W/C ratio)

The Water/Cement ratio in the batch report is calculated like this:

dosed quantity of water type components + quantity of water in the aggregates + (dosed quantities of components containing water x % water contained)
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
dosed quantity of cement type components + (dosed quantities of addings type components x % of influence on W/C ratio)

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Automatic Error Compensation between fractions

During automatic production, the system tries to contain the dosage errors to the minimum,
together with the resulting tolerance alarms, keeping at the same time an high production output
rate, optimizing the component's batching free fall and reducing the pulse dosage phase.

This goal becomes particularly critical when the total amount of material to be dosed is split in
many subsequent fractions. In this case, the system tries to minimize the errors in the total final
mix (corresponding normally to the complete cycle or to the total mix transported by the truck)

For this reason, when the production is split in many fractions batched one after the other:

- the pulse dosage batching for reaching the requested tolerance is performed only on the last
fraction of the production cycle;

- the check of the batched quantity, with possible tolerance error signal, is performed only on the
last fraction of the production cycle;

- the batching error for each component batcher is deducted from the next upcoming fraction,
trying to compensate the error progressively.

I. e., for batching 900 Kg of SAND in 3 fractions (300 Kg each), allowing a tolerance of +/-3%:

Theoretical
Theoretical Actually Error
Fraction to be Error Note
target dosed %
dosed

The +15 kg error (+5% on this fraction) is

deducted from the quantity to be dosed in
1 300 300 315 +15 /
the next fraction (300 - 15 = 285), but
no tolerance alarm is signaled at this stage.
The -20 kg error (-7% on this fraction) is
deducted from the quantity to be dosed in
2 300 285 265 -20 /
the next fraction (300 - -20 = 320), but
no pulse dosage is performed at this stage.
The +10 Kg error (+3% on this fraction)
cannot be compensated anymore, this is
3 300 320 330 +10 / the last fraction. If necessary, the pulse
dosage for falling into tolerance limit is
performed.

The total absolute error is only +10 Kg on

TOTAL 900 / 910 +10 0,45
the totally dosed quantity, that is +1.11%

Not all components are compensated between subsequent fractions like shown above:

- errors on the ice dosage are always compensated on the water batching;

- water is re-calculated and compensated according to the water correction method.

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Plant mimic
Animated plant mimic
The plant mimic:
graphically represents the plant type controlled by the automation system;
displays, by means of symbols, the different types of components used while batching;
allows access to the operating parameters of the parts/devices composing the plant;
displays the status of motors, valves, etc. used for transporting the components involved in
the mix.

Sample of mimic (move the mouse cursor on the picture here below: when the cursor
becomes like a "hand", click on the position for more specific information on the selected
object).

(WARNING: the picture is a sample only, it may not match your actual plant!)

The various parts of the plant are identified by specific icons. By clicking on the icon corresponding
to each part, one can access the operative parameters.

Over the icons there are command buttons that can be used for controlling the specific part in
"manual" operation.
When a part/device (motor, valve, belt, screw conveyor, etc.) or a sensor (limit switch, probe, etc.)
is active or operating, over its icon an operation symbol appears (normally an arrow or a
colored circle).

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Common types of batchers shown on the mimic:

Icon Component type

Aggregate

Cement, Powder, Microsilica, Ash

Water, Ice

Additive

Color, Fiber

Filler, Fiber

On every component batcher there are some useful informations for following the dosage
progress.

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Common types of scales/meters shown on the mimic:

Icon Type of scale/meter

Scale

Scale, meter by volume

Scale for Ice

Volumetric meter (liter-counter,

pulse-launcher) for liquid
components

On every meter/scale there are some useful information for following the batch progress.

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Commands on the plant mimic

Moving the mouse's cursor (the arrow) on the command buttons located on the
components/batchers icons on the plant mimic, the cursor turns into a "hand" and it is possible to
click on the button to activate/deactivate a specific function.

WARNING: pay the utmost attention while operating the plant with the mouse. The manual
commands actually activate motors, valves, etc. but the visual feedback on the PC monitor
is slightly delayed from the actual event by approx. 2 seconds. Proceed with caution!!

For preventing the manual operation commands from being activated simultaneously on the main
control switchboard and on the Genyx mimic, in order to avoid potentially dangerous interferences,
there is a main switch button which enables/disables the commands from the mouse.
To get control of the manual operations commands from the Genyx mimic, make sure the icon
depicting an electric "switchboard" on the mimic is as shown here (led on the "switchboard" must
be GREEN):

If the led on the "switchboard" is BLACK, click on the button beside the "switchboard" on
the mimic to switch the status (and vice versa).

The most part of the available commands on the Genyx mimic are enabled when the plant is
in MANUAL status (when the led on the "switchboard" icon is GREEN).
When the plant is in MANUAL (control desk) (when the led on the "switchboard" icon is BLACK) or
in any other status, the most part of the available commands on the Genyx mimic are disabled.

The symbols for various available commands are as follows:

Symbol Function Meaning

command
start motor/function
ON
command
stop motor/function
OFF
command
stop motor/function
OFF
command start dosage, start motor, open valve/discharge (normal or slow
ON extraction)
command
start dosage, start motor, open valve/discharge (fast extraction)
ON
command
start vibrator/fluidificator (air blower)
ON
command
rotation: reversible belt conveyor etc.
ON
command
rotation: reversible belt conveyor etc.
ON

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Symbol Function Meaning

command
stop dosage, motor, close valve/discharge, vibrator (if self-retained)
OFF
command
open discharge, gate, chute
ON
command
close discharge, gate, chute
ON
operation
select manual operation mode
mode
operation
select automatic operation mode
mode
command
start dust filter cleaning
ON
command
interrupt operation mode
OFF

Other possible variations of the command buttons are

Meaning of icons and symbols showing operating parts of the plant

When a part/device or signaling device of the plant is working, it is shown on the plant mimic as:

Symbol Function Meaning

signal
level sensor, motor, valve, limit switch, etc. is OFF
OFF
signal level sensor, motor, valve, limit switch, etc. is ON (other colors
ON than green can be shown).
signal dosage, open valve, scale discharge, screw conveyor, belt - ON (normal
ON or slow)
signal
dosage, open valve, scale discharge, screw conveyor, belt - ON (fast)
ON
signal
rotation: reversible belt, etc.
ON
signal
rotation: reversible belt, etc.
ON

Other possible variations of signal symbols are

If the symbol appears of FLASHING RED color, it signals an anomaly or fault on the plant
part/device (i.e. missing limit switch, thermal protection, etc.)
WARNING: there is always a small delay from the actual event on the plant and the
corresponding signal on the plant mimic: this delay is normal and it is because of the data
exchange procedure continuously running between the PC and the automation PLC.

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Dosage information - components

On each batcher/component shown on the plant mimic, there are some information which are
useful for following the dosage progression.

(This example shows the aggregate dosage group, but the information are the same for any
batcher/component)

Meaning of the text/number boxes on the batcher/component icon.

1 = Component identification code

2 = Quantity for 1 cubic meter (from formula/mix design)
3 = Total theoretical quantity to be dosed
4 = Actually dosed quantity
5 = Progressive number identifying the silo/hopper/tank (batcher)

There are command buttons on the icons, through which one can "manually" control the plant.
When a part/device (motor, valve, belt, screw conveyor, etc.) or a sensor (limit switch, probe, etc.)
is operating (ON), over it appears a operation symbol (normally an arrow or a colored circle).

By clicking on any batcher/component, one can directly access the operating parameters.

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Dosage information - meters

On each scale/meter shown on the plant mimic, there are some information which are useful for
following the dosage progression.

(This example shows the cement dosage group, but the information are the same for any meter)

Meaning of the text/number boxes on the meter icon.

1 = Quantity actually in the scale/meter

2 = Scale/meter status
3 = Production cycle/fraction number. Two numbers representing:
- the number of the cycle/fraction for the requested production
- the number of the production line currently running
For example: 1.1 = production line 1, cycle 1
1.2 = production line 1, cycle 2
5.3 = production line 5 cycle 3

There are command buttons on the icons, through which one can "manually" control the plant.
When a part/device (motor, valve, belt, screw conveyor, etc.) or a sensor (limit switch, probe, etc.)
is operating (ON), over it appears a operation symbol (normally an arrow or a colored circle).

By clicking on any scale/meter, one can directly access the operating parameters.

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Scale/meter status symbols

On every icon representing a scale/meter there is a symbol which refers to the operating phase of
the scale.

Symbol Function Meaning

signal scale/meter empty (within the empty threshold), ready for a new dosage.
signal scale/meter loading, component batching.
signal scale/meter discharging.
signal scale/meter waiting to discharge, dosage ended.

The above mentioned statuses allow to understand in which phase of the process a scale/meter is.

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Components batchers parameters

Access to this function could be limited by operator's access rights.

For accessing the operating parameters of a component batcher, click on the icon corresponding
to the desired batcher from the plant mimic.

Available functions: Edit - Print - Semi-auto - Stop - Storage - Exit

Batcher parameters information

Access to some parameters may be locked during automatic production.

For every batcher one can define various parameters, for trimming the optimal operation. Some
parameters are available only for some types of batchers.

Name: click on for selecting the component name to assign to the batcher. The name will be
used for identifying the batcher on alarms, in the dosage sequences pages, and for the

simultaneous dosage function. Click on to cancel the name and not assign any component: in
this case, the batcher will never be used.

Maximum quantity that can be measured: maximum quantity that can be extracted from the
hopper/silo, until filling completely the available space in the meter/scale. For example, for the
aggregate hoppers, one should enter the actual maximum quantity that can be dosed before the
material build up reaches the extraction chute, blocking further flow of material. Try to set this
parameter with the maximum possible accuracy, since it is used for calculating the fractions during
automatic production. If there are more batchers assigned to the same component, the total
quantity of requested component is divided among the batchers, considering the maximum and
minimum quantity that can be measured for each one.

Minimum: minimum quantity that can be extracted from the hopper/silo for obtaining an accurate
measurement. This parameter can be set to zero. If there are more batchers assigned to the
same component, the total quantity of requested component is divided among the batchers,
considering the maximum and minimum quantity that can be measured for each one.

Slow down preset: weight threshold where the dosage speed switches from fast to slow, for better
dosage accuracy. Example: when batching 1500 Kg and the slow down preset is 50 Kg, until
reaching 1450 Kg the dosage goes in fast mode, then it goes to slow mode. note Set this value in
order to obtain a good compromise between dosage speed and dosage accuracy. When this value
is too high, it will slow down the dosage excessively but, when the value is too low, it will speed up
the dosage reducing the accuracy. This parameter makes sense only if the batcher on the plant is
made for double speed dosage, or when the simultaneous dosage function is enabled, in order to
define the threshold where the simulate nous batching is stopped and the dosage ends with the
first component specified in the dosage sequence.

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Free fall correction base quantity: reference weight to be used as base for the automatic
calculation of the free fall (see description of parameter Free fall self learning). The suggested
value is Maximum quantity that can be measured / 10 (so, again, the importance of accurately
defining the maximum dosable quantity). This parameter is available only for batchers on meters
where the components are not piled up one on the other, modifying the free fall height between the
batcher and the base of the meter). note

Free fall self learning: by enabling the free fall self learning (recommended), the system
automatically detects the tail of material falling on the meter after closing the batcher, then adjusts
the closing instant on the batcher for achieving dosage speed and accuracy (on the first installation
of the system, it will take 2-3 dosages for reaching the optimal accuracy). If the free fall self
learning is not enabled, it is necessary to enter values in the following fields. note

Free fall for dosage range 0 to BQ: free fall value to be used for dosing
quantities between 0 and the Free fall correction base quantity (here called BQ).

Free fall for dosage range from BQ + 1 to BQ x 2: free fall value to be used for
dosing quantities between the base quantity + 1 and two times the base quantity.

Free fall for dosage range from BQ x 2 + 1 to BQ x 4: free fall value to be used for
dosing quantities between two times the base quantity + 1 and four times the base
quantity.

Free fall for dosage range from BQ x 4 + 1 to BQ x 8: free fall value to be used for
dosing quantities between four times the base quantity + 1 and eight times the base
quantity.

Free fall for dosage range from BQ x 8 + 1 to BQ x 16: free fall value to be used for
dosing quantities between eight times the base quantity + 1 and the Maximum quantity
that can be measured.

Example: if the Free fall correction base quantity is 300 Kg and 1000 Kg are required, the system
will use the free fall value corresponding to the third range (0 - 300, 301 - 600, 601 - 1200, 1201 -
2400, 2401 - Maximum quantity that can be measured). It is thus very important to define a Free
fall correction base quantity allowing 5 dosage ranges to be used for the different quantities that
can be dosed by the batcher (for example for different volumes dosages: 0.5 m3 1 m3, 1.5 m3,
etc.).

MAX acceptable free fall for self-correction: maximum acceptable quantity of material
automatically detected as free fall tail. It has the purpose to avoid excessive automatic corrections
after anomalies like valve locking, chute obstruction, etc. It is always recommended to specify a
quite high value (i.e. 500 Kg for aggregates, 50 Kg for cement, 10 Kg for water, 1 Kg per additives).

Dosage tolerances (-%).... (+%): enter the tolerance, as percentage on the dosed quantity, for
defining the limit out of which an alarm will be signaled. The upper tolerance value (+) does not
affect the dosage accuracy, but sets the threshold for signaling the alarm. The lower tolerance
value (-) may affect the dosage accuracy when the minimum quantity that can be dosed is quite
high. In this case, the dosage error can quickly go, for example, from -1.5% to +2.5%. In these
situations, it is recommended to set an higher value of lower tolerance: in any case the system will
try to compensate the errors on the next dosage fraction. note

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Pulse dosage time: opening time of the batcher when in pulse dosage phase. The pulse dosage
happens after competing the normal dosage, when the dosed quantity is below the lower dosage
tolerance. The pulse dosage phase is cycled until the dosed quantity falls between the tolerance
limits, and it consists in opening the batcher for the specified time, in order to extract a small
amount of material. note Set this value with caution: a time which is too short increases the
accuracy but extends the total dosage time, while a time which is too long reduces the dosage
accuracy. Normally, the recommended values are: sand - from 0.9 to 1.5 seconds, gravel - from
0.4 to 0.7 seconds, cement - from 0.8 to 1.5 seconds, water and additive 0.5 seconds. The pulse
dosage time depends by the actual chute opening and by the material flow speed. When it is
difficult to trim the pulse dosage time, it is recommended to keep the vibrator on the extraction
chute always on.

Clogging threshold... Every: minimum quantity of material that must flow out of the dosage chute
in a specified time (Every, in seconds). If the flow speed is lower, the dosage chute may be
clogged. In this case, the system activates the vibration (if available). After the number of vibrations
defined in the specific parameter, if the dosage is still clogged, a clogging alarm is signaled. In
order to force the system to vibrate more, increase the Clogging threshold without modifying
the Every value, or vice versa.

Number of vibrations: number of times the vibration (or fluidification) is repeated for trying to
remove the clogging on the batcher. Even when there is no vibrator/fluidificator on the batcher, it is
recommended to set a value of 1. The clogging alarm is signaled only after completing the number
of vibrations, therefore this parameter affects the delay after which the component exchange
request is brought up.

Duration (vibration): duration in seconds of each vibration.

Pause (vibration): pause in seconds between one vibration and the next.

Use the component (YES/NO): enable the usage of the batcher. If set to No, the batcher is not
used. If the component assigned to the batcher is specified in a formula selected in a production
line, an error is signaled. If set to Yes, if there are more batchers assigned to the same component,
the total quantity to be dosed is equally divided among the batchers, considering the maximum and
minimum quantity that can be dosed for each of them.

Permanent component's exchange: the component exchange can stay active permanently or for
the current cycle only, depending on the setting of this parameter. When this parameter is enabled,
after the exchange the batcher is always replaced by the specified alternative for all production
cycles, until the exchange is canceled. When the permanent exchange is not enabled, the
exchanged batcher is replaced by the alternative only for the current cycle or for the next cycle
after setting the exchange (if there is no automatic production in progress when setting the
exchange). WARNING: the component exchange is under the operator's responsibility,
Genyx does not run any intrinsic check. Make sure not to create any problem for the mix
design in production!!

usage % (recycled): available only for the second water batcher in the plan, normally used for the
recycled water. Enter the percentage of recycled/hot/cold/etc. water to be used in the mix, on the
total quantity of requested water. This parameter is used only when the formula selected for
the production does not states explicitly the quantity of water assigned to the second batcher.

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Edit

For editing the parameters of the selected batcher, click on . Inside the page you can use the
standard functions for data editing.

up

Printing

For printing the parameters of the selected batcher, click on : when the print preview is

shown, click on .

up

Semi-auto dosage

For dosing the component assigned to the batcher in semi-auto mode, enter the Quantity to be

dosed in the specific box then click on : this will start a dosage fully controlled by the
operating parameters of the batcher, until reaching the requested quantity.

In any moment, the semi-auto dosage can be stopped by clicking on .

A semi-auto dosage can be started only in these circumstances:

- plant in MANUAL mode, no production paused;

- manual commands enabled for Genyx.

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Stop automatic dosage

During the automatic dosage of the component assigned to the batcher, by clicking on , it is
possible to stop the dosage for the current fraction.

WARNING: stopping the dosage is under the operator's responsibility, Genyx does not run
any intrinsic check. Make sure not to create any problem for the mix design in production!!

If there are more fractions after the one in progress, the dosage from the stopped batcher will start
normally on the next fraction.

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Storage

For enabling and controlling the component storage level in the hopper/silo corresponding to the

batcher, click on . Inside the page you can use the standard functions for data editing.

If you need to control the storage level in the hopper/silo, enable the parameter Enable storage
detection. Specify also:

Capacity: total capacity of the hopper/silo containing the component. It is necessary for displaying

the level indication, on the page accessed by clicking on from the main menu in the
Production group or on the quick access icons.

Minimum stock: storage threshold under which the name of the component on the batcher's icon
is highlighted in RED, for signaling that the component's stock is running out.

Current storage: quantity currently contained in the hopper/silo to control.

The quantity currently available inside the hopper/silo is displayed by accessing the batcher

parameters page or accessing the level indication page, by clicking on from the main
menu in the Production group or on the quick access icons.

For changing the current storage, enter a value in the Variation box, then click on to add it to
the current quantity, or on to subtract it.

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Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

COMPONENT BATCHING DIAGRAM

END OF
FREE FALL
SLOW DOSAGE
START (END OF
DOWN (requested
DOSAGE AUTOMATIC
PRESET quantity +/-
DOSAGE)
tolerance)

| | |
FAST DOSAGE | |
SLOW DOSAGE |
MATERIAL FREE FALL

PULSE DOSAGE (IF AFTER FREE FALL

QUANTITY IS STILL OUT OF TOLERANCE) ---->

- +
| |
TOLERANCE
RANGE

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Scales/meters parameters
Access to this function could be limited by operator's access rights.

For accessing the operating parameters for a meter/scale, click on the corresponding icon on
the plant mimic.

Available functions: Edit - Print - Calibration - Sequence - Exit

Meter parameters information

Access to some parameters may be locked during automatic production.

For each meter one can define various parameters, for trimming the optimal operation. Some
parameters are available only for some types of meters.

Name: click on for entering or modifying the name assigned to the meter. The name will be
useful for identifying the meter on alarms and in the dosage sequences pages.

Free fall correction base quantity: reference weight to be used as base for the automatic
calculation of the free fall. This parameter is available only for meters where the components
are piled up one on the other, modifying the free fall height between the batcher and the base of
the meter). See Free Fall in Batchers parameters.

Clogging threshold... Every: minimum quantity of material that must flow out of the meter
discharge in a specified time (Every, in seconds). If the flow speed is lower, the meter
discharge may be clogged. In this case, the system activates the vibration (if available). After
the number of vibrations defined in the specific parameter, if the discharge is still clogged,
a clogging alarm is signaled. In order to force the system to vibrate more, increase the Clogging
threshold without modifying the Every value, or vice versa.

Number of vibrations: number of times the vibration (or fluidification) is repeated for trying to
remove the clogging on the meter.

Empty meter tolerance: tolerance on the weight detected by the meter, in order to consider it
empty. For example, if the meter is 5 Kg even when it is actually empty (i.e. because of residual
material sticking on the scale walls), enter 5.

Pause time: waiting time, after the end of the batching of each component, for stabilizing the
measured weight/value. The dosage of the next component starts only after the stabilization
time. WARNING: the stabilization/pause time should never be set below 2 seconds. Very short
times can affect the dosage accuracy!

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Complete discharge time: time of opening of the meter discharge (chute, belt, etc.), after
reaching the empty meter tolerance while discharging. This allows the complete discharge of all
residual material in the meter.

Washing water quantity: if foreseen, enter the quantity of water that must be delivered for
washing the meter after the dosage cycle (on the last fraction). It is normally used on additive
meters.

Simultaneous dosage of same components: tick this enable box for simultaneously dosing from
the batchers containing the same component (recognized by the component name). In this case,
the dosage of the same components start simultaneously and continues until the set slow-down
threshold, then it terminates with a single component (the first of the group, specified in the dosage
sequence.

up

Edit

For editing the parameters of the selected meter, click on . Inside the page you can use the
standard functions for data editing.

up

Printing

For printing the parameters of the selected meter, click on : when the print preview is shown,

click on .

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Calibration

Access to the calibration function may be locked during automatic production.

For calibrating the PLC analog channel receiving the signal proportional to the weight contained in

the meter, click on .

Before using the meter in automatic production cycle, it is compulsory to calibrate it.

The available parameters for the calibration, may change according to the meter type:

Precision (n° of decimal digits): number of decimal digit to show for the quantities measured by
the mete, that is the measurement accuracy on the basis of the kilogram (or liter). Example: scale
with 0.1 Kg accuracy, number of decimal digits 1. WARNING: by modifying the meter accuracy, the
decimal digit is moved for all the other parameters and for the parameters of all batchers
associated to the meter.

Capacity: maximum capacity of the meter. The maximum capacity is used for calculating the
fractions during automatic production.

Scale factor: only for volumetric meters (pulse-launchers). Multiplying factor in Lt/Kg, for the
pulses received by the metering pulse-launcher. For example, if every pulse of the meter
corresponds to 1 Lt dosed, enter 1; if every pulse corresponds to 0.5 Lt dosed, write 2.

Weight shown when empty: weight shown by the scale digital display, when the meter does not
contain any material. See meters calibration procedure.

Known weight: weight shown by the scale digital display, after loading a known weight on the
scale. See meters calibration procedure.

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Calibration procedure

For calibrating a volumetric (pulse-launcher) meter, simply define the Scale factor.

For calibrating a scale, it is necessary to define two values of reading for the analog channel,
corresponding to the situation of empty meter and meter loaded with a known weight.

1) Remove all material from the meter

2) Read the weight shown on the digital display

3) Write it in the Weight shown when empty entry, then click on the button Associate. For
example, if the empty meter (without any material in it) shows 10 Kg, write 10 in Weight shown
when empty.

4) Load the meter with a known weight (at least 70% of the Capacity)

5) Wait for the stabilization of the weight, then read the weight shown on the digital display

6) Write it in the Known weight entry, then click on the button Associate. For example, load the
scale with 1000 Kg then write 1000 in Known weight.

It is recommended to use sample weights, whenever possible, in order to check the

detection accuracy of the digital display.

On the right of the entries Weight shown when empty and Known weight, there are two Analog
boxes: here you can see the reading values from the analog channel corresponding to the entered
weight, every time you click on the Associate button.

The numeric value in GREEN marked as Measured, is the value converted by the system
according to the current calibration settings.

The numeric value in YELLOW marked as Analog, is the current value read from the analog
channel (in signal points). This is the value transfered to the Analog entries corresponding
to Weight shown when empty and Known weightPeso_Noto.

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Dosage sequence

Modification of the dosage sequence may be locked during automatic production.

For defining the dosage order of the components during automatic production, click on .

The number in the Sequence column on the left shows the dosage order of the components
associated to the meter.

For modifying the dosage order, click on the component you want to move, then click on or

. Inside the page you can use the standard functions for data editing.

For Water meters, when they are scales, you must define a specific parameter:

Head water dosage %: in order to achieve the maximum possible accuracy, the system must
compensate the dosed water according to the actually dosed aggregate, cement, additive
quantities, for compensating the moisture thus keeping the theoretical W/C ratio. In order to reduce
the production time, the system can dose a quantity of water, in percentage on the total, at the
same time with the other components, leaving the remaining percentage as margin for
compensation. WARNING: defining a very high percentage, you risk having excess water in the
final mix.

up

Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

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Aggregate moisture parameters

Access to this function could be limited by operator's access rights.

For accessing the operating parameters of a moisture meter for aggregates, click on the
corresponding icon on the plant mimic.

Available functions: Edit - Print - Calibration - Probe position - Exit

Moisture meter parameters information

Access to some parameters may be locked during automatic production.

For each moisture meter one can define various parameters, for trimming the optimal operation.
Some parameters are available only for some types of moisture meters.

Name: the name identifies the component on which the moisture meter is used. It can be modified
from the batcher parameters.

Absorption %: percentage, on the aggregate weight, of water absorbed until saturation. It is taken
into account together with the moisture, measured by the sensor or manually entered, while
calculating the active moisture for the water compensation.

Manual moisture %: if the automatic detection from the probe is enabled, this value represents
the minimum moisture percentage that can be accepted. If the automatically detected moisture is
lower than this value, the system will use the last valid detection or, if none is available, it will use
the value entered here. If no automatic detection from the probe is enabled, the value represents
the moisture percentage hypothetically held by the aggregate.It is taken into account together with
the absorption %, while calculating the active moisture for the water compensation.

Automatic moisture detection: enables or not the reading from the probe. Available only if the
associated batcher is equipped with a probe for the automatic detection (see Probe position).

Probe coverage quantity: minimum quantity of component to dose for obtaining a valid moisture
reading from the probe. This parameter is valid only for probes positioned in the weighing
hopper. Available only if the associated batcher is equipped with a probe for the automatic
detection (see Probe position).

Max. quantity for detection: maximum quantity of component to dose before determining the
moisture reading from the probe. It allows defining the width of the sample of material to
read. Available only if the associated batcher is equipped with a probe for the automatic detection
(see Probe position).

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Max. valid value for detected moisture: maximum percentage of moisture that can be accepted
on automatic reading. If the detected moisture is higher than this value, the system gives
an alarm. Available only if the associated batcher is equipped with a probe for the automatic
detection (see Probe position).

up

Edit

For editing the parameters of the selected moisture meter, click on . Inside the page you can
use the standard functions for data editing.

up

Printing

For printing the parameters of the selected moisture meter, click on : when the print preview

is shown, click on .

up

Calibration

Access to the calibration function may be locked during automatic production.

For calibrating the PLC analog channel receiving the signal proportional to the measured moisture

held by the dosed component, click on .

Before using the moisture meter during the automatic production it is compulsory to calibrate it.

1st sample moisture: percentage of moisture associated to the first sample measurement made
through the probe (or shown on the display connected to the probes, in which case, see the display
user manual). See calibration procedure.

2nd sample moisture: percentage of moisture associated to the second sample measurement
made through the probe (or shown on the display connected to the probes, in which case, see the
display user manual). See calibration procedure.

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Remember that the moisture probes, of any kind, always measure the absorption of the
aggregate. Keep this into account when calibrating!

Calibration procedure

For calibrating the moisture meter associated to a batcher, it is necessary to define two values of
reading for the analog channel, corresponding to two different samples of materials holding
different moisture percentages. Both samples must be of known moisture, assessed in a
laboratory. As first sample, one can also use the "probe in the air" situation, that is 0% moisture.

If you are using probes connected to a MM400 type digital display, pay attention to the fact that,
when aligning the signal of the analog channel, the display always selects the probe no. 1 (the first
among the 4 that can be connected): in this case, cover with the materials to check only probe
number 1. If you are using a single MM400 for more probes associated to different batchers, it is
enough to calibrate the analog channel only for probe number 1.

1) Clean the probe from any residual material.

2) Read the moisture shown on the digital display, if any

3) Write it in the 1st sample moisture entry then click on the Associated button. For example, if
the probe not covered with any material reads 0.3 %, write 0.3 % in 1st sample moisture.

4) Cover the prove with a sufficient quantity of material

5) Wait for the stabilization of the measurement, then read the moisture shown on the digital
display, if any

6) Write it in the 2nd sample moisture entry then click on the Associated button. For example, if
the probe not covered with any material reads 5.4 %, write 5.4 % in 2nd sample moisture.

On the right of the entries 1st sample moisture and 2nd sample moisture, there are two Analog
boxes: here you can see the reading values from the analog channel corresponding to the entered
moistures, every time you click on the Associate button.

The numeric value in GREEN marked as Measured, is the value converted by the system
according to the current calibration settings.

The numeric value in YELLOW marked as Analog, is the current value from the analog channel
(in signal points). This is the value transfered to the Analog entry corresponding to 1st sample
moisture and 2nd sample moisture.

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Remember that the moisture probes, of any kind, always measure the absorption of the
aggregate. Keep this into account when calibrating!

up

Probe position

For defining the measurement mode for the moisture on the batcher, click on .

Define the parameters:

Probe position: select the measurement mode among:

None: no sensor is installed, only the manual definition of the moisture is used.

Scale: probe installed in the weighing hopper. The measurement is made on a sample of
material that must properly cover the probe.

Hopper: probe installed in the storage hopper containing the component. The measurement
is made on a sample of material that must properly cover the probe.

Hopper w/average: probe installed in the storage hopper containing the component or,
preferably, under the extraction chute, in order to measure by a weight average on a wider
sample of material, increasing dramatically the detection accuracy.

Instrument number: identification number of the digital display controlling the probe associated to
the batcher. Normally, a digital display controls many sensors (up to 4 for the MM400). If the
sensor is connected directly to the PLC analog channel without any digital display, here you have
to write the number of the probe.

Probe number: identification number of the probe associated to the batcher. If the sensor is
connected directly to the PLC analog channel without any digital display, here you have to write
1.

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Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

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up

Mixer parameters
Access to this function could be limited by operator's access rights..

For accessing the operating parameters for a mixer, click on the corresponding icon on the plant
mimic.

Available functions: Edit - Print - Scales discharge sequence - Exit

Mixer parameters information

Access to some parameters may be locked during automatic production.

For each mixer one can define various parameters, for trimming the optimal operation. Some
parameters are available only for some types of mixers.

Mixer maximum capacity: enter the maximum capacity of the mixer, as compacted cubic meter.
When executing a production request for an higher cubic meters quantity, the system fractions the
load accordingly (see fraction calculation during automatic production).

Minimum concrete request: enter the minimum quantity of concrete that can be properly mixed.

Mixing time for 1 m3 ... + (sec) x m3: enter the mixing time that normally will be used, if not
explicitly specified in the formula. note

Partial opening discharge time for 1 m3 ... + (sec) x m3: enter the discharge time, with the
chute in partial position, that normally will be used, if not explicitly specified in the formula. note

Total opening discharge time for 1 m3 ... + (sec) x m3: enter the discharge time, with the chute
in total opening position, that normally will be used, if not explicitly specified in the formula. note

Closed-partial opening time: enter the time needed for opening the discharge chute to the partial
position. It can be used if the mixer does not have a partial opening sensor on the discharge chute.
If the sensor is there and it sends the position signal before the defined time expires, the chute
opening is interrupted anyway. This timer is used if not explicitly specified in the formula.

Partial-total opening time: enter the time needed for opening the discharge chute from partial
opening position to total opening. This timer is linked to the next parameter Step opening pause

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time. It is useful if one wants to discharge from the partial opening to the total opening through a
pause-work mode. The chute opens for the time here defined, then pauses for the time defined in
Step opening pause time then this cycles restarts until the chute reaches the sensor for total
opening. This timer is used if not explicitly specified in the formula.

Step opening pause time: enter the pause time from one opening pulse and the next in the
pause-work mode. This parameter works together with the previous one Partial-total opening
time. See its description. This timer is used if not explicitly specified in the formula.

Discharge time reduction %: enter the percentage of reduction, on the total opening discharge
time, to be used for all fractions but the last one, in order to save some discharge time in
intermediate fractions, leaving the complete total discharge time only on the last one. Define this
percentage in order not to leave too much material in the mixer in intermediate fractions!

Switch-off delay time: enter the idle time after which, without automatic production in progress,
the mixer must be automatically switch off.

No. of greasing cycles: number of automatic greasing cycles (refer the the mixer manual for
further information).

Max. greasing time: maximum control time, for verifying that all greasing cycles have been
completed (refer the the mixer manual for further information). If the time expires before completing
all greasing cycles, an alarm is signaled.

Pause between greasing cycles: pause time, in minutes, between one greasing cycle and the
next.

Washing water quantity: if the automatic washing of the mixer is available, enter the quantity of
water used for the washing. The water quantity is taken into account on the next production
fraction.

Washing time: if the automatic washing of the mixer is available, enter the duration time for
activating the washing circuit.

Washing reset time: if the automatic washing of the mixer is available, enter the time after which
the water contained in the mixer after washing must not be considered anymore, because it is
completely dripped off through the discharge chute.

The mixer operating timers are always set as:

base timer for 1 m3 + increment for each additional m3 or fraction
The base timer is used for the mixing/discharge of quantities between 0 and 1 cubic meter. For each additional cubic meter or fraction of
it, the time set in the next entry [+ ... (sec) x m3] multiplied by the additional cubic meters or fractions is added to the base timer.
For example, if the mixing/discharge time is 20 sec and the increment for additional cubic meters is 5 sec, the total mixing/discharge
time will be:
production of 1 m3 = 20 sec
production of 2 m3 = 20 + 5 = 25 sec
production of 2,5 m3 = 20 + 5 + 5 = 30 sec
etc.

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Edit

For editing the parameters of the selected mixer, click on . Inside the page you can use the
standard functions for data editing.

up

Scales discharge sequence

For defining the discharge mode of the scales/meters, once the dosage of all components

specified in the formula is completed, click on .

Remember that the discharge sequence begins when the dosage of all components specified in
the formula is completed.

Access to some parameters may be locked during automatic production.

The configuration of the discharge sequence allows to discharge the meters into the mixer (wet
load) by:

- setting a delay starting from the discharge sequence start moment;

- linking the beginning of the discharge to the percentage of material discharged from another
meter;

- discharging a meter in two separate phases (that can also be a combination of the two
previously mentioned modes);

The grid for the discharge sequence contains, from left to right, the columns:

Meter description: shows the identification name of the meter, as defined in the meter
parameters.

Associated scale: when it is necessary to condition (link) the discharge of a meter to a certain
percentage of material discharged from another one, select from the available meters list the one
to link. Not all meters are available for the association to another meter: this depends from your
plant's configuration.

Waiting: enter the delay, in seconds,starting from the discharge sequence start moment or from
the moment when the percentage discharge condition on the Associated meter is satisfied, for
beginning the discharge of the meter

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% associated: enter the discharge percentage on the Associated meter corresponding to which
the meter has to begin its discharge.

% discharge: when it is necessary to discharge the meter in two phases, enter the percentage of
material to be discharged on the first phase. Then enter the values in the following
columns Associated scale, Waiting, % associated and % discharge.

Associated scale: as Associated scale, but referred to the second discharge phase.

Waiting: as Waiting, but referred to the second discharge phase.

% associated: as % associated, but referred to the second discharge phase.

% discharge: as % discharge, but referred to the second discharge phase. It is calculated

automatically when entering the % discharge, referring to 100%.

All: enabling the All parameter , the system considers as associated meter not only the selected
one, but all meters of the same type (see example).

Examples:

1) for starting the cement scale discharge 10 seconds after the beginning of the discharge
sequence start moment: click on the Waiting column on the cement meter row, then write 10.

2) for starting the additive meter discharge after discharging 90% of the cement: click on
the Associated meter column on the additive meter row, and select the cement meter. Then click
on % associated column and write 90.

3) for discharging 50% of the additive meter at the beginning of the discharge sequence, then the
remaining part after discharging 90% of the cement: click on the % discharge column on the
additive meter row, then write 50. Then click on the Associated meter column (for the second
phase), and select the cement meter. Click on the % associated row (for the second phase) and
write 90.

4) for starting the cement scale discharge only after discharging the additive meter: click on
the Associated meter column on the cement scale row, then select the additive meter. Then click
on % associated column and write 100. When it is necessary to apply the same discharge
method, for all possibly used additive scales, click on the All column.

After any modification of the sequence, remember to click on to confirm the modifications
made.

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Printing

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For printing the selected mixer parameters, click on : when the print preview is shown, click

on .

up

Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

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Dry loading point parameters (truck mixer drip edge)

Access to this function could be limited by operator's access rights.

For accessing the operation parameters of the truck mixer dry loading point, click on the icon
corresponding to the desired loading point on the plant
mimicParametri_di_lavoro_organi_impianto.htm.

Available functions: Edit - Print - Scales discharge sequence - Exit

Truck mixer loading point information

Access to some parameters may be locked during automatic production.

For each truck mixer loading point one can define various parameters, for trimming the optimal
operation. Some parameters are available only for some types of loading points.

Washing water quantity: quantity of water for washing the loading point after all other
components specified in the produced formula have been discharged. The washing water is
delivered on the last production fraction.

Tail aggregate quantity: for the purpose of cleaning the loading point after all other components
specified in the produced formula have been discharged, one can set a quantity of aggregate to be
discharged only at the last production fraction, after all other components but before the washing
water.

Clogging control delay: if there is a sensor for detecting the clogging of the loading point, enter
the delay after which, when the sensor detects material building up, it is necessary to stop
conveying the components and to signal the clogging alarm.

Vibration duration: enter the duration of the vibration to be activated at the end of the truck load,
in order to remove residual material from the loading point.

up

Edit

For editing the parameters of the selected loading point, click on . Inside the page you can
use the standard functions for data editing.

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Scales discharge sequence

For defining the discharge mode of the scales/meters, once the dosage of all components

specified in the formula is completed, click on .

Remember that the discharge sequence begins when the dosage of all components specified in
the formula is completed (except for scales with head quantity % discharge).

Access to some parameters may be locked during automatic production.

The configuration of the discharge sequence allows to discharge the meters into the truck mixer
(dry load) by:

- discharging a head quantity, before all other components;

- setting a delay starting from the discharge sequence start moment;

- linking the beginning of the discharge to the percentage of material discharged from another
meter;

- discharging a meter in two separate phases (that can also be a combination of the two
previously mentioned modes);

The grid for the discharge sequence contains, from left to right, the columns:

Meter description: shows the identification name of the meter, as defined in the meter
parameters.

Head quantity: only for water and additive type meters, it is possible to define a percentage of
material to be discharged before all other components. The head quantity discharge starts only
after completing the dosage of the component (water/additive), when the truck mixer presence is
notified (after pressing key F9-F12).

Associated scale: when it is necessary to condition (link) the discharge of a meter to a certain
percentage of material discharged from another one, select from the available meters list the one
to link. Not all meters are available for the association to another meter: this depends from your
plant's configuration.

Waiting: enter the delay, in seconds,starting from the discharge sequence start moment or from
the moment when the percentage discharge condition on the Associated meter is satisfied, for
beginning the discharge of the meter

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% associated: enter the discharge percentage on the Associated meter corresponding to which
the meter has to begin its discharge.

% discharge: when it is necessary to discharge the meter in two phases, enter the percentage of
material to be discharged on the first phase. Then enter the values in the following
columns Associated scale, Waiting, % associated and % discharge.

Associated scale: as Associated scale, but referred to the second discharge phase.

Waiting: as Waiting, but referred to the second discharge phase.

% associated: as % associated, but referred to the second discharge phase.

% discharge: as % discharge, but referred to the second discharge phase. It is calculated

automatically when entering the % discharge, referring to 100%.

All: enabling the All parameter , the system considers as associated meter not only the selected
one, but all meters of the same type (see example).

Examples:

1) for discharging 70% of the water as head component, before discharging all other components:
click on the Head quantity column on the water meter row, then write 70.

2) for starting the cement scale discharge 10 seconds after the beginning of the discharge
sequence start moment: click on the Waiting column on the cement meter row, then write 10.

3) for starting the additive meter discharge after discharging 90% of the cement: click on
the Associated meter column on the additive meter row, and select the cement meter. Then click
on % associated column and write 90.

4) for discharging 50% of the additive meter together with the head water, then the remaining part
after discharging 90% of the cement: click on the Head quantity column on the additive meter row,
then write 50. Then click on the Associated meter column, and select the cement meter. Click on
the % associated row and write 90.

5) for starting the cement scale discharge only after discharging the additive meter: click on
the Associated meter column on the cement scale row, then select the additive meter. Then click
on % associated column and write 100. When it is necessary to apply the same discharge
method, for all possibly used additive scales, click on the All column.

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It is moreover possible to define these parameters:

Maximum quantity per batch: enter the cubic meters quantity that can be loaded (dosed) by the
plant in a single batch. When executing a production request of a total quantity greater than that,
the system splits the total load in fractions. The maximum quantity per batch is used
when calculating the fractions during automatic production.

% aggregate/cement de-phasement: enter the maximum allowed difference, in percentage,

between the aggregate and cement quantities discharged in every moment from the scales, in
order to keep the proportions while loading the truck. If one of the two components discharges
faster than the other, the discharge of the faster scale is stopped, until the discharged quantity re-
alignes to the one in the slower scale. When calculating the de-phasement percentage, the system
uses also the quantities defined as aggregates inclined belt capacity and cement scale discharge
screw conveyor capacity.

After any modification of the sequence, remember to click on to confirm the modifications
made.

up

Printing

For printing the selected loading point parameters, click on : when the print preview is shown,

click on .

up

Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

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Belt conveyors parameters

Access to this function could be limited by operator's access rights.

For accessing the operating parameters for a belt conveyor, click on the corresponding icon on
the plant mimic.

Available functions: Edit - Print - Exit

Belt conveyor informations

Access to some parameters may be locked during automatic production.

For each belt conveyor one can define various parameters, for trimming the optimal operation.
Some parameters are available only for some types of belt conveyors.

Complete discharge time: time needed for completely emptying the belt, after stopping any other
conveyor/discharge before it, in order to remove any residual material from the belt.

Capacity: weight of the material present on the belt during normal operation. This parameter is
used for controlling the maximum aggregate/cement de-phasement.

Discharge chain start delay: delay in seconds for starting the conveyor/discharge before this belt
conveyor. It is used for avoiding the overload of the belt when the time needed for reaching its
normal transportation speed is slower of the conveyor/discharge before it.

Stop between cycles: normally the belt conveyor keeps on running between one production
fraction and the next, even after being completely emptied. This happens also at the last fraction of
a production cycle or load, if there is already another production request in progress. If you prefer
stopping the belt conveyor after the emptying, enable this switch.

Stop on de-phasement: in case of aggregates/cements de-phasement, the system normally stops

only the aggregate scale discharge (belt) if the amount of transported material is excessive
compared to the cement. If you prefer stopping the belt conveyor as well, enable this switch.

Start siren time: duration of the warning siren signal, before starting the belt, if foreseen.

Pre-load time: when it is necessary to optimize the production rate of the plant, one can pre-load
the aggregate inclined belt, discharging the aggregate scale for the specified time, before actually
starting the discharge of all components into the truck mixer or the mixer. Warning: make sure
the belt cant be started when loaded, before setting this parameter!

Skid control delay time/Skid control time: parameters for controlling the belt conveyor skidding,
if a skidding detection sensor is installed on it. After starting the belt, when the control delay time
is over, if for the duration of the control time the system continuously receives the skidding signal
from the sensors, the belt is stopped.

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up

Edit

For editing the parameters of the selected belt conveyor, click on . Inside the page you can
use the standard functions for data editing.

up

Printing

For printing the parameters of the selected screw conveyor, click on : when the print preview

is shown, click on ..

up

Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

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Screw conveyors parameters

Access to this function could be limited by operator's access rights.

For accessing the operating parameters for a screw conveyor, click on the corresponding icon on
the plant mimic. These parameters refer only to the scale discharge screw conveyors, not to the
components batching screw conveyors (for which you have to refer to batchers parameters).

Available functions: Edit - Print - Exit

Screw conveyor parameters information

Access to some parameters may be locked during automatic production.

For each screw conveyor one can define various parameters, for trimming the optimal operation.
Some parameters are available only for some types of screw conveyors.

Complete discharge time: time needed for completely emptying the screw, after stopping any
other conveyor/discharge before it, in order to remove any residual material from the screw.

Capacity: weight of the material contained into the screw during normal operation. This parameter
is used for controlling the maximum aggregate/cement de-phasement.

Discharge chain start delay: delay in seconds for starting the conveyor/discharge before this
screw conveyor. It is used for avoiding the overload of the screw when the time needed for
reaching its normal transportation speed is slower of the conveyor/discharge before it.

Stop between cycles: normally the screw conveyor keeps on running between one production
fraction and the next, even after being completely emptied. This happens also at the last fraction of
a production cycle or load, if there is already another production request in progress. If you prefer
stopping the screw conveyor after the emptying, enable this switch.

Stop on de-phasement: in case of aggregates/cements de-phasement, the system normally stops

only the cement scale discharge (valve) if the amount of transported material is excessive
compared to the aggregate. If you prefer stopping the screw conveyor as well, enable this switch.

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Edit

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For editing the parameters of the selected screw conveyor, click on . Inside the page you can
use the standard functions for data editing.

up

Printing

For printing the parameters of the selected screw conveyor, click on : when the print preview

is shown, click on .

up

Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

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Skip parameters
Access to this function could be limited by operator's access rights.

For accessing the operating parameters for a skip, click on the corresponding icon on the plant
mimic.

Available functions: Edit - Print - Exit

Skip parameters information

Access to some parameters may be locked during automatic production.

For each skip one can define various parameters, for trimming the optimal operation. Some
parameters are available only for some types of skips.

Complete discharge time: time for completely discharging all material inside the skip hopper,
after reaching the discharge position over the mixer.

Max ascent time (low to wait position): maximum time needed for going up from the loading
position to the wait position. If the timer expires, the skip is stopped and an alarm is signaled.

Max descent time (high to wait position): maximum time needed for descending from the
discharge position to the wait position. It is more likely the skip can remain crammed in this
descent phase. If the timer expires, the skip is stopped and an alarm is signaled.

Max descent time (wait to low position): maximum time needed for descending from the wait
position to the loading position. If the timer expires, the skip is stopped and an alarm is signaled.

Start siren time: duration of the signal siren warning, before starting the skip, if available.

Starting delay: for avoiding to stop the skip in wait position, you can use this delay: when for
completely closing the mixer (in the previous fraction) only the time specified here remains, the
skip starts going up.

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Edit

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For editing the parameters of the selected skip, click on . Inside the page you can use the
standard functions for data editing.

up

Printing

For printing the parameters of the selected skip, click on : when the print preview is shown,

click on .

up

Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

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Stand-by hoppers parameters

Access to this function could be limited by operator's access rights.

For accessing the operating parameters for a stand-by hopper (aggregates), click on the
corresponding icon on the plant mimic.

Available functions: Edit - Print - Exit

Stand-by hoppers parameters informations

Access to some parameters may be locked during automatic production.

For each stand-by hopper one can define various parameters, for trimming the optimal operation.
Some parameters are available only for some types of stand-by hoppers.

Complete discharge time: time needed for completely discharging all material contained in the
hopper, after stopping the belt conveyors/discharges before it.

Vibration time: duration of the vibrator activation, after reaching the minimum level threshold. If
there is no minimum level sensor, use the Delay for starting vibrator to activate the vibrator at the
desired moment during discharge.

Pause between vibrations: pause between one vibration and the next.

Number of vibrations: number of vibration cycles during discharge.

Delay for starting vibrator: delay time, after reaching the minimum level (or from the beginning of
the discharge, if there is no sensor), for starting the vibrations cycle.

Chute partial opening time: duration of the discharge with the chute in partial opening (if the
discharge has double opening).

Discharge delay time: delay for starting the discharge, in order to synchronize the discharge of
the material from the hopper with conveyors after it.

Flow control delay time: delay for starting the material presence/flow checking, through the
specific sensor, from the beginning of the discharge. Normally used for ground hoppers, for loading
the aggregates bins, in order to let the flow of material on the belt conveyors to stabilize.

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Associated bin for loading: number of the aggregate storage hopper to associate to the ground
hopper, for the loading.

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Edit

For editing the parameters of the selected stand-by hopper, click on . Inside the page you
can use the standard functions for data editing.

up

Printing

For printing the parameters of the selected stand-by hopper, click on : when the print preview

is shown, click on .

up

Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

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Thermometer parameters
Access to this function could be limited by operator's access rights.

For accessing the operating parameters of a thermometer for measuring the environment or a
component temperature, click on the corresponding icon on the plant mimic.

The temperature, measured or manually entered, is recorded in the batch reports and, if
configured, can be printed in the delivery docket.

Available functions: Edit - Print - Calibration - Exit

Thermometer parameters information

Access to some parameters may be locked during automatic production.

For each thermometer one can define various parameters, for trimming the optimal operation.
Some parameters are available only for some types of thermometers

Automatic temperature detection: enables or not the automatic detection from the temperature
sensor. If detection from the sensor is not enabled, the system always use the Current manual
temperature.

Current manual temperature: if detection from the sensor is not enabled, this values has to be
manually detected and entered by the operator.

Minimum acceptable temperature: minimum temperature acceptable for the automatic load. If
the current temperature is lower, an alarm is signaled, but the load can be started anyway.

Meteo: description of the current meteorological conditions. For example: RAIN, CLOUDY, ICY,
etc. This description, if configured, can be printed in the delivery docket. The meteorological
conditions can be entered only for the environment temperature thermometer.

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Edit

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For editing the parameters of the selected thermometer, click on . Inside the page you can
use the standard functions for data editing.

up

Printing

For printing the parameters of the selected thermometer, click on : when the print preview is

shown, click on

up

Calibration

Access to the calibration function may be locked during automatic production.

For calibrating the PLC analog channel receiving the signal proportional to the measured

temperature, click on .

Before using the thermometer for automatic detection of the temperature, it is compulsory to
calibrate it.

1st sample temperature: temperature associated to the first sample measurement made through
the sensor (or shown on the display connected to the sensors, in which case, see the display user
manual). See calibration procedure.

2nd sample temperature: temperature associated to the second sample measurement made
through the sensor (or shown on the display connected to the sensors, in which case, see the
display user manual). See calibration procedure.

Calibration procedure

For calibrating a thermometer, it is necessary to define two values of reading for the analog
channel, corresponding to two different temperatures.

1) Submerge the temperature sensor in an "environment" which temperature is known (water can
be used), and wait a few minutes for stabilization.

2) Read the temperature shown on the digital display, if any

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3) Write it in the 1st sample temperature entry, then click on the Associate button. For example,
if the sensor is submerged in water at 5 °C, write 5.0 in 1st sample temperature.

4) Submerge the temperature sensor in an "environment" which temperature is known (water can
be used), but hotter than before, and wait a few minutes for stabilization.

5) Read the temperature shown on the digital display, if any

6) Write it in the 2nd sample temperature entry, then click on the Associate button. For example,
if the sensor is submerged in water at 30 °C, write 30.0 in 2nd sample temperature.

On the right of the entries 1st sample temperature and 2nd sample temperature, there are
two Analog boxes: here you can see the reading values from the analog channel corresponding to
the entered temperatures, every time you click on the Associate button.

The numeric value in GREEN marked as Measured, is the value converted by the system
according to the current calibration settings.

The numeric value in YELLOW marked as Analog, is the current value read from the
analog channel (in signal points). This is the value transfered to the Analog entries
corresponding to

1st sample temperature and 2nd sample temperature.

up

Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

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Wattmeter parameters
Access to this function could be limited by operator's access rights.

For accessing the operating parameters of a wattmeter, for the detection of the mixer
absorption, click on the corresponding icon on the plant mimic.

The absorption is also used for controlling some automatic procedures during the production cycle.

Available functions: Edit - Print - Calibration - Exit

Wattmeter parameter information

Access to some parameters may be locked during automatic production.

For each wattmeter one can define various parameters, for trimming the optimal operation. Some
parameters are available only for some types of wattmeters.

Empty threshold: absorption of the mixer when empty. Meters are not discharged into the mixer if
the absorption is higher than this value. For not using this feature, set this parameter to 0.

Absorption threshold for discharge intermediate/total: absorption of the mixer, during the
mixing cycle, for allowing the discharge chute opening from partial to total position. This threshold
has priority on the timers defined for the mixer discharge. For not using this feature, set this
parameter to 0.

Use wattmeter control: enables or not the workability/slump control through the wattmeter. If the
wattmeter control is disabled, all parameters for the slump thresholds (S1-S5) are ignored. If the
control is enabled, at the end of the mixing time, the system reads the absorption to assess the
slump of the mix: if the slump corresponds to the class defined in the formula in production, the mix
is discharged. If not, the system signal an alarm, that must be acknowledged for discharging the
mixer.

Threshold S5: upper limit of mixer absorption, for assessing that the mix contained into it is at
slump class S5.

Threshold S4: upper limit of mixer absorption, for assessing that the mix contained into it is at
slump class S4. The lower limit is the one defined as threshold S5.

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Threshold S3: upper limit of mixer absorption, for assessing that the mix contained into it is at
slump class S3. The lower limit is the one defined as threshold S4.

Threshold S2: upper limit of mixer absorption, for assessing that the mix contained into it is at
slump class S2. The lower limit is the one defined as threshold S3.

Threshold S1: upper limit of mixer absorption, for assessing that the mix contained into it is at
slump class S1. The lower limit is the one defined as threshold S2.

up

Edit

For editing the parameters of the selected wattmeter, click on . Inside the page you can use
the standard functions for data editing.

up

Print

For printing the parameters of the selected wattmeter, click on : when the print preview is

shown, click on .

up

Calibration

Access to the calibration function may be locked during automatic production.

For calibrating the PLC analog channel receiving the signal proportional to the absorption

measured by the wattmeter, click on .

Before using the wattmeter for the automatic measurement of the mixer absorption it is compulsory
to calibrate it.

1st sample absorption: absorption associated to the first sample measurement made through
the wattmeter (shown by the wattmeter display on the control panel). See calibration procedure.

2nd sample absorption: absorption associated to the second sample measurement made
through the wattmeter (shown by the wattmeter display on the control panel). See calibration
procedure.

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Calibration procedure

For calibrating the wattmeter, it is necessary to define two values of reading for the analog
channel, corresponding to two different absorptions. Before calibrating the analog channel, make
sure the wattmeter display on the control panel is properly configured for the absorption
measurement on you mixer (refer to the display user manual).

1) Start the mixer, make sure the value shown on the wattmeter display on the control panel is as
much as possible stabilized (and accurate)

2) Read the absorption on the digital display

3) Write it in the 1st sample absorption entry, then click on the Associate button. For example, if
the empty mixer absorbs 15 kw, write 15.00 in the 1st sample absorption entry.

4) Load the mixer for at least 70% of its capacity, in order to read on the wattmeter display on the
control panel, an higher value than before (and accurate)

5) Read the absorption on the digital display

6) Write it in the 2nd sample absorption entry, then click on the Associate button. For example,
if the empty mixer absorbs 45 kw, write 45.00 in the 2nd sample absorption entry.

On the right of the entries 1st sample absorption and 2nd sample absorption, there are two Analog
boxes: here you can see the reading values from the analog channel corresponding to the entered
absorptions, every time you click on the Associate button.

The numeric value in GREEN marked as Measured, is the value converted by the system
according to the current calibration settings.

The numeric value in YELLOW marked as Analog, is the current value from the analog channel
(in signal points). This is the value transfered to the Analog entry corresponding to 1st sample
absorption and 2nd sample absorption.

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Exit and return to plant mimic

For exiting and returning to the plant mimic, click on .

up

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Commands for plant status change

Function keys from F1 to F12 are assigned to commands affecting the status on which the plant
and/or the automatic process is.

According to the status on which the plant is, the available commands are the following
(undescribed combinations have no effect)

Key Resulting plant Effect on the automatic production in progress

Initial plant status
status
F1 SUSPENDED The automatic production in progress is
suspended (paused), with the chance of re-
F2 MANUAL starting it from the point of interruption.
Acknowledge of the signaled alarms, the
AUTOMATIC F4 AUTOMATIC automatic production cycle paused upon alarm
continues.
Stops the water batching, ignoring the amount
ALT+F4 AUTOMATIC actually foreseen by the automatic production
cycle in progress.
Truck presence for the corresponding loading
point, enabling the discharge of the batched
F9-F12 AUTOMATIC material into the truck itself. Pressing the key
again, cancels the truck presence, thus
pausing the discharge of the material into it.

The automatic production in progress is re-

SUSPENDED F1 AUTOMATIC
started from the point of interruption.
None, production already suspended
F2 MANUAL
(paused).
Cancels the automatic production in progress
(ABORT): the components quantities possibly
F3 SUSPENDED batched inside the scales, mixers, belts, etc.
must be removed through manual operations
commands

AUTOMATIC If there is no suspended (paused) automatic

production cycle, plant goes directly in
F2
SUSPENDED AUTOMATIC, otherwise it goes in
SUSPENDED status.
MANUAL Cancels the automatic production in progress
(ABORT): the components quantities possibly
F3 MANUAL batched inside the scales, mixers, belts, etc.
must be removed through manual operations
commands.

There is no communication connection and data

exchange between the PC and the automation
PLC. Check the connection cables and the
WAIT PLC WAIT PLC
COMM.
/ COMM.
communication configuration. In this case, no
function key is available and the information shown
on the plant mimic are not corresponding to the
true situation on the plant.

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Key Resulting plant Effect on the automatic production in progress

Initial plant status
status

A PLC Reset is in progress. In this case, no

function key is available and the information
shown on the plant mimic are not
PLC FAULT / PLC FAULT
corresponding to the true situation on the
plant. Wait for the plant to return to MANUAL
status

Here follow some examples of the on screen plant status console, with the available function keys
in various situations:

The command corresponding to the function key is effective by both pushing the key and clicking
on the button on the on screen plant status console

Function keys from F9 to F12 are normally related to the truck presence command, that is the
authorization to discharge the scales or the mixer into the truck itself. To let Genyx know that the
truck is available and ready for loading, push (or click) on the key corresponding to the desired
loading point as shown on the plant mimic.

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Production
Components / Raw materials
Access to this function could be limited by operator's access rights.

For accessing the components/raw materials file, click on the icon from the main menu
in the Production group.

Here you can define the characteristics of the components used for the production. Before starting
automatic production, inserting formulas, recording raw materials input and stock, it is necessary to
define the components used by the plant.

Available functions: Filter - Edit - New - Delete - Import - Export - Print - Exit

Components information
For each component/raw material one can define various information for production and
accountancy purposes. Hereinafter you will find the compulsory ones and the most importants.

Code: component identification code. It is compulsory and must be unique because it will be used
to identify the specific component in various sections of Genyx.
Description: component description. Used as extended description of the component.
Unit of Measurement: unit of measurement used for dosing the component. It is automatically
assigned by Genyx according to the plant's configuration.
1 =: gravity (specific weight) of the component, only for components dosed through volumetric
systems (i.e, batching cylinders, liter-counters, pulse launchers, etc.) and for the liters to kilograms
conversion in the calculations.
Alternative component code: optional code of the component to be used as an alternative during
the automatic dosage process, if the batcher faults or if the component stock inside the
hopper/silo/tank is not enough for completing the dosage (clogging alarm). Select the component's
code among the available ones on the same meter.
Colour: for each component type (aggregate, cement, water, etc.) an identification colour can be
selected, in order to quickly locate the type in various Genyx pages: after modifying the colour of a
component, Genyx must be restarted. It is anyway warmly advised not to change the standard
colors.
specific informations for Aggregates
Absorption %: percentage of moisture absorbed by the aggregate. It is necessary for the moisture
compensation calculation during the automatic production.
Max diameter: maximum diameter of the aggregate stone/grain. It is necessary to print the
aggregate characteristics in the delivery docket.
specific information for Cements
Class: identification class of the cement. It is necessary to print the cement characteristics in
the delivery docket.

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specific information for Water

% of water contained: percentage of water contained in the component (useful only for
components like recycled water, ice, etc.). It is necessary for the moisture compensation
calculation during the automatic production and for the calculation of the Water/Cement ratio.
Ice: component of Ice type, for plants that foresee this feature. It is necessary for identifying the Ice
component.
specific information for Additives
% of water contained: percentage of water contained in the component. It is necessary for
the moisture compensation calculation during the automatic production and for the calculation of
the Water/Cement ratio.
% on cement: percentage used in formula, for automatically calculating the additive quantity
according to the quantity of cement used.
specific information for Colors
% of water contained: percentage of water contained in the component. It is necessary for
the moisture compensation calculation during the automatic production and for the calculation of
the Water/Cement ratio.
specific information for Addings
% of influence on W/C ratio: percentage of influence on the Water/Cement ratio. It is necessary
for taking into account the influence of components containing powders, fine materials, or liquid on
the Water/Cement ratio.
% on cement: percentage used in formula, for automatically calculating the component quantity
according to the quantity of cement used.
specific information for Mixtures
Aggregates mixtures can be used for defining a basic composition by specifying the percentages
for each aggregate. In this way, one can use a common mixture for different formula, in order to
allow quick update and maintenance. Modifying the composition of an aggregates mixture, all
formulas containing the mixture are automatically updated.

For adding an aggregate to the mixture, click on , then select the component and enter the
desired percentage.
For removing an aggregate from the mixture, click on the line containing the aggregate, then click

on .
Inside the page you can use the standard functions for data editing.

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Filter
For accessing any component type available on the plant, click on the buttons described
hereinafter.

Component type: aggregate

Component type: cement

Component type: water

Component type: admixture

Component type: colour

Component type: adding

Component type: aggregates

mix

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Editing a component
For editing the information of a component, select the line containing the desired component from
the list, then double click on it with the left mouse button. The component page contains the
currently entered data. Inside the page you can use the standard functions for data editing.

up

Inserting a new component

To insert/create a new component, click on : the edit page which opens is blank. Inside the
page you can use the standard functions for data editing.
up

Deleting a component
For permanently deleting a component from the list, select the line containing the desired truck

and click on , then confirm the deletion. Deleting a component is possible only if there are no
formulas using it.
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Exporting components
For exporting the components towards an external software, generating the text file according
to Onyma specifications, to bring it for example to the PC where the accountancy software is

installed, click on . Select the folder where you want to generate the text file containing the
exported components.
This function, available for any component type, exports ALL defined components for all
types: the exported file contains the component available on the plant, for all types.
up

Importing components
For importing components from an external software, generate the text file according to Onyma

specifications, bring it to the PC on which Genyx is installed, then click on . Select the
folder where the text file containing the components to be imported is.
This function, available for any component type, imports ALL defined components for all
types: the import takes from the file all components available, for all types.
up

Printing a component

For printing the components list click on : when the print preview is shown, click on .

For printing the data of a specific component, open the desired component page (double clicking

on the component line on the list), then click on

up

Exit and return to main menu

For exiting the components page and returning to the main menu, click on or on .
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Components exchange
Access to this function could be limited by operator's access rights.

The batchers exchange page can be accessed:

from the main menu in the Production group;
through automatic pop-up from the Genyx during the production cycle.

Access from Production menu

From the main menu, on the Production group, click on the icon . This access mode
can be used for setting the batchers exchange before beginning the automatic production. See the
exchange setting mode.
up

Automatic access
While automatically dosing a component, Genyx monitors the dosage flow, using the parameters
Stoppage threshold / every (sec) set for each specific batcher.

If the dosage flow, that is the quantity of material coming out of the batcher in the time unit, does
not reach at least what defined in the control parameters (i.e.100 Kg every 10 seconds) and, if
even after the vibration/fluidification cycle the normal flow is not recovered, Genyx signals
a dosage clogged alarm and automatically opens the exchange page, where the component in
alarm is highlighted in red.

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See the exchange setting mode.

up

Exchange setting
For each batcher for the dosage of a component which is shown in the exchange page, you can
assign an alternative batcher, to be used as replacement of the original one, during the automatic
production.
WARNING: Genyx does not check the selected alternative batcher: pay attention not to set
the exchange to a component which is not compatible for the mix design you have to
produce!!
For assigning a batcher exchange, click on the column Exchange with on the right side of the
batcher code for which setting the exchange, then select the code of the alternative batcher.

For confirming the setting and closing the page, click on .

For exiting without confirming the settings, click on .

- Example of batchers with active exchanges -

If the exchange page has been brought up automatically upon dosage clogged alarm, exiting from the page acknowledges the alarm as
well.

A batcher exchange can only be set toward batchers dosing on the same meter to which the
original batcher belongs. A component which is dosed alone on a meter, like normally happens
with additives, cannot be exchanged.

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When a batcher is exchanged on another, the quantity to be dosed in automatic production for the
original batcher is actually dosed by the alternative batcher. See note.
If the alternative batcher is assigned before starting the automatic production cycle, all the
requested quantity for the component on the original batcher is actually dosed by the alternative
batcher.
If the alternative batcher is assigned during the automatic production cycle, upon dosage clogged
alarm, only the quantity remaining when the alarm is signaled is dosed by the alternative batcher.
This function allows to complete the production cycle in progress, when it is impossible to recover
the material flow from the original batcher (component finished, batcher breakdown, etc.)
The batcher exchange can can stay active permanently or for one cycle only, depending on the
setting of the parameter Permanent component's exchange for each batcher.
If the permanent exchange is enabled, after the exchange the batcher is always replaced
by the specified alternative for all production cycles, until the exchange is canceled.
If the permanent exchange is not enabled, the exchanged batcher is replaced by the
alternative only for the current cycle or for the next cycle after setting the exchange (if there
is no automatic production in progress when setting the exchange).

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Dosage interruption
When the exchange page is open, it is possible to interrupt (stop) the dosage from the

selected batcher , for the current dosage fraction, by clicking on (even during a dosage
clogged alarm situation).
This function allows to stop a dosage when a very small amount of material, not affecting the
quality of the mix, is left for the dosage, and there is a situation of dosage clogged alarm.
WARNING: Genyx does not check the quantity remaining from the stopped batcher: pay
attention not to create problems in the mix design you have to produce!!
If there are other fractions following the one in progress, the dosage from the stopped batcher will
start again normally from the next fraction.

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Formulas
Access to this function could be limited by operator's access rights.

For accessing the formulas (mix designs) file, click on the icon from the main menu in
the Production group.

Here one can define the formulas to be used for making the products mixed and delivered with the
plant. Before starting the automatic production, it is necessary to enter data for some formulas.
If one has to link products information for the accountancy to the formulas, before creating the
formulas it is recommended to define the corresponding products.

All data entered in the formulas are free and not controlled. In other words, the definition of
the composition of a formula is upon complete responsibility of the user.

Available functions: Edit - Insert - Copy - Delete - Find - Print - Import - Export - Exit

Formula (mix design) information

For each formula one can define various information for production and accountancy purposes (i.e.
for printing into the delivery docket). Hereinafter you will find the compulsory ones and the most
importants:

Code: unique identification code for the formula. It is compulsory and must be unique.
Description: description comment of the formula.
Rck/Strength: strength class for the concrete to which the formula refers. note
Slump: slump class for the concrete to which the formula refers (type in or select from the pre-
defined). note
Exposure class: exposure class for the concrete to which the formula refers (type in or select from
the pre-defined). note
Aggregate max. diameter: maximum diameter (in mm) of the aggregate used in this formula. note
Granulometric curve: type of granulometric curve used as reference when defining this formula.
note

Oversanded: indicates an oversanded granulometric curve. Information available for compatibility

with some old systems. note
Water/Cement Ratio: characteristic Water/Cement ratio for the formula. Modifying this value, the
water quantities entered in the formula's components are re-calculated, and vice versa. note
+/- %: maximum tolerance in percentage on the Water/Cement ratio, to be tested during automatic
production, for signaling an error when exceeding the limits. Always set a value greater than 0,
otherwise Genyx will always signal a tolerance error.
Product code: code of the product to be linked to this formula (select the code from the list). If a
product code is linked to a formula, it is possible printing it automatically in the delivery note, if
foreseen, in order to mention the correct accountancy reference.
Time limit for concrete use: maximum time limit for using the fresh concrete after production. note
Certificate/Certifying corporation: information referring to the certification of the mix design. note

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Mixer times
If there is a mixer in the plant, it is possible to define the working timings for the mixer, specific for
this formula, in order to used them in place of the general ones available in the mixer operating
parameters.
When any of the timers is zero, the general one is used.
Mixing time for 1 m3 ... + (sec) x m3: if necessary, enter the specific mixing time for the formula.
note
Partial opening discharge time for 1 m3 ... + (sec) x m3: if necessary, enter the specific
discharge time with the chute in partial position, for the formula. note
Total opening discharge time for 1 m3 ... + (sec) x m3: if necessary, enter the specific
discharge time with the chute in total opening position, for the formula. note
Closed-partial opening time: if necessary, enter the time needed for opening the discharge chute
to the partial position. It can be used if the mixer does not have a partial opening sensor on the
discharge chute. If the sensor is there and it sends the position signal before the defined time
expires, the chute opening is interrupted anyway.
Partial-total opening time: if necessary, enter the time needed for opening the discharge chute
from partial opening position to total opening. This timer is linked to the next parameter Step
opening pause time. It is useful if one wants to discharge from the partial opening to the total
opening through a pause-work mode. The chute opens for the time here defined, then pauses for
the time defined in Step opening pause time then this cycles restarts until the chute reaches the
sensor for total opening.
Step opening pause time: if necessary, enter the pause time from one opening pulse and the
next in the pause-work mode. This parameter works together with the previous one Partial-total
opening time. See its description.

Components defined in the formula

In this section, enter the requested quantities for the components needed for mixing 1 cubic meter
of concrete with this formula.
Warning: quantities for aggregates and water must be calculated for Saturated Surface Dry
(S.S.D.), that is without taking into account the moisture held by the aggregates. See notes
for water.

Detail of the components used in the formula

Component: code of the component to be dosed for this formula.
Description: description of the component to be dosed. From the components file.
Uom: unit of measurement for dosing the component, assigned by Genyx according to the plant
configuration.
Quantity: quantity of component for 1 cubic meter.
% on cement: percentage of component calculated on the total quantity of cement defined in the
formula. It is useful for the components which quantity is related to the quantity of cement (i.e.
admixtures).
S.W.: specific weight (gravity) of components dosed through volumetric batcher (i.e. liter counters,
pulse launchers).
Aggregates in mixture: net quantities for each aggregate included in the mixture selected for this
formula (quantities shown only if an aggregate mixture has been selected, and the corresponding
quantity entered).

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Formula editing
For editing the data of a formula, select the desired formula from the list, then double lick on it with
the mouse's left button. The edit page which opens contain the current formula data.

For adding a component to the formula, click on the icon corresponding to the component type:

Aggregate

Cement

Water

Additive

Color

Adding

Aggregates
mixtures

then select the component to be added from the list and enter the requested quantity for 1 cubic
meter. After inserting an aggregates mixture, it will not be possible to insert single aggregates and
vice versa.

For modifying the quantity of a component in the formula, double click on the row containing the
component to be changed.

For deleting a component from the formula, select the component to be removed from the section
Components in formula by clicking on the row containing it, in order to highlight it, then click on

Inside the page you can use the standard functions for data editing.

Automatic calculations in formula

Genyx automatically calculates come values upon modifications of other values in the formula:
modifying the W/C Ratio, the quantity of water is re-calculated (the re-calculated water is
always the one assigned to the first batcher on the plant);
modifying the quantity of water, the W/C Ratio is re-calculated;
modifying the quantity of cement, the W/C Ratio is re-calculated;
modifying the quantity of cement, the net quantities of the components related to the
cement in percentage (i.e. additives) are re-calculated;
modifying the quantity of components containing water (i.e. ice, additives, etc.), the W/C
Ratio is re-calculated;
Formula total weight: modifying the quantity of any component, the total weight is
updated, taking into account the specific weight (gravity) of components dosed by volume
(in liters).
See note for W/C calculation.

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About the water quantity

Pay attention to the total quantity of water to be defined in the formula.
Remember that the aggregates must be specified S.S.D. (saturated surface dry), so the total
quantity of water is the formula surely is greater than the one normally foreseen for the manually
dosed formulas.
Pay attention to the calibration of the moisture meters available on the plant, make sure to set the
correct detection mode, and to select the desired moisture compensation mode.
It is possible to explicitly define the amount of recycled water (water 2) to be used in the formula,
but normally it is recommended using the % available in the recycled water operating parameters
(for maintenance easiness).

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Inserting/creating a new formula

For inserting/creating a new formula, click on : the edit page which opens is blank. Inside the
page you can use the standard functions for data editing. See also details for editing a formula.
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Copying (duplicating) a formula

For duplicating an existing formula, for example for editing only some parts of it thus creating

quickly a new formula, click on : enter the code of the new formula then click on .
After the copy, the editing page of the new formula opens automatically.
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Finding a formula

For finding a specific formula within the list, click on to open the find function.
This list has a quick find feature linked to the code. Without clicking any button, just type the code
of the item you need to find and the cursor will position itself on the first line/code matching the
typed characters.
up

Deleting a formula
For permanently deleting a formula from the list, select the line containing the desired formula and

click on , then confirm the deletion.

It is possible to remove more formulas from the list at the same time, using the multiple selection
mode.
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Printing a formula

For printing the formulas list click on : when the print preview is shown, click on .

For printing the data of a specific formula, open the desired formula page (double clicking on the

formula line on the list), then click on

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Importing formulas
For importing a formulas list from an external software, generate the text file according to Onyma

specifications, bring it to the PC on which Genyx is installed, then click on . Select the folder
where the text file containing the formulas to be imported is.
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Exporting formulas
For exporting the formulas list towards an external software, or even towards a second installation
of Genyx on another computer, generating the text file according to Onyma specifications, to bring

it to the other PC, click on .

Select the folder where you want to generate the text file containing the exported formulas.
up

Exit and return to main menu

For exiting the formulas list and returning to the main menu, click on .
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Products
Access to this function could be limited by operator's access rights.

For accessing the products file, click on the icon from the main menu in the Production
group. This function is available only if the system is configured for delivery dockets (delivery
notes).
Here you can define the products that are produced and delivered by the plant. The products can
be used for defining reference codes between production and accountancy, in order to correctly
assign the prices for invoicing to clients.
Before starting automatic production, if you have to print delivery dockets showing product codes
for the accountancy, it is necessary to enter the products data.

Available functions: Edit - New - Find - Delete - Print - Import - Export - Exit

Products information
For each product one can define various information for production and accountancy purposes (for
printing into the delivery docket). Hereinafter you will find the compulsory ones and the most
importants:

Code: unique product identification code. It is compulsory and must be unique.

Description: description of the product.
Type: product type (select the type from the pre-set list).
UOM: unit of measurement (select the type from the pre-set list).
Specifications: if the product is of Concrete type, this section is available for specifying the
technological characteristics.

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Product editing
For editing the data of a product, select the desired product from the list, and double click on it with
the mouse's left button. The edit page which opens contain the current product data. Inside the
page you can use the standard functions for data editing.

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Inserting a new product

For inserting/creating a new product, click on : the edit page which opens is blank. Inside the
page you can use the standard functions for data editing.
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Finding a product

For finding a specific product inside the list, click on to open the find function.
This list has a quick find feature linked to the code. Without clicking any button, just type the code
of the item you need to find and the cursor will position itself on the first line/code matching the
typed characters.
up

Deleting a product
For permanently deleting a product from the list, select the line containing the desired product and

click on , then confirm the deletion.

It is possible to remove more products from the list at the same time, using the multiple selection
mode.
up

Printing a product

For printing the products list click on : when the print preview is shown, click on .

For printing the data of a specific product , open the desired product page (double clicking on

the product line on the list), then click on .

.
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Importing products
For importing a products list from an external software, generate the text file according to Onyma

specifications, bring it to the PC on which Genyx is installed, then click on . Select the folder
where the text file containing the products to be imported is.
up

Exporting products
For exporting the products list towards an external software, generating the text file according
to Onyma specifications, to bring it for example to the PC where the accountancy software is

installed, then click on . Select the folder where you want to generate the text file containing
the exported products.
up

Exit and return to main menu

For exiting the products list and returning to the main menu, click on .
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Clients
Access to this function could be limited by operator's access rights.

For accessing the clients/destinations file, click on the icon from the main menu in the
Production group. This function is available only if the system is configured for delivery dockets
(delivery notes).

Here you can define the clients to which the material produced by the plant is delivered. Before
starting automatic production, if you have to print delivery dockets, it is necessary to enter the
clients and destination/delivery sites data.

Available functions: Destinations - Edit - New - Find - Delete - Print - Import - Export - Exit

Client information
For each client one can define various information for production and accountancy purposes (for
printing into the delivery docket). Hereinafter you will find the compulsory ones and the most
importants:

Code: unique client identification code. It is compulsory and must be unique.

Company name: name of the company. It is compulsory.
No regular payments: indicates that this client cannot be supplied anymore, in other words it
prevents the selection of this client while entering the data of a delivery docket.
Validity - m3 to deliver: indicates that this client can be supplied until reaching the defined
quantity. This quantity is decreased at every delivery down to 0, then a warning is signaled every
time the client is selected for a delivery.
Validity - end date: indicates that this client can be supplied until the defined date. A warning is
signaled every time the client is selected for a delivery after the specified date.
This client requires report printing inside docket page: indicates that on every delivery docket
printed for this client, the batch report with the detailed batched components must be included
(printed in the paper form). In this situation, the Delivery docket configuration in the System
menu group must be defined in order to include the printing of the batch report (in a properly sized
space).

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Destinations
For adding or editing the destinations/delivery sites for a client, select the line containing the client

on the list, then click on . The destinations/sites are specific for each client: in other words, it
is not possible to define generic destinations to be used with all clients, but every client must have
his own destinations.
See information on destinations.

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Client editing
For editing the data of a client, select the desired client from the list, and double click on it with the
mouse's left button. The edit page which opens contain the current client data. Inside the page you
can use the standard functions for data editing.

up

Inserting a new client

For inserting/creating a new client, click on : the edit page which opens is blank. Inside the
page you can use the standard functions for data editing.
up

Finding a client

For finding a specific client inside the list, click on to open the find function.
This list has a quick find feature linked to the code. Without clicking any button, just type the code
of the item you need to find and the cursor will position itself on the first line/code matching the
typed characters.
up

Deleting a client
For permanently deleting a client from the list, select the line containing the desired client and click

on , then confirm the deletion.

It is possible to remove more clients from the list at the same time, using the multiple selection
mode.
up

Printing a client

For printing the clients list click on : when the print preview is shown, click on .

For printing the data of a specific client, open the desired client page (double clicking on the client

line on the list), then click on

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Importing clients
For importing a clients list from an external software, generate the text file according to Onyma

specifications, bring it to the PC on which Genyx is installed, then click on . Select the folder
where the text file containing the clients to be imported is.
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Exporting clients
For exporting the clients list towards an external software, generating the text file according
to Onyma specifications, to bring it for example to the PC where the accountancy software is

installed, then click on . Select the folder where you want to generate the text file containing
the exported clients.
up

Exit and return to main menu

For exiting the clients list and returning to the main menu, click on .
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Destinations/delivery sites
Access to this function could be limited by operator's access rights.

For accessing the destination/delivery sites file, click on the icon from the main menu
in the Production group. This function is available only if the delivery dockets (delivery notes)
functions is foreseen.

Here one can define, for each client, the destinations/sites to which the produced material is
delivered. Before starting automatic production, if you have to print delivery dockets, it is necessary
to enter the clients and the destinations/sites for the delivery.

Destinations/sites are specific for each client: in other words, it is not possible defining general
destinations to be used with all clients, but every client must have its own destinations.

Available functions: Clients - Edit - New - Find - Delete - Print - Import - Export - Exit

Destination information
For each destination/site of a specific client one can define various information for production and
accountancy purposes (for printing into the delivery docket). Hereinafter you will find the
compulsory ones and the most importants:
Code: unique destination identification code. It is compulsory and must be unique.
Address: delivery address. It is compulsory.
Minimum load m3: minimum quantity, in cubic meters, that can be loaded by a truck on a single
delivery without having to charge the minimum load difference.
Radial: geographic radial for the delivery to this destination, for possibly managing the truck
driver/owner payment.
Latitude, Longitude: geographic coordinates for this destination (this information makes sens
only if the Genyx is linked to a VTS system, for automatically tracking the position and
status of the trucks).

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Clients

For going back to the clients list, click on . See information on clients.

up

Destination editing
For editing the data of a destination, select the line containing the destination on the list, and
double click on it with the mouse's left button. The edit page which opens contain the current client
data. Inside the page you can use the standard functions for data editing.

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Inserting a new destination

For inserting/creating a new destination click on : the edit page which opens is blank. Inside
the page you can use the standard functions for data editing.
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Finding a destination

For finding a specific destination inside the list, click on to open the find function.
This list has a quick find feature linked to the code. Without clicking any button, just type the code
of the item you need to find and the cursor will position itself on the first line/code matching the
typed characters.
up

Deleting a destination
For permanently deleting a destination from the list, select the line containing the desired

destination and click on , then confirm the deletion.

It is possible to remove more destinations from the list at the same time, using the multiple
selection mode.
up

Printing a destination

For printing the destinations list click on : when the print preview is shown, click on .

For printing the data of a specific destination, open the desired destination page (double clicking on

the destination line on the list), then click on .

up

Importing destinations
For importing a destinations list from an external software, generate the text file according

to Onyma specifications, bring it to the PC on which Genyx is installed, then click on . Select
the folder where the text file containing the destinations to be imported is.
This function, available for all destinations, affects in any case ALL destinations
simultaneously: the import takes from a file all available destinations, for all clients.
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Exporting destinations
For exporting the destinations list towards an external software, generating the text file according
to Onyma specifications, to bring it for example to the PC where the accountancy software is

installed, click on . Select the folder where you want to generate the text file containing the
exported destinations.
This function, available for all destinations, affects in any case ALL destinations
simultaneously: the export generates a file with all available destinations, for all clients.
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Exit and return to main menu

For exiting the destinations list and returning to the main menu, click on .
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Trucks
Access to this function could be limited by operator's access rights.

For accessing the trucks file, click on the icon from the main menu in the Production
group.

Here you can define the trucks used for delivering the material produced by the plant. Before
starting automatic production, if you have to print delivery dockets, it is necessary to enter the
trucks data.

Available functions: Edit - New - Find - Delete - Print - Import - Export - Exit

Trucks information
For each truck one can define various information for production and accountancy purposes (for
printing into the delivery docket). Hereinafter you will find the compulsory ones and the most
importants:

Code: unique truck identification code. It is compulsory and must be unique.

Property: owner of the truck, SENDER, CONSIGNEE, CARRIER. It is compulsory.
Company name: name of the company handling the truck. It is compulsory.
Plate: plate number (registration) of the truck. It is compulsory.
Driver: name or identification of the truck driver. It is compulsory.
Driver code: identification code of the driver (this data is necessary only if the Genyx is linked
to the VTS system, for automatically checking the position and status of the trucks)
Capacity: maximum transportation capacity of the truck, in cubic meters.
Pump boom length: length of the pump boom when totally extended (this data is necessary only if
the truck is a concrete placing pump and if you need to charge the concrete pumping according to
the boom length). Specifying the boom length, you will see the truck code in the concrete placing
pump selection list, for example while entering a new delivery docket.

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Truck editing
For editing the data of a truck, select the desired truck from the list, and double click on it with the
mouse's left button. The edit page which opens contain the current truck data. Inside the page you
can use the standard functions for data editing.

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Inserting a new truck

For inserting/creating a new truck, click on : the edit page which opens is blank. Inside the
page you can use the standard functions for data editing.
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Finding a truck

For finding a specific truck inside the list, click on to open the find function.
This list has a quick find feature linked to the code. Without clicking any button, just type the code
of the item you need to find and the cursor will position itself on the first line/code matching the
typed characters.
up

Deleting a truck
For permanently deleting a truck from the list, select the line containing the desired truck and click

on , then confirm the deletion.

It is possible to remove more trucks from the list at the same time, using the multiple selection
mode.
up

Printing a truck

For printing the trucks list click on : when the print preview is shown, click on .

For printing the data of a specific truck, open the desired truck page (double clicking on the truck

line on the list), then click on

up

Importing trucks
For importing a trucks list from an external software, generate the text file according to Onyma

specifications, bring it to the PC on which Genyx is installed, then click on . Select the
folder where the text file containing the trucks to be imported is.
up

Exporting trucks
For exporting the trucks list towards an external software, generating the text file according
to Onyma specifications, to bring it for example to the PC where the accountancy software is

installed, click on . Select the folder where you want to generate the text file containing the
exported trucks.
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Exit and return to main menu

For exiting the trucks list and returning to the main menu, click on .
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Orders
Access to this function could be limited by operator's access rights.

For accessing the orders file, click on the icon from the main menu in the
Production group or on the quick access icons. This function is available only if the system is
configured for delivery dockets (delivery notes).

Here one can define the production/delivery orders received from clients or from the planning
department. Entering an order allows quick recall and setting of the data necessary to the
preparation of a delivery docket.

Available functions: Edit - New - Find - Delete - Print - Exit

Orders information
For each order one can define various information for production and accountancy purposes.
Hereinafter you will find the compulsory ones and the most importants:

Number: unique identification code for the order. It is compulsory and must be unique. It is
automatically assigned by Genyx, following progressive numbering. It is always possible to change
the progressive number which is automatically assigned to the order, from the function Plant's
data - Production from the System menu group.
Description: description of the order, for identifying it more easily.
Client order: code reference of the order received from the client.
Date: date on which the order from the client has been received.
Delivery date: delivery date foreseen/requested by the client (it affects the position of the order in
the list).
Time: delivery time foreseen/requested by the client (it affects the position of the order in the list).
Client: information of the client placing the order. It is compulsory.
Address: delivery address (destination/site) for the produced material. It is compulsory.
Formula: code of the composition formula for the product to be delivered. It is compulsory.
Structure type: description of the pour/structure objective of the delivery, for printing the
information in the delivery docket.
Requested m3: cubic meters of product requested by the client. It is compulsory.
Remaining m3: cubic meters of product still to be delivered (balance).
Delivered m3: cubic meters of product delivered so far (automatically calculated).
Notes (1 and 2): comment notes to the order, for printing the information in the delivery docket.

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Order editing
For editing the data of an order, select the desired order from the list, and double click on it with the
mouse's left button. The edit page which opens contain the current order data. Inside the page you
can use the standard functions for data editing.

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Inserting/creating a new order

For inserting/creating a new order, click on : the edit page which opens is blank. Inside the
page you can use the standard functions for data editing.
up

Finding an order

For finding a specific order inside the list, click on to open the find function.
This list has a quick find feature linked to the code. Without clicking any button, just type the code
of the item you need to find and the cursor will position itself on the first line/code matching the
typed characters.
up

Deleting an order
For permanently deleting an order from the list, select the line containing the desired order and

click on , then confirm the deletion.

It is possible to remove more orders from the list at the same time, using the multiple selection
mode.
up

Printing an order

For printing the orders list click on : when the print preview is shown, click on .

For printing the data of a specific order, open the desired order page (double clicking on the order

line on the list), then click on .

up

Exit and return to main menu

For exiting the orders list and returning to the main menu, click on .
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Production
Access to this function could be limited by operator's access rights.

For accessing the production programming and execution function, click on from the

main menu in the Production group, or click directly on in the right bottom corner of the
plant mimic, or on the quick access icons.

Available functions: Insert/Edit - Execution - Interrupt - Truck - Docket - Delete - Disable - Fractions
analisys - Production monitor - Exit

Production request information

There are 32 available production requests/lines. Each line contains information regarding the
automatic production that can be executed.
Many production requests can be concurrently executing. In other words, it is possible to program
and to execute 32 automatic production simultaneously, so they will be launched in the
programmed execution order, according to the availability of the meters on the plant.
When a request is started while another is already executing, as soon as any of the meters
requested by the components specified in the formula is free, the dosage for the new request is
launched, for optimizing the plant production capacity.

The production requests list contains the following information:

Status: execution/progression status of the production request. According to the status, various
operations can be performed on the production line.

Request Status Meaning - Possible actions

Request not yet programmed (missing data) or ready for execution

(note).

Request inserted (queued) in the production sequence: the actual

execution will start as soon as the turn order of the request in the
QUEUED
specified sequence will come, and when the execution conditions are
satisfied.

The system is transmitting the production request to the automation

TRANSMISSION
PLC: all information are being aligned for starting the actual dosage.

Request is in production: the dosage of the component specified in the

selected formula is going on. The dosage progress can be followed
PRODUCTION
from the plant mimic, in order to check in which meters the
various cycles/fractions of the request are.

The production in progress is paused (suspended): the F1 key key

has been pressed, so the plant is paused. All dosages are paused and
SUSPENDED
the dosage progress can be followed from the plant mimic, in order to
check in which meters the various cycles/fractions of the request are.

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Request Status Meaning - Possible actions

The request production is finished (terminated): all requested

TERMINATED cubic meters have been produced and the batch reports have been
recorded. The production request can be re-started.

The request production is terminated following an interruption

INTERRUPTED command: if the button has been pressed before beginning the
execution of the last cycle/fraction of the request, not all the originally
requested cubic meters have been produced.

The interruption of the request is in progress, following the command

INTERRUPTING
from the button .

The interruption of the request is in progress, following the command

INTERRUPTING from the button , but the plant is paused after pressing the F1
key: all dosages are paused and the dosage progress can be followed
from the plant mimic, in order to check in which meters the
various cycles/fractions of the request are.

The request production is finished: all requested cubic meters have

WAIT ENDING been produced and the recording of the last batch report (or the total
sum report) is in progress.

The cancellation (aborting) of the production request is in progress,

after pressing the F3 key: all dosages in progress are canceled and
ABORTING
the system is recording batch reports containing incomplete quantities,
for the dosages actually carried out until the cancellation.

The request production is terminated following a cancellation (abort)

command, after pressing the F3 key: all dosages in progress have
been canceled and the system has recorded batch reports containing
incomplete quantities, for the dosages actually carried out until the
ABORTED
cancellation. From the plant mimic, check which meters contain the
dosed components that must be manually discharged before starting a
new automatic production. Check from batch reports the detail of the
various components which are contained in the scales/meters.

Seq.: order number of sequential execution. In case of concurrent execution of many production
lines, the number in this column shows the sequence position of the production request. For
example, the number 3 shows that before beginning the dosages for that production line, the
system has to complete the cycle of the requests marked with the numbers 1 and 2.
Formula: formula selected on the production line: by clicking once on any production line, the
bottom part of the page displays information about the selected formula and, if the delivery docket
(delivery note) feature is foreseen, about the client order as well.
requested m3: cubic meter quantity requested for production.
produced m3: cubic meter quantity produced so far. This value is automatically updated according
to the progression of the production.

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Premix: shows if the mix is going to be produced through mixer (wet mix) or directly into the truck
mixer (dry mix).
Client: company name of the client selected for the delivery docket.
Destination: destination address selected for the delivery on the delivery docket.

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Information on specific production request

By clicking once on any production line containing data, the bottom part of the page displays
information about the selected formula and, if the delivery docket (delivery note) feature is
foreseen, about the client order as well.

If the delivery docket (delivery note) feature is foreseen, the bottom part of the page shows also the
status of the delivery docket associated to the production request, for example:

The status ca be:

Incomplete = Docket not completely filled in, it cannot be printed. note

Ready = Docket completely filled in, ready for printing, according to the configured print
mode.
Printed = Docket already printed.

By clicking on you can directly access the delivery docket edit page, without opening the
production request edit page.

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Inserting/editing a production request

For opening the edit page, select the production line to operate on by clicking on it, then click on

. Alternatively, simply double click on the desired production line.

In the edit page:

Client order: number of the client order to be used for quick selection of the production formula
and of the client/destination data, for the delivery docket associated to the production you are
programming. This entry is available only if the delivery docket (Delivery Note) feature is foreseen.
Formula: code of the formula to be produced in automatic mode. This data must be
entered compulsorily.
Delivery m3: cubic meters to to be produced in automatic mode. This data must be
entered compulsorily.
Water in truck: enter the residual washing water possibly already present in the truck. The
specified quantity will be deducted from the total to be dosed according to the selected formula.
Premixed: specify (clicking on the enable box ) if the formula has to be produced with the
mixer (only for plants with wet/dry bypass option).
Mixer gate: select the mixer discharge chute to be used on the selected mixer (only for plants with
mixers having more discharge chutes).
Loading point: select the loading point of the plant to which routing the production (only for plants
with many loading points).

When the truck that will transport the newly produced material already contains some material
returned from the previous load/delivery, in order to recycle this material for the current delivery:
Returned from previous load m3: enter the cubic meters quantity already in the truck mixer.
Example: Delivery m3 = 9.00, Returned m3 = 2.00, actual production = 7.00 m3, generated batch
report = 9.00 m3, printed delivery docket = 9.00 m3. The returned quantity will be shown in any
case in the batch report generated for the new production.
Docket no. for returned m3: enter the docket number referring to the returned material (for
showing the reference in the batch report and for deducting the returned m3 for the accountancy, if
necessary).
Returned formula: select the code of the formula corresponding to the m3 already in the truck
mixer. The returned formula code is automatically proposed:
if a Returned from previous load m3 is entered, the returned formula code is
automatically assigned as identical to the newly selected code in Formula;
if a Docket no. for returned m3 is entered, the returned formula code is automatically
assigned from the specified delivery docket.
If the returned formula code is different from the formula to produce, Genyx tries to compensate
the quantities of the returned components appearing in both formulas (same codes), in order to try
and guarantee the total volume of the mixed product. WARNING: Genyx compensates only
between components with the same code, therefore it is recommended to thoroughly check
the calculated fraction before executing a production containing a returned formula.

After selecting the formula to produce, on the right side of the edit page, all details of the
selected formula will be shown.

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If the delivery docket feature is foreseen, by clicking on you access the edit page of the
docket.

When a production line is executing, all its data cannot be modified.

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Executing a production line

After entering the necessary data for a production line, specifying at least the formula to
produce and the requested cubic meters, in order to start the production:
- select the production line by clicking on it, then

- click on .

If the necessary conditions for the automatic production are satisfied, the dosage of the
components specified in the formula will begin.

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Interrupting a production line

When a production line is executing (see statuses), you can interrupt it before all requested cubic
meters have been produced, while the cycles/fractions already in progress are normally carried to
the end.

Select the production line by clicking on it, then click on .

When the last cycle/fraction is completed, the quantity of cubic meters actually produced until the
interruption is automatically assigned as requested cubic meters.
If the production line foresees the printing of a delivery docket printed at the end of the load, the
document will show the actually produced cubic meters.

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Truck mixer code

For assigning a truck code to the production line, in order to show it in the batch report, select the

production line by clicking on it, then click on , and finally select the truck code from
the file.

If the delivery docket feature is foreseen, the truck code specified here will be assigned also to the
docket associated/generated by the production line.
This feature is useful for re-using the same production line for repeated deliveries to the
same client/same delivery site, without having to open the docket editing page, and without re-
typing all data necessary for the printing, thus changing only the truck used for transportation.
As specified in the production request statuses information, a TERMINATED production line can
be set in execution again.

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Delivery docket editing

For editing the data to be printed in the delivery docket automatically generated by executing a

production line, select the desired production line by clicking on it, then click on . For editing
the necessary data, see the chapter about delivery dockets (note).

You can also access the docket editing page from the production line editing page.

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Deleting a production line

For permanently removing all data contained in a production line, click on the line you want to

delete then click on , and confirm the deletion.

You cannot delete production lines which status is: QUEUED, TRANSMISSION, PRODUCTION,
SUSPENDED, INTERRUPTING, WAIT ENDING, ABORTING

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Disabling (blocking) a production line

For blocking a production line, in order to prevent an unwanted execution (i.e. to prevent receiving
a production start from an external pushbutton box installed on a pouring bed in a pre-cast factory),

select the production line by clicking on it, then click on .

A blocked line is highlighted by the red color around the line identification number.

To unblock a line, click on or open it as for data editing, then re-confirm the specified data by

clicking on .

The system can automatically block a production line when there are particular conditions requiring
an operator check (client order modification, formula cannot be executed, etc.). To unlock it,
proceed as described above, or try and modify the data in the request.

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Fraction analisys - components quantities

Once all data for a production line have been specified, by clicking on after selecting the
desired line, you can display a preview of the single components quantities that are going to be
dosed, in order to see how the system decided to fraction the requested production, by assigning
the available batchers.

The page contains the list of all available batchers and, for each one, the theoretical quantity to be
dosed according to the selected formula and the requested cubic meters.

If the system splits the requested production in many fractions, by clicking on and

, you can check each single fraction. The fraction number is shown under the page
header.

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Production monitor window

By clicking on the production monitor window is displayed. This window can be places
anywhere on the screen. It allows monitoring of the 3 production lines in a more advanced
progression situation, without having to go to the production page.

For hiding the production monitor page, close it by clicking on .

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Exit and return to main menu

For exiting the production requests page and going back to the main menu (or to the plant mimic)

click on .
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Automatic calculation of production fractions

Every time that:

- a new production line is entered;

- a formula specified in a production line is modified;

- a plant operating parameter affecting the fraction calculation is modified,

the system automatically re-calculates the fractions for the production line containing valid values.

During the automatic re-calculation, which can require a few seconds, the system assesses the
quantities to be dosed for each component batcher, according to the selected formula and to
the plant operating parameters.

At the end of the procedure, the system show a page highlighting the result of the calculation, for
each production line:

- the message Ok! shows that the fractions have been calculated correctly, then the production line
can be started;

- any other message, containing the detailed description of the problem, shows that the production
line cannot be started, so a modification is requested (normally it is required to modify the selected
formula or to make sure that the components specified in the formula are assigned to at least
one batcher among the available ones).

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Delivery dockets (delivery notes)

Access to this function could be limited by operator's access rights.

For accessing the delivery dockets file, click on the icon from the main menu in the
Production group or on the quick access icons. This function is available only if the system is
configured for delivery dockets (delivery notes).

Here you can retrieve or create new delivery dockets sent along with the materials produced by the
plant.

The delivery dockets list shows all dockets prepared up to the current date, allowing access to the
data contained in each one.

Available functions: Details - New - Find - Filter - Delete - Print - Export - Exit

Delivery dockets information

The delivery docket contains the information related to the delivery of the produced material to the
client's site. Normally, all these information are the same that are present on the paper document
which is part of your company procedures.
The data included in the delivery docket and the printout form can be customized with the
function Docket printing configuration in the System menu group.

Dockets list information

The dockets are listed in decreasing chronological order, that is the most recently issued docket is
on top of the list.
Docket: progressive number for docket identification, automatically assigned upon actual printing
of the docket or when inserting/creating a new one. It is always possible to change the progressive
number which is automatically assigned to the dockets, from the function Plant's data -
Production from the System menu group.
dd - mm - yyyy: day, month and year of creation/recording of the docket.
Time: time of creation/recording of the docket.
Client: company name of the client for which the docket is issued.
Address: destination address of the client where the produced material is delivered.
City: destination city of the client where the produced material is delivered.
Truck: truck code used for the delivery.
Formula: code of the formula (mix design) used for the production.
m3: cubic meters defined in the docket as delivered quantity.
Note: information notes, printed in the docket.

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Docket page information

For accessing the information contained in a specific docket, open it double clicking on the line of
the list corresponding to the desired docket, or single clicking on the line to select it, then clicking

on .
Normally, all these information are the same that are present on the paper document which is part
of your company procedures.
The data included in the delivery docket and the printout form can be customized with the
function Docket printing configuration in the System menu group.
The data contained in a new or in an already printed docket can be edited, simply clicking on the
data to be modified/entered, then typing the desired value or selecting the desired option from a
list.

In order to understand what data are available in a delivery docket, please see section Data that
can be set/printed in the delivery docket. Some data are compulsory, so they have to be set and
entered in the delivery docket, in order to print it. See note.

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Editing a docket
For editing the information contained in an already printed docket, open it double clicking on the
line of the list corresponding to the desired docket.
Not all data in an already printed delivery docket can be modified. To modify a data, click on the
data to be modified/entered, then type in the desired value or select the desired option from the list.
The option of allowing the modification of a specific data in the delivery docket, after printing it, can
be controlled from Docket printing configuration in the System menu group.
The docket page contains the current data entered/printed for the selected docket. Inside the page
you can use the standard functions for data editing.

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Inserting a new docket

For inserting/creating a new docket, click on : the edit page which opens is blank. Inside the
page you can use the standard functions for data editing.
The progressive number for identification of the docket is automatically assigned from the
automatic numbering system kept by Genyx. It is always possible to change this number by
clicking on it and typing in the desired number.
When the new docket is saved (recorded into the file), the identification number is assigned
together with the creation date/time, eve if the docket is not actually printed.
Some data in the docket are compulsory, so they have to be set and entered in the delivery
docket, in order to print it. See note.

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Finding a docket

For finding a specific docket or a group of specific dockets inside the list, click on to open
the find function.
This list has a quick find feature linked to the docket number. Without clicking any button, just type
the number of the item you need to find and the cursor will position itself on the first line/code
matching the typed characters.
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Docket filter
For applying a filter on the dockets list, in order to show only specific dockets in the list (i.e. the

ones referring to a specific client and/or issued on a specific time frame), click on for
entering the filter function.
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Deleting a docket
For permanently removing a delivery docket from the list, select the line containing the desired

docket then click on , then confirm the deletion.

It is possible to remove more dockets from the list at the same time, using the multiple selection
mode.

It is moreover possible to delete more daily records simultaneously from the list, by clicking on

and entering the date range for which to delete the records.

Remember that statistics and sums are calculated on the files containing batch reports
and delivery dockets (if present). After removing batch reports and dockets from the files,
the sums could turn out incomplete.
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Printing a docket
For printing the selected docket, open it by double clicking on the line containing the desired

docket on the list, then click on .

The printout of the delivery docket is affected by the settings in functions Genyx configuration -
Print and Docket printing configuration in the System menu group.
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Exporting dockets
For exporting the dockets issued in a specific time frame towards an external software, generating
the text file according to Onyma specifications, to bring it for example to the PC where the

accountancy software is installed, click on .

Then, select the desired time frame and the folder where you want to generate the text file, and

finally click on to start exporting.

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Exit and return to main menu

For exiting the dockets list and returning to the main menu, click on .
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Batch reports
Access to this function could be limited by operator's access rights.

For accessing the batch reports file, click on the icon from the main menu in the
Production group or on the quick access icons.

Here one can see the batch reports generated on every cycle or fraction of automatic and manual
production.
It is necessary to complete at least one automatic or manual batch to generate a batch report.

The batch report list shows all batch reports generated up to date, allowing access to the detailed
data contained in the single batch reports.

To understand correctly the data contained in the batch reports, refer to the information
about the water correction method and about the automatic error compensation between
fractions.

Available functions: All - Totals - Find - Filter - Delete - Print - Exit

Batch report information

The batch report contains detailed information about the components dosed and mixed for each
production cycle or fraction. Most data available in the batch reports comes from what defined
when programming a production request.
The batch reports list shown when entering the reports file contains different kinds of batch reports:
Batch report for single cycle/fraction, which contains the detail of the components dosed
for a specific cycle/fraction. If the cycle/fraction to which the report refers has been
interrupted (aborted) by the operator, before its normal completion, the batch reports shows
the note ABORTED.
Summary batch reports, sum of many fractions, containing the detail of the components
dosed in subsequent fractions referring to the same production (i.e. when the plant loads a
truck with 12 m3, but split in 4 fractions of 3 m3 each).
Batch report for manual dosage, which contains the detail of the components dosed for
a cycle executed manually by the operator. The manual batch report, when generated by
the Genyx, does not obviously contain any reference to the dosed formula, or to the client
which possibly ordered that load: by opening the batch report, you can manually enter the
missing information, in order to complete the batch report.

For easy identification of the different batch report types, each line is highlighted in a different way.
batch report for single fraction
summary batch report (sum of many fractions)
batch report for manual dosage without formula reference
batch report for manual dosage after defining a formula reference
batch report for dosage aborted by the operator

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By clicking on Totals the batch reports list shows only the summary reports. By clicking on All

, the list shows all batch reports, including the ones for the single fractions.

Batch report list information

The batch reports list is ordered in decreasing chronological order, that is the most recent batch
report is on top of the list.
Date: recording date of the batch report.
Time: recording time of the batch report.
Mix Id: progressive number for batch report identification, automatically assigned when the report
is generated. The single cycles or fractions batch reports referring to (part of) the same production
have the same identification number. The progressive number automatically assigned to the batch
report can be modified from Plant's data - Production from the System menu group.
Docket: if the delivery docket feature is available, and for the production which generated the
batch report the system printed a delivery docket, here you can see its identification number.
Client: if the delivery docket feature is available, the client receiving th delivery is shown.
Destination: if the delivery docket feature is available, the address of the delivery destination is
shown.
Truck: if the delivery docket feature is available, the code of the truck used for the delivery is
shown.
Formula: code of the formula used for the production.
Order: if the delivery docket feature is available, the number of the delivery order used for the
production is shown.

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Batch report detail information

For seeing the data contained in a specific batch report, open the report page (by double clicking
on the report line on the list).
If the report comes from a manual dosage, and not all the reference data have been entered, the
standard data editing functions are available.
Header
Mix Id: progressive number for batch report identification, automatically assigned when the report
is generated. The single cycles or fractions batch reports referring to (part of) the same production
have the same identification number. The progressive number automatically assigned to the batch
report can be modified from Plant's data - Production from the System menu group.
Start date and time: date and time when the production begun.
End date and time: date and time when the production ended (generation of the report).
Request: number of the production request line used for this automatic production.
Cycle: cycle number belonging to the same production request.
Batches: fraction of the cycle belonging to the same production request. If the report is a summary
batch report, here is shown the total number of fractions completed for the production cycle.

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Produced m3: cubic meters production to which the report refers. For example, for a 12.00 m3
production split in 2 fractions of 6.00 m3, the Produced m3 entry will be 6.00 m3 (for fractions, or
12.00 m3 for summary).
Order: number of the delivery order used for the production.
Formula: code of the formula used for the production.
Product: code of the product referring to the formula used for the production.
Total m3: total requested cubic meters for the total production to which the batch report refers. For
example, for a 12.00 m3 production split in 2 fractions of 6.00 m3, the Total m3 will be12.00 m3.
Rck, Slump, Exposure class, Max diameter: technological characteristics of the formula, see
detail for Rck, Slump, Exposure class, Max diameter.
Cycles no.: total number of cycles necessary for completing the total requested production. For
example, for a 15.00 m3 production split in 5 cycles of 3.00 m3, the entry Cycles no. will be 5.
m3 per cycle: cubic meters produced on each cycle necessary for completing the total requested
production. For example, for a 15.00 m3 production split in 5 cycles of 3.00 m3, the entry m3 per
cycle will be 3.00.
Operator: identification code of the operator on duty when the production to which the batch report
refers was carried out.
Returned m3: only for truck mixer loading. Quantity of material already present in the truck before
starting the production, returned from the previous delivery carried out with the same truck.
Returned docket: only for truck mixer loading. Number of the delivery docket to which the
returned quantity specified in the Returned m3 entry refers.
Returned formula: only for truck mixer loading. Code of the formula used for producing
the returned quantity specified in the Returned m3 entry.
Docket: only for truck mixer loading. if the delivery docket feature is available, and for the
production which generated the batch report the system printed a delivery docket, here you can
see its identification number.
Client: only for truck mixer loading. Company name of the client for which the production has been
ordered.
Destination: only for truck mixer loading. Destination address of the client where the produced
material is delivered.
Truck: only for truck mixer loading. Code of the truck used for the delivery of the produced
material.

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Components detail (the components rows highlighted in red, refers to dosages with tolerance
errors)
Component: code of the component dosed or foreseen for the dosage.
Description: description of the component dosed or foreseen for the dosage.
U: unit of measurement.
Design: theoretical requested quantity from the formula, for 1 cubic meter.
Batch: theoretical requested quantity adjusted for the total cubic meters to be produced.
Absorption %: percentage of moisture absorption for the component. See notes about the method
for calculating the moisture compensation and the characteristics of the component.
Moisture %: percentage of detected moisture for the component (or active moisture, according to
the system configuration). This column can also show the water contained in the component. The
compensation on the water to be dosed, and on the actual quantity of component to be dosed
depending on the component's moisture, is calculated on the active moisture:
Active moisture % = Moisture % - Absorption %.
The marker M (manual) or A (automatic) shown after the moisture percentage indicates if the value
is detected Automatically from a probe or it is entered Manually. See notes about the method for
calculating the moisture compensation.
Correct: theoretical quantity to be dosed according to the component's moisture compensation
(this value differs from Batch normally only for aggregates and water, or because of dosage errors
compensation).
Actual: actually dosed quantity for the component.
Manual: manually added quantity, by the operator.
Var: absolute difference between Correct and Actual.
Var %: percentage difference between Correct and Actual.
H2O contained: quantity of water contained in the actually dosed component. See notes about the
method for calculating the moisture compensation and water contained in the component.
Actual/m3: actual quantity (Saturated Surface Dry for aggregates) for the component, referred to 1
cubic meter (when there are no tolerance differences, it should match Design).
°C : temperature of the component at dosage time, if foreseen.

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Footer detail
TOTAL WEIGHT: summary weight calculated from the quantities of single components for Design,
Batch, Correct, Actual, H2O Contained, Actual/m3.
Aggregates moisture: quantity of water contained as moisture in the dosed aggregates. See
notes about the method for calculating the moisture compensation.
Water in components: quantity of water contained in the dosed components (not aggregates).
Dosed water: quantity of water actually dosed.
Water in truck: quantity of water entered as water already in the truck when starting the
production.
Trim water: only for mixer. Quantity of water manually entered for mix moisture correction.
Total water: sum of all water quantities described in the previous fields.
Design W/C ratio: Water/Cement ratio specified in the formula, followed by the tolerance % and
the validity range. note
Actual W/C ratio: actual Water/Cement ratio, calculated on the basis of the actually dosed
quantities in the final mix. note
Environment temperature: environment temperature at load start.
Mixer temperature: temperature detected inside the mixer, at mixing time.
Mixer absorption: mixer absorption, in kW, at the end of the mixing time.
Cycle time: total duration of the production cycle, from the moment the production is started to the
generation of the batch report.
Plant cycle: it makes sense only if the mixer is used. Duration of the production cycle, from the
moment the discharge of the component into the mixer starts, to the end of the discharge of the
mixed material.
Water inlet time: time when the water got in contact with the cement in the produced mix.
Discharge time: only if the mixer is used. Duration of the discharge of the material from the mixer.
Mixing time: only if the mixer is used. Duration of the mixing of the material in the mixer.

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Finding a batch report

For finding a specific batch report inside the list, click on to open the find function.
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Filtering the batch report list

For applying a filter on the batch reports list, in order to show only specific reports in the list (i.e. the

ones referring to a specific formula and/or issued on a specific time frame), click on for
entering the filter function.
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Deleting a batch report

For permanently removing a batch report, select the line containing the desired batch report then

click on , then confirm the deletion.

It is possible to remove more batch reports from the list at the same time, using the multiple
selection mode.

It is moreover possible to delete more daily records simultaneously from the list, by clicking on

and entering the date range for which to delete the records.

Remember that statistics and sums are calculated on the files containing batch reports
and delivery dockets (if present). After removing batch reports and dockets from the files,
the sums could turn out incomplete.
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Printing a batch report

For printing the batch reports list click on : when the print preview is shown, click on .

For printing the data of a specific batch report, open the batch report page (by double clicking on

the report from the list), then click on .

The batch report print mode is defined by the settings of the function Genyx configuration - Print
of the System menu group.
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Exit and return to main menu

For exiting the batch reports list and returning to the main menu, click on .
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Consumptions
Access to this function could be limited by operator's access rights.

For accessing the components/raw materials consumptions, click on the icon from the
main menu in the Production group.

Here you can check the components/raw materials consumptions recorded during the production.

Available functions: Filter - Find - Delete - Print - Export - Exit

Consumptions information
The consumption situation displayed when entering the page is the one updated to the current date
and, for each component/raw material used during production , it is updated automatically every
time that a component is dosed both in automatic production and on manual dosage.

Each component's consumption line is automatically created when a component is dosed, for
every production day, therefore it is necessary to dose at least one component to activate the
consumption recording on the current day.

On every dosage, the consumed quantity for each component is increased according to the dosed
quantity.

The data available for every component consumption are the following.
Date: recording date.
Component: identification code of the component, from the components/raw materials file.
Description: component description, from the components/raw materials file.
Automatic consumption: component quantity dosed during automatic production.
Manual consumption: component quantity dosed during manual extraction.
Total consumption: total used quantity of the component (automatic + manual).
Uom: unit of measurement for the component.

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Filter
It is possible to filter the displayed component consumptions shown in the list, in order to list only
the consumptions for a specific group of raw materials/components.
To activate the filter showing all consumed components since the beginning of use of the plant,
click on any of the following buttons.

Show all components (no

filtering)

Show only aggregates

Show only cement

Show only water

Show only admixtures

Show only colors

Show only additions

Show only aggregates mixes

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Finding consumptions
When the consumption page is opened, normally the list shows the components consumptions
for the current production day. If the consumption page is empty, this means that no
components dosages have been done for the current day.

It is possible to show consumptions for other days, or time frames, by clicking on then
specifying the date interval and, if necessary, the specific component code to search for.

When the list show consumptions for more than one production days, the consumptions for each
component are grouped and summed up, in order to show a single entry in the list. In this case, the
Date column is empty. The analisys time frame is shown on the page header.
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Deleting consumptions
For permanently removing the consumption records for a component, click on the line to be

removed, then click on , and finally confirm the deletion.

It is possible to remove more records from the list at the same time, using the multiple selection
mode (in any case within the currently shown list).

It is moreover possible to remove from the list more daily consumption records by clicking on

then specifying the date interval for which to remove the consumptions.
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Printing consumptions

For printing the components/raw materials list, click on : when the print preview is shown,

click on .
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Exporting consumptions
For exporting the consumption list towards an external software, generating the text file according
to Onyma specifications, to bring it for example to the PC where the accountancy software is

installed, click on . Select the folder where you want to generate the text file containing the

exported consumptions, and finally click on to start the export.

up

Exit and return to main menu

For exiting the consumptions list and returning to the main menu, click on .
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Statistics
Access to this function could be limited by operator's access rights.

For accessing the statistics function, click on from the main menu in the Production
group.

Here one can obtains some reports querying the data collected by Genyx during production. The
results are shown on the monitor, as graphical histograms.

Remember that statistics and sums are calculated on the files containing batch reports
and delivery dockets (if present). After removing batch reports and dockets from the files,
the sums could turn out incomplete.

Available functions: Formulas/Clients - Formulas - Components/Clients - Components - Trucks -

Trucks deliveries - Clients - Products - Print - Exit

Report for Formulas/Clients

Available only if the delivery docket feature is enabled. By clicking on , for each client you
can see, for any specified time frame, the formula types delivered by the plant.

To get the report, enter the time frame then click on .

For changing the selected client, click on the client code/company name listed on the left side of

the page, then click again on .

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Report for Formulas

By clicking on you can see, for any specified time frame, the produced quantities for each
formula.

To get the report, enter the time frame then click on .

You can also set a filter on specific formulas, by entering the technological parameters Aggregates

max. diameter, Rck, Slump, Exposure class, then clicking on .

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Report for Components/Clients

Available only if the delivery docket feature is enabled. By clicking on , for each client you
can see, for any specified time frame, the components/raw materials used for the production
ordered for the specific client.

To get the report, enter the time frame then click on .

For changing the selected client, click on the client code/company name listed on the left side of

the page, then click again on .

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Report for Components

By clicking on you can see, for any specified time frame, the components/raw materials used
for the production.

To get the report, enter the time frame then click on .

For changing the selected component, click on the box for defining the component type on the top

left side of the page, then click on .

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Report for Trucks

By clicking on , for each truck you can see, for any specified time frame, the transported
cubic meters.

To get the report, enter the time frame then click on .

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Report for Trucks deliveries

By clicking on , for each truck you can see, for any specified time frame, the number of
deliveries.

To get the report, enter the time frame then click on .

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Report for Products/Clients

Available only if the delivery docket feature is enabled. By clicking on , for each client you
can see, for any specified time frame, the products delivered from the plant.

To get the report, enter the time frame then click on .

For changing the selected client, click on the client code/company name listed on the left side of

the page, then click again on .

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Report for Products

Available only if the delivery docket feature is enabled. By clicking on , for each product you
can see, for any specified time frame, the products delivered from the plant.

To get the report, enter the time frame then click on .

For changing the selected product, or defining a filter on specific characteristics of the product, use

the entries on the left side of the page, then click on .

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Printing

For printing the report page currently on the screen, click on : when the print preview is

shown, click on .

Before printing a displayed page, remember to define the time frame, then to click on .
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Exit and return to the main menu

For exiting the statistics page and returning to the main menu, click on .
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Suppliers
Access to this function could be limited by operator's access rights.

For accessing the suppliers file, click on the icon from the main menu in the Production
group.

Here one can define the suppliers from which receiving the components/raw materials used for the
production.

Available functions: Edit - New - Find - Delete - Print - Import - Export - Exit

Supplier information
For each supplier one can define various information for accountancy purposes. Hereinafter you
will find the compulsory ones and the most importants:

Code: unique supplier identification code. It is compulsory and must be unique.

Company name: name of the supplier company. It is compulsory..

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Supplier editing
For editing the data of a supplier, select the desired supplier from the list, and double click on it
with the mouse's left button. The edit page which opens contain the current supplier. Inside the page
you can use the standard functions for data editing.

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Inserting/creating a new supplier

For inserting/creating a new supplier, click on : the edit page which opens is blank. Inside the
page you can use the standard functions for data editing.
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Finding a supplier

For finding a specific supplier inside the list, click on to open the find function.
This list has a quick find feature linked to the code. Without clicking any button, just type the code
of the item you need to find and the cursor will position itself on the first line/code matching the
typed characters.
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Deleting a supplier
For permanently deleting a supplier from the list, select the line containing the desired supplier

and click on , then confirm the deletion.

It is possible to remove more suppliers from the list at the same time, using the multiple selection
mode.

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up

Printing a supplier

For printing the suppliers list click on : when the print preview is shown, click on .

For printing the data of a specific supplier, open the desired supplier page (double clicking on the

supplier line on the list), then click on

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Importing suppliers
For importing a suppliers list from an external software, generate the text file according to Onyma

specifications, bring it to the PC on which Genyx is installed, then click on . Select the folder
where the text file containing the suppliers to be imported is.
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Exporting suppliers
For exporting the suppliers list towards an external software, generating the text file according
to Onyma specifications, to bring it for example to the PC where the accountancy software is

installed, click on . Select the folder where you want to generate the text file containing the
exported suppliers.
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Exit and return to main menu

For exiting the suppliers list and returning to the main menu, click on .
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Raw materials reception

Access to this function could be limited by operator's access rights.

For accessing the components/raw materials reception file, click on the icon from the
main menu in the Production group.

Here one can record the raw material reception when receiving a delivery from a supplier.

Available functions: Filter - Edit - New - Find - Delete - Print - Exit

Raw material reception information

Every time that one component/raw material is delivered to the plant, one can record the reception
specifying various information for accountancy purposes. Hereinafter you will find the compulsory
ones and the most importants.

Component information
Code: identification code of the component received. It is compulsory and it must be selected

among the components defined for the plant: click on and find the desired component. Inside
the component selection page, the standard data editing functions can be used.
Description: description of the received component. Automatically inserted by Genyx when
selecting the component code, but you can also change it.
Quantity: quantity of received component. The entered quantity is automatically added to the
quantity currently in stock for the specified component.
In which extractor?: one can specify the hopper/silo/tank (generally "batcher") where the receive
component is loaded. The batcher must be selected among the ones assigned to the component

code: click on and find the desired batcher. Inside the batcher selection page, the
standard data editing functions can be used. If a batcher is selected, the entered quantity is
automatically added to the quantity in storage for the selected batcher as well.
Supplier information
Code: identification code for the supplier delivering the received component. It must be selected

among the suppliers defined for the plant: click on and find the desired supplier. Inside
the supplier selection page, the standard data editing functions can be used.
Company name: description of the supplier. It is automatically inserted by Genyx when
the supplier code is selected.
Delivery doc N°: number of the delivery note received with the raw material.
Notes: notes referring to the delivery.

The entered quantity is automatically added to the quantity currently in stock for the specified
component. If a batcher is selected, the entered quantity is automatically added to the quantity
in storage for the selected batcher as well.

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Filter
It is possible to filter the entries shown in the raw materials reception list, by using the filter buttons,
in order to see only the receptions referring to a specific group of raw materials/components.
For activating a filter and show all receptions of raw materials/components since the beginning of
use of the plant, click on any of the following buttons.

Show all components (no

filter)

Show aggregates only

Show cement only

Show water only

Show additive only

Show color only

Show addings only

Show aggregates mixes only

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Editing a raw material reception record

For editing the data of a raw material reception record, select the desired record from the list, then
double click on it with the mouse's left button. The edit page which opens contain the currently
entered data: after creating a new record, only the received component quantity and the supplier
information can be changed. Inside the page you can use the standard functions for data editing.

up

Inserting/creating a new raw material reception record

For inserting/creating a new record of a raw material reception, click on : the edit page which
opens is blank. Inside the page you can use the standard functions for data editing.
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Finding raw materials reception records

For finding a specific raw material reception record inside the list, click on to open the find
function. Enter the component code and the time frame for the search.
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Deleting a raw material reception record

For permanently deleting a raw material reception record from the list, select the line containing

the desired record and click on , then confirm the deletion. The deletion of a reception record
can also delete the received quantity from the stock:
click on "Only in reception" for deleting the reception record only, leaving the stock as it is;
click on "Also from stock" for deleting the reception record and subtracting the received
quantity from the stock.

The deleted reception record does not affect the specific storage quantity for the
hopper/silo anyway.

It is possible to remove more reception records from the list at the same time, using the multiple
selection mode.
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Printing raw material reception records

For printing the raw materials reception records list click on : when the print preview is shown,

click on .

For printing the data of a specific raw material reception record, open the desired record page

(double clicking on the record line on the list), then click on

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Exit and return to main menu

For exiting the raw materials reception records list and returning to the main menu, click on .
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Stock
Access to this function could be limited by operator's access rights.

For accessing the raw materials stock file, click on the icon from the main menu in the
Production group.

Here one can check the stock of raw materials/components used for the production.

Available functions: Filter - Edit - Find - Delete - Print - Exit

Stock information
The shown stock situation is updated to the current date and, for each component used during the
production, it is updated
automatically:
every time a component/raw material is received and recorded in raw materials reception
every time a component quantity is dosed, both in automatic production and on manual
dosage.
directly:
every time the stock page for a specific component is edited.

Each component's stock situation line is automatically created when entering the first reception
record, therefore it is necessary to create at least one raw material reception record to activate the
stock situation.

Upon every reception record, the received quantity is added to the quantity currently in stock.

Upon every dosage, the extracted quantity is subtracted to the quantity currently in stock. If the raw
materials receptions are not recorded on a regular basis, the quantities in stock may become
negative.

The available data for each component/raw material are the following.
Code: component identification code. Automatically generated on the first raw material reception
recording, taken from the components/raw materials file.
Description: description of the component. Automatically generated on the first raw material
reception recording, taken from the components/raw materials file.
Quantity: quantity of material currently in stock.

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Filter
It is possible to filter the entries shown in the stock list, by using the filter buttons, in order to see
only the stock referring to a specific group of raw materials/components.
For activating the filter, click on any of the following buttons.

Show all components (no

filter)

Show aggregates only

Show cement only

Show water only

Show additives only

Show colors only

Show addings only

Show aggregates mixes only

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Stock editing
For editing the stock data of a component/raw material, select the desired record from the list, then
double click on it with the mouse's left button. The edit page which opens contain the current data:
only the quantity of component currently in stock can be modified. Inside the page you can use the
standard functions for data editing.

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Finding a stock record

For finding a specific stock record inside the list, click on to open the find function. Enter the
component code for the search.
This list has a quick find feature linked to the code. Without clicking any button, just type the code
of the item you need to find and the cursor will position itself on the first line/code matching the
typed characters.
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Deleting a stock record

For permanently deleting a stock record from the list, select the line containing the desired record

and click on , then confirm the deletion.

It is possible to remove more records from the list at the same time, using the multiple selection
mode.
up

Printing the stock

For printing the raw materials stock page click on : when the print preview is shown, click on

up

Exit and return to main menu

For exiting the raw materials stock page and returning to the main menu, click on .
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Files
Data storage
Access to this function could be limited by operator's access rights.

The Files group contains some functions that are useful for saving and restoring configuration
and/or production data.

The files handled by those procedures are:

File name Description

TOTAL Backup dd-mm-yyyy.gkp Backup of all production data (components, formulas,
clients, products, consumptions, delivery notes, batch
reports, etc.), for day dd-mm-yyyy.
Dockets dd-mm-yyyy -- DD-MM- Backup of delivery notes from date dd-mm-yyyy to date
YYYY.gkp DD-MM-YYYY
Reports dd-mm-yyyy -- DD-MM- Backup of batch reports and consumptions from date
YYYY.gkp dd-mm-yyyy to date
DD-MM-YYYY
Common dd-mm-yyyy.gkp Backup of components, formulas, clients, products, etc.
for day dd-mm-yyyy.
GenYx.Plc Plant configuration parameters (scales calibration,
batchers setup parameters, etc.)
Sequenza.Plc Scales discharge sequences

The generated files are "compressed" (to save disk space), therefore cannot be directly read from
Windows, but they have to be restored, when necessary, from Genyx.

Assisted data backup

Click on to start the assisted backup procedure, then follow the on screen instruction
to proceed.
Take duly note of the destination disk folder where you made the backup, in order to find and move
the files in a storage place safer than the PC hard disk, for example on a CD-ROM, in order
to restore them in case of need.

It is strongly advised to take a complete backup of all data handled by Genyx at least once
every week.

Assisted data restore

Click on to start the assisted restore procedure, then follow the on screen instruction
to proceed. You can select if you want to overwrite or keep the data already existing in the main
Genyx database.

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Plant configuration data backup

Click on to start the assisted backup procedure for the plant configuration data (scales
calibration, batchers setup parameters, dosage sequences, etc.).
Take duly note of the destination disk folder where you made the backup, in order to find and move
the files in a storage place safer than the PC hard disk, for example on a CD-ROM, in order
to restore them in case of need.
It is strongly advised to take a backup of the plant configuration data at least once after
completing the plant first start-up (commissioning), and once again after each major
mechanical or electrical modification.

Plant configuration data restore

Click on to start the assisted restore procedure for the plant configuration data (scales
calibration, batchers setup parameters, dosage sequences, etc.).
If you took a backup of a surely working plant configuration, you can restore it in case of need.
WARNING: the restore procedure overwrites the current plant configuration. Restore only if you
are absolutely certain of what you are doing and if you are certain that the backup configuration is
valid!

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System
Genyx configuration
Access to this function could be limited by operator's access rights.

For accessing the general configuration parameters of the Genyx, click on the icon
from the main menu in the System group.

Here one can define some software operation parameters, in order to adapt it to the specific user's
need.

Available functions: General - Print - Paths - Save - Exit

General

For accessing the general parameters configuration, click on :

General Data
Enable operator password: if ticked (enabled), at Genyx start up the operator access password
will be requested.

Sound effects
Sound card + speakers: if ticked (enabled), Genyx will signal alarms and acoustic reminders
through the PC audio system.

PLC

Reset PLC request: click on to Reset the automation PLC memory. This function can be
useful to solve some problems on the PLC operation.
After the PLC Reset, Genyx must transfer all configuration data and setup parameters for scales,
batchers, etc. to the PLC, therefore for a few seconds the plant status will be PLC FAULT. Wait for
the system to return to MANUAL status. At the end of the PLC Reset procedure, all settings
for components exchange are canceled.
Warning: this operation resets all memories for the production in progress, therefore it will be
probably necessary to remove all materials contained in the scales of the plant, after the PLC
Reset, in manual operation.
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Print
For accessing the configuration of the printing mode for delivery dockets and batch reports, click

on :

Dockets printing setting

Print when: select when the delivery docket has to be printed.
by user = manually, only upon explicit request of the operator, opening it and printing it from
the delivery dockets file.
at the beginning of production = automatically, when the production starts (if
the compulsory information have been correctly and completely entered - see docket
status).
at the end of production = automatically, at the end of the truck load, that is at the end of
the automatic production cycle (if the compulsory information have been correctly and
completely entered - see docket status).

Docket type: select the print mode for the delivery docket.
docket on form-paper (only values) = for printing on dot matrix impact printers, on pre-
printed continuous module, with multiple copy chemical paper. In this case, it is necessary
to properly set up the printing positions for the various entries, by row/column coordinates.
docket printed completely = for printing on InkJet or Laser printers, on white normal paper.
Obviously, in this case, the complete form including logo, header, etc. will be printed
together with the variable entries. It is necessary to properly set up the printing positions
for the various entries on the background image, using the graphical set up function.
graphic printing without form = for printing on InkJet or Laser printers, on pre-printed paper.
Only the variable entries will be printed on the pre-printed form. It is necessary to
properly set up the printing positions for the various entries on the background image,
using the graphical set up function.

Printer to be used: select the printer to be used for delivery dockets, only for graphic printing.
Make sure the printer is properly installed with the right Windows driver before printing.

Number of copies: enter the number of copies to be printed each time a delivery docket is
printed, only for graphic printing.

Font: specify the print font size for the variable entries to be printed in the delivery docket, only
for graphic printing.

Simulate: tick (enable) if you do not want to actually print the delivery docket, but only simulate the
printing. WARNING: enable only for test purposes and under the supervision of Onyma technical
service.

LPT: select the parallel printer port (LPT1, LPT2, etc.) to which the dot matrix impact printer is
connected, for printing delivery dockets, only for printing in text mode.

Horizontal: tick (enable) if you need to print the variable entries of the delivery docket, in graphic
printing without form mode, on a pre-printed form, horizontally oriented.

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Report printing setting

Print when: select when the batch report has to be printed.
by user = manually, only upon explicit request of the operator, opening it and printing it from
the reports file.
all reports = automatically, at the end of every production cycle/fraction, including the
summary batch reports grouping many individual cycles/fractions batch reports.
only summary reports = automatically, at the end of every completed load, that is only the
summary batch reports grouping many individual cycles/fractions batch reports.
only partial reports = automatically, at the end of every production cycle/fraction, excluding
the summary batch reports grouping many individual cycle/fractions batch reports.

Report type: select the print mode for the batch report.
docket on form-paper (only values) = for printing on dot matrix impact printers. In this case
the batch report is printed in text mode.
graphic report printing = for printing on InkJet or Laser printers, on normal white paper.
Obviously, in this case, the complete form including logo, header, etc. will be printed
together with the variable values.
graphic printing without form = for printing on InkJet or Laser printers, on pre-printed form
paper or normal white paper. Only the variable values of the batch report, together with
spacing and simplified separators, are printed.

Printer to be used: select the printer to be used for batch report printing, only for graphic
printing. Make sure the printer is properly installed with the right Windows driver before printing.

Font: specify the print font size for the variable values to be printed in the batch reports, only
for graphic printing.

LPT: select the parallel printer port (LPT1, LPT2, etc.) to which the dot matrix impact printer is
connected, for printing batch reports, only for printing in text mode.

Horizontal: tick (enable) if you need to print the variable entries of the batch report, in graphic
printing without form mode, on a pre-printed form, horizontally oriented.
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Paths

For accessing the configuration of the folders for import/export file exchange, click on .

Here you can define the folders to be used when automatically exchanging information with other
softwares, for production and reporting:

Import/Export Configuration
Folder used for production ASCII file: when defined, allows to automatically import in Genyx
the Production schedule. The exchange file must match the format defined by Onyma
specifications.

Folder used for report ASCII file: when defined, Genyx automatically creates a file containing
the batch reports, updating the file at every production cycle. The exchange file format is defined
by Onyma specifications.

Folder used for dockets ASCII file: when defined, Genyx automatically creates a file containing
the delivery dockets, updating the file at every printed docket. The exchange file format is defined
by Onyma specifications..
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Data Backup

For accessing the configuration of the automatic data backup function, click on .

Here you can enable the daily automatic backup function, defining the backup folders:

Automatic Data Backup configuration

Enable: tick (enable) the box for enabling the automatic backup function.

Path (Save ...): define (compulsory) the folder to which Genyx generates the automatic backup file
(for each data group).

The files created by this procedure are:

File name Description

Dockets dd-mm-yyyy -- DD-MM- Backup of delivery dockets from date dd-mm-yyyy to
YYYY.gkp date DD-MM-YYYY
Common dd-mm-yyyy.gkp Backup of common data: formulas, components,
clients, products, etc.
Reports dd-mm-yyyy -- DD-MM- Backup of batch reports and consumptions from date
YYYY.gkp dd-mm-yyyy to date DD-MM-YYYY

The generated files are "compressed" (to save disk space), therefore cannot be directly read from
Windows, but they have to be restored, when necessary, from Genyx.

The automatic backup of the selected data is activated on date change (midnight), or upon Genyx
start up after date change.
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Exit, saving modifications, returning to the main menu

To confirm the modifications made, exiting and returning to the main menu, click on .
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Exit, without saving modifications, returning to the main menu

To exit without confirming the modifications made, returning to the main menu, click on .
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Communication configuration
Access to this function could be limited by operator's access rights.

For accessing the configuration parameters of the communication and data exchange between the

Genyx PC and the automation PLC, click on from the main menu in the System
group.

Here one can define the communication protocol parameters, in order to adapt it to the installation
type or computer available.

WARNING: modify the communication parameters only under the supervision of trained
personnel. A wrong setup could prevent the proper operation on the plant.

For obtaining information on the Genyx/PLC communication status, check the icon located
in the bottom right corner of the plant mimic:
if there are moving coloured lines, the communication is running;
if the icon is static, with nothing moving the communication is not running.

Communication monitor

Selected port: serial communication port currently selected for the link with the PLC.
Plc 1 status: PLC communication status. Check together with Queue Status.
Queue status (com-rec-res): status of the logical communication queues. The communication
statuses are:

STATUS Queue Description Action

status
(com-rec-
res)
data exchange in
changing progress, the link with no action required, operations
IDLE <-> RX/TX
numbers the PLC is valid and normal
active
- check connection cable,
- check connection with the
SYNCH <-> link with PLC not
0-0-0 serial port currently selected,
ABORT established
- check MS485 converter
- check PLC CPU card
Queue serial port is not - try and select a different serial
IDLE
Label available on the PC port

Polling: when operations are normal, beside the message you should see a small blinking block. If
not try and select a different serial port on the PC.

The other information such as Command/Priority Queue, Rx Monitor, TX Monitor, are useful under
the supervision of Onyma technical personnel.

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Available functions

COM Ports: click on to select a different serial port on the PC. After selection, Genyx must be
restarted. Make sure the connection cable between the PC and the PLC is plugged into the
selected serial port.

Exit: click on to exit.

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Delivery Docket Printing Configuration

Access to this function could be limited by operator's access rights.

For accessing the configuration and customization of the delivery docket to be printed and sent
along with the transportation of the materials produced/sold through the plant, click on the icon

from the System group in the main menu.

The docket configuration function allows:

set up the delivery docket form and entries position in graphic mode (for laser or ink-jet
printers) or text mode (for dot matrix impact printers)
define the background image for the delivery docket editing page;
define the data entries to be shown when editing/printing a docket;
define the editing/printing characteristics of the data (length, decimal points, background
colour, font, display only, modify after printing);
move or delete data entry into the page;
repeat the printing a data entry into the page;
assign a conditioned printing to a data entry;
save and reload a printing configuration;
print a test page for the current configuration.
For assigning the printer to be used for the delivery dockets and the preferred printing
mode (format, number of copies, etc.), see section Genyx configuration - Print.

Configuration mode
With any available delivery docket printing mode, it is always necessary to configure the data to
show (and then print) when editing a delivery docket during production: only the data which are
present and visible on the background image in the delivery docket printing configuration can be
printed!
The delivery docket configuration modes are two.

1. Clicking on you access the graphic configuration mode which allows:

to define which data can be edited and printed;
to define the position of the data entries on the docket page, when graphic mode printing is
selected.

2. Clicking on you access the text configuration mode, by row/column, which allows:
to define the printing coordinates by row/column on the docket printing page, when text
mode printing is selected.
to define conditioned printing or data entry associations for the repeated data on printout.
In the text configuration list of available data, those highlighted in blue are the ones configured for
editing/printing, as shown on the graphic configuration page.
Some data must be compulsorily defined and entered, in the delivery docket, in order to print it.
See note.

If the characteristics of the requested delivery docket (form, size, etc.) have not been clarified to
Onyma before delivery/commissioning of the Genyx, the standard form foresees practically all

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data entries which could be necessary to edit/print in the docket, therefore it is warmly
recommended to customize the page as described hereinafter.

Onyma standard delivery docket sample, with all necessary data entries configured and printed

Selecting the background image of the delivery docket

Click on for selecting the graphic configuration mode: click on to select the image file
to be used as background for the delivery docket, on which to enter the variable data. It is
recommended to scan the actual paper form, so the operator can see on the screen what exactly
will be printed.
The image formats compatible with the Genyx interface are:
&bull; JPG or JPEG : (Joint Photographic Experts Group) a compressed image format.
&bull; BMP : (Bitmap) a very common Windows image format.
&bull; WMF : (Windows Metafile) a graphic format for Windows images, often used for printouts.
&bull; EMF : (Enhanced Metafile) like WMF.

Once selected, the image should appear on the screen page background, in order to allow the
configuration of the data entries directly on it.
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Selecting and configuring the data for editing/printing

Click on for selecting the graphic configuration mode: click on to see the
available data list among which selecting what can be entered/printed in the docket.
To insert a data entry in the delivery docket, select it from the Fields list by clicking on it, keeping
the left mouse button pressed, dragging the data from the list to the docket page, then positioning it
on the desired location, and finally releasing the mouse button.
On the docket image, the data entry appears like a code (such as &ldquo;I2I2I2I2I2I22I2I&rdquo;,
"H7H7H7H7H&rdquo;, etc). If, dragging the data on the docket image, the data does not appear,
this means it is already present somewhere on the page: try and find it.
For repeating a data entry in the docket, use repeated fields.
The "drag and drop" operation must be done for all data entries needed for editing/printing in the
docket, whatever the selected printing method (text or graphic).

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Moving a data entry

Click on the data entry code on the docket image (code like &ldquo;I2I2I2I2I2I22I2I&rdquo;,
"H7H7H7H7H&rdquo;, etc) then, keeping the left mouse button pressed, drag the data to the new
desired position, and finally release the mouse button.
Note that, every time the mouse cursor is moved on a data entry code on the docket image, the
X.Y coordinates of the data position are shown in the bottom right corner of the page. These
coordinates represent the distance of the top left corner of the data entry field, from the top left
corner of the docket page (assigned to coordinates 0.0). If you want to align two data entires
(horizontally or vertically), while moving a data check the coordinate (X and/or Y) and make it
match with the desired one/s.
Aligning the data entries is important for keeping the correct tab order, that is, defining the
sequence according to which the active editing cursor will jump from one data to the next, every
time the Invio (or Enter) key is pressed while editing the docket.

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Deleting a data entry

Click on the data entry code on the docket image (code like &ldquo;I2I2I2I2I2I22I2I&rdquo;,
"H7H7H7H7H&rdquo;, etc) with the right mouse button. On the context menu that opens, click on
Delete. The data should disappear from the docket.

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Modifying the length of a data entry

For modifying the length of a data entry, to adapt it to its position on the docket image (and for the
printout as well in graphic printing mode), click on the rightmost end of the data entry code on the
docket image (code like &ldquo;I2I2I2I2I2I22I2I&rdquo;, "H7H7H7H7H&rdquo;, etc) then, keeping
the left mouse button down, move the cursor (which should look like a double pointed arrow) to the
right/left until reaching the desired length.

For trimming the data length in text printing mode, click on for selecting the text configuration
mode, by row/column.
Locate the data for which you need to change the printing length, then click on its line over
the Length column, and finally type in the desired length in number of characters.
Clicking over the Offset column, you can define the printing start position for the data.
Example 1: you need to print only the 2 initial characters of data D0 (Workability/Slump). Insert

data D0 in any position of the docket, then click on and, over the D0 line, click on Length
column and type in the number 2. Click then on Offset column and type in the number 0.
Example 2: you need to print 10 characters of data D1 (Exposure class), beginning from the 4th

character of the data. Insert data D1 in any position of the docket, then click on and, over the
D1 line, click on Length column and type in the number 10. Click then on Offset column and type
in the number 4.

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Modifying the decimal digits number for a numerical data entry

Click on for selecting the text mode configuration, by row/column.

Locate the data for which you need to change the number of decimal digits (this operation makes
sense only for numerical data). Click on the line containing the desired data entry, over the dec no.
column, then type in the required number of decimal digits.
This operation affects both text mode printing and graphic mode printing.

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Making a data entry visible/editable but not printable

Click on the data entry code on the docket image (code like &ldquo;I2I2I2I2I2I22I2I&rdquo;,
"H7H7H7H7H&rdquo;, etc) with the right mouse button. On the context menu that opens, click
on DO NOT print. The background of the box surrounding the data entry field should turn to cyan
colour, showing that the data can be edited modified while creating/modifying a docket, but that the
data will not be actually printed. Note: it could be necessary to click on a different data entry, then again on the subject data
entry, to see the effect of the operation.

For enabling the printing of a disabled data, repeat the above operation, removing the tick sign
beside DO NOT print in the context menu.

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Making a data editable after printing/recording the docket

Normally, every data entry in the delivery docket can be modified only before validating the docket,
that is before recording (saving) or printing the docket.
In order to allow modification of a specific data, click on the data entry code on the docket image
(code like &ldquo;I2I2I2I2I2I22I2I&rdquo;, "H7H7H7H7H&rdquo;, etc) with the right mouse button.
On the context menu that opens, click on Modify ALWAYS.
For preventing modification of a data after docket printing/recording, repeat the above operation,
removing the tick sign beside Modify ALWAYS in the context menu.

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Customizing the background colour of a data entry

Selecting as background image for the delivery docket a Bitmap (.BMP) file, and in this case only,
you can assign a background colour other than white to each data entry, in order to adapt it to the
background colour of the docket form area on which the data entry is positioned.

Click on the button then click on a point of the docket image containing the desired colour. If
the colour selection is correct, a small box in the bottom right corner of the page (beside the X.Y
coordinates of the cursor) should show the selected colour.
For assigning the selected colour to the desired data, click on the data entry code on the docket
image (code like &ldquo;I2I2I2I2I2I22I2I&rdquo;, "H7H7H7H7H&rdquo;, etc) with the right mouse
button. On the context menu that opens, click on Assign color. The background of the box
surrounding the data entry field should turn to the the assigned colour. Note: it could be necessary to click on
a different data entry, then again on the subject data entry, to see the effect of the operation.

If the image file containing the delivery docket form is not a Bitmap file, you can proceed as
follows:
1. Generate a copy of the docket image in Bitmap format (practically all image editing
softwares allow saving any image in BMP format).
2. Temporarily select this new Bitmap as background image.
3. Select the colours for the data entries following the above instruction.
4. Re-select the background image from the original file format (other than Bitmap).

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Repeating the printing of a data entry in different positions in the delivery docket page
When you need to print a data in different positions in the delivery note form page, click on
any Repeated fields not yet used, from the list Fields list then, keeping the left mouse button
pressed, drag it on the docket form image, and finally release the mouse button where you want to
see the data.

Click on to select the text mode configuration, by row/column.

Locate the selected repeated field code and click on its line over the Associated column, then
select the data entry code which you need to repeat.
Example: you need to repeat the issue date of the docket in 2 different positions inside the docket
form. Configure the data entry A1 (date) in first position, then the data entry M2 (repeated field) in

the second position. Click on and, on the M2 line, click over the Associated column, and
select the code A1.
For the repeated fields, you can define a printing condition, as for any other data entry. If no
specific condition is assigned to a repeated field, the corresponding data entry is printed according
to the same condition possibly defined for the Associated data entry.

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Assign a conditioned printing to a data entry

When you need to print a data on the delivery docket only in specific cases, for example if another

data has a certain value, after inserting the data in the desired position, click on for selecting
the text mode configuration, by row/column.
Locate the data entry code that you need to condition and click on its line over the Associated
column, then select the data entry code you want to use as "compare" value for the condition (the
associated field can be the same field you need to condition).
On the same line, click on the Condition column and enter the desired "comparison test". The
condition must contain the comparison type and the comparison value. The available choices are:
"Equal to", identified by the symbol =
"Different from", identified by the symbol !
"Greater than", identified by the symbol >
"Less than", identified by the symbol <
For example, for setting the condition "Equal to 001", write =001, while to set the condition
"Different from SENDER", write !SENDER.
Example: you want to print the details of the truck used for delivering the concrete (like the
&ldquo;Company name&rdquo;) only if the transportation is carried out by
a &ldquo;CARRIER&rdquo; (these data are described in the trucks function).
Insert the E8 data entry (Truck Company name) in any position on the docket page, than click on

and, on the line containing E8, click over the Associated column, and finally select code I3
(Transport by).
Again, on the E8 line, click over the Condition column, and type in: =CARRIER.

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There are some condition modifiers, normally used for the repeated fields:
"Ignore the specified condition", identified by the symbol @
"Apply the same condition", identified by the symbol +
"Apply the inverse condition", identified by the symbol -
Example: you need to print the delivered cubic meters (data entry O7) in two different position
according to the code of the delivered product (data entry G5).
Insert data O7 on any position in the docket, then click on it with the right mouse button and
select DO NOT print. Insert where you need them in the docket data entries M2 and M3 (repeated
fields).

Click on and, on the O7 line, click over the Associated column and select code G5 (product
1 code).
Again on the O7 line, click over the Condition column and type in @!POLV for specifying the
condition "Different from POLV", specifying at the same time that the condition must be ignored for
the O7 data entry. The condition defined here will be used by the associated repeated fields, as
described hereinafter.
Over the M2 line, click on the Associated column and select the O7 code. Click over the column
Condition, and write + for specifying the condition "Different from POLV" (inherited from O7), in
order to print M2 only if the condition is satisfied (i.e. the product code is "R25S4X0").
Over the M3 line, click on the Associated column and select the O7 code. Click over the column
Condition, and write - for specifying the inverse condition of "Different from POLV" (inherited from
O7), that is "equal to POLV", in order to print M2 only if the condition is NOT satisfied (i.e. the
product code is "POLV").

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Printing a data entry with a specific character/font

In text mode printing, if you want to print a data with a specific font, maybe different from the one
used for other data, in order to see it better or differentiate it, after inserting the data entry in the

desired position on the docket image, click on to select the text mode configuration, by
row/column.
Locate the data entry code for which you need to assign the specific print font, then click on its line
over the Style column, and finally select the desired mode:
0 - Normal (10 CPI character)
1 - Bold (10 CPI character, bold)
2 - Double width (double width character)
3 - Compresses (17.1 CP character)
You can assign the NORMAL (10 CPI) or COMPRESSED (17.1 CPI) mode to all data entries

simultaneously, by clicking on and selecting the desired mode. In this configuration page,
you can also define the total page length in printing lines.
After modifying the printing character setting, it is advisable to print a test page, for checking the
result: it could be necessary to trim the row/columns coordinates for some data.

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Saving the configuration and exit

After completing the delivery docket printing configuration, remember to save the modifications by

clicking on .

To exit from the configuration, click on .

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Importing/Exporting a configuration file

For loading a configuration already set for a different Genyx installation, in order to restore the
same settings:

in graphic mode, click on and select the file name containing the configuration. The
default file name is Genyx.esb and normally it is located in the folder
C:\Onyma\Genyx\EasyBolla.

in text mode, click on and select the file name containing the configuration. The
default file name is ConfBolle.gnx and normally it is located in the folder
C:\Onyma\Genyx\EasyBolla.

In text mode, you can also export the current configuration, in order to take it to another Genyx

installation. Click on ans define the file name on which you want to export the configuration.

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Printing the test page in graphic mode configuration

In graphic mode, for printing the test page containing the docket image/form and all configured

data entries, in order to check the result of the setting, click on and select the printer to be
used.
The same operation can be done saving the print image (hard copy) on a file, for example to send

it to the Onyma technical service. In this case, click on and assign a file name.

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Printing the test page in text mode configuration

In text mode, for printing the test page containing the docket image/form and all configured data

entries, in order to check the result of the setting, click on and select the PC's parallel port to
be used. Remember that the text mode printing is recommended on dot matrix printers.

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Data entries that can be entered/printed in the delivery docket

The available data entries for configuring the delivery docket are listed hereinafter. The data with
no description are currently NOT used.
The actual content (value) to be printed, if not differently and specifically stated, is usually taken
directly from the delivery docket, as inserted/created by the operator.

A0 Docket Number
Number of the delivery docket. It is normally automatically assigned as progressive number.
A1 Date
Date of creation/printing of the delivery docket.
A2 Time
Time of creation/printing of the delivery docket.
A3 Order Code
Order number/code linked to the production for which the delivery docket is printed (note).
A4 Order Description
Linked order description (note).
A5 Order Note 1
First line of notes written in the linked order (note).
A6 Order Note 2
Second line of notes written in the linked order (note).
A7 Plant: Code
Name/code of the production plant (note).

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A8 Plant: Company Name

Company name of the production plant (note).
A9 Plant: Address
Address of the production plant (note).
B0 Plant: ZIP
ZIP of the production plant (note).
B1 Plant: City
City in which the production plant is (note).
B2 Plant: Phone
Telephone number of the production plant (note).
B3 Plant: VAT/Fiscal code
Fiscal Code / VAT of the production plant (note).
B4 Formula: Code
Code of the formula used for the production (note). This data entry must be always configured
and entered, for printing the delivery docket.
B5 Formula: Characteristics
Description of the formula used for the production (note).
B6 Under load
Difference between the delivered concrete m³ and the minimum load quantity defined for the
destination site selected in the docket. Can be used for charging the difference from the minimum
load to the client (note).
B7 Premixed
Indicates that the production of the mix is made by mixer (wet).
B8 Cement 1: Type
Description of the cement type specified in the used formula (note) (note).
B9 Cement 1: Class
Class of the cement type specified in the used formula (note) (note).
C0 Cement 1: Quantity / m³
Quantity per m³ for the cement specified in the used formula (note).
C1 Cement 2: Type
Description of the second, if any, cement type specified in the used formula (note) (note).
C2 Cement 2: Class
Class of the second, if any, cement type specified in the used formula (note) (note).
C3 Cement 2: Quantity / m³
Quantity per m³ for the second cement, if any, specified in the used formula (note).
C4 Additive 1: Type
Description of the additive specified in the used formula (note) (note).
C5 Additive 1: Quantity / m³
Quantity per m³ for the additive specified in the used formula (note).
C6 Additive 2: Type
Description of the second additive, if any, specified in the used formula (note) (note).

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C7 Additive 2: Quantity / m³
Quantity per m³ for the second additive, if any, specified in the used formula (note).
C8 RCK - Strength
Resistance/strength class of the concrete, as specified in the used formula (note).
C9 Water / Cement Ratio
W/C Ratio of the concrete, as specified in the used formula (note).
D0 Workability / Slump
Slump of the concrete, as specified in the used formula (note).
D1 Exposure Class
Exposure class of the concrete, as specified in the used formula (note).
D2 Aggregate Max. Diameter
Aggregate maximum diameter in the concrete, as specified in the used formula (note).
D3 Granulometric Curve
Granulometric curve of the concrete, as specified in the used formula (note).
D4 Oversanded (Y/N)
Indicates that the concrete mix design is oversanded, as specified in the used formula (note).
D5 Client: Code
Code of the client to which the produced material is delivered (note). This data entry must be
always configured and entered, for printing the delivery docket.
D6 Client: Company Name
Company name of the client to which the produced material is delivered (note).
D7 Client: Address
Address of the client to which the produced material is delivered (note).
D8 Client: ZIP
ZIP of the client to which the produced material is delivered (note).
D9 Client: City
City of the client to which the produced material is delivered (note).
E0 Client: VAT/Fiscal code
VAT code of the client to which the produced material is delivered (note).
E1 Destination: Code
Code of the destination (linked to the client) to which the produced material is delivered (note). This
data entry must be always configured and entered, for printing the delivery docket.
E2 Destination: Company Name
Company name of the destination to which the produced material is delivered (note).
E3 Destination: Address
Address of the destination to which the produced material is delivered (note).
E4 Destination: ZIP
ZIP of the destination to which the produced material is delivered (note).
E5 Destination: City
City of the destination to which the produced material is delivered (note).

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E6 Destination: Radial
Geographic radial inside which the produced material is delivered (note). Can be used for identifying
the delivery area for the invoicing, for clients or trucks handled by CARRIERs.
E7 Truck: Code
Code of the truck used for the delivery (note). This data entry must be always configured and
entered, for printing the delivery docket.
E8 Truck: Company Name
Company name of the carrier company handling the truck used for the delivery (note).
E9 Truck: Address
Address of the carrier company handling the truck used for the delivery (note).
F0 Truck: ZIP
ZIP of the carrier company handling the truck used for the delivery (note).
F1 Truck: City
City of the carrier company handling the truck used for the delivery (note).
F2 Truck: VAT/Fiscal code
Fiscal code / VAT of the carrier company handling the truck used for the delivery (note).
F3 Truck: Plate no.
Plate (registration) number of the truck used for the delivery (note).
F4 Truck: Driver
Name of the driver of the truck used for the delivery (note).
F5 Pump: Code
Code of the concrete placing pump possibly used on the pouring site (note).
F6 Pump: Company Name
Company name of the carrier company handling the concrete placing pump possibly used on the
pouring site (note).
F7 Pump: Address
Address of the carrier company handling the concrete placing pump possibly used on the pouring
site (note).
F8 Pump: ZIP
ZIP of the carrier company handling the concrete placing pump possibly used on the pouring site
(note).
F9 Pump: City
City of the carrier company handling the concrete placing pump possibly used on the pouring site
(note).
G0 Pump: VAT/Fiscal code
Fiscal code / VAT of the company handling the concrete placing pump possibly used on the
pouring site (note).
G1 Pump: Plate no.
Plate (registration) number of the concrete placing pump possibly used on the pouring site (note).
G2 Pump: Driver
Name of driver of the concrete placing pump possibly used on the pouring site (note).
G3 Pump: Pumped Quantity
m³ possibly pumped on the pouring site using a concrete placing pump (note).

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G4 Pump: Boom length

Length of the boom of the concrete placing pump possibly used on the pouring site (note).
G5 Product 1: Code
Code of the product linked to the formula used for the batching, or code of the additional product
delivered together with the concrete (note).
G6 Product 1: Description
Description of the product linked to the formula used for the batching, or description of the
additional product delivered together with the concrete (note).
G7 Product 1: Unit of Measure
Unit of measure of the product linked to the formula used for the batching, or unit of measure of the
additional product delivered together with the concrete (note).
G8 Product 1: Quantity
Quantity of product linked to the formula used for the batching, or quantity of the additional product
delivered together with the concrete (note).
G9 Product 2: Code
Code of the additional product possibly delivered and entered in the docket (note).
H0 Product 2: Description
Description of the additional product possibly delivered and entered in the docket.
H1 Product 2: Unit of Measure
Unit of measure of the additional product possibly delivered and entered in the docket.
H2 Product 2: Quantity
Quantity of additional product possibly delivered and entered in the docket (note).
H3 Product 3: Code
Code of the additional product possibly delivered and entered in the docket (note).
H4 Product 3: Description
Description of the additional product possibly delivered and entered in the docket.
H5 Product 3: Unit of Measure
Unit of measure of the additional product possibly delivered and entered in the docket.
H6 Product 3: Quantity
Quantity of additional product possibly delivered and entered in the docket (note).
H7 Product 4: Code
Code of the additional product possibly delivered and entered in the docket (note).
H8 Product 4: Description
Description of the additional product possibly delivered and entered in the docket.
H9 Product 4: Unit of Measure
Unit of measure of the additional product possibly delivered and entered in the docket.
I0 Product 4: Quantity
Quantity of additional product possibly delivered and entered in the docket (note).
I1 Structure Type
Can be used for indicating the structure type on the pouring site where the delivered concrete is
going to be used (note).

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I2 Exterior Appearance of Goods

Exterior appearance of the delivered material. This data entry is pre-loaded with the default value
defined in Plant's data - Admin, in the System menu group (note).
I3 Transport by
Company handling/owning the truck, pre-loaded when selecting the truck (note).
I4 Transport Reason
Reason for transporting the produced material. This data entry is pre-loaded with the default value
defined in Plant's data - Admin, in the System menu group (note).
I5 Additive Charge
States that the additive added to the concrete has to be charged to the client (note).
I6 Cube sample boxes no.
Number of sample cubes for concrete possibly delivered together with the transported material
(note).
I7 Pump on site setting
Number of settings of the concrete placing pump when on the pouring site, to be charged to the
client (note).
I8 Meters of pipe added
Meters of concrete pouring pipe added to the truck when on the pouring site, to be charged to the
client (note).
I9 Notes: Row 1
Notes written when entering the docket: row 1.
J0 Notes: Row 2
Notes written when entering the docket: row 2.
J1 Environment Temperature At Load Start
Environmental temperature detected (or manually entered) with the thermometer foreseen on the
plant, for external temperature. Value assigned automatically when printing the docket.
J2 Returned to sender
Quantity of concrete rejected on the pouring site, and returned to the production plant
(note). USUALLY NOT USED
J3 Volume mass
Volume mass (total weight of the components) in the produced formula. Assigned automatically
when selecting the formula into the docket (note).
J4 Meteorological Conditions
Free note containing the meteorological conditions on the production plant, normally taken from
what entered in the thermometer foreseen on the plant, for external temperature.
J5 Net Weight
Net total weight (kg) of the material produced by the plant, for the subject delivery (note).
J6 Order: Client order code
Code/Number of the order assigned by the client which is linked to the production for which
the delivery docket is printed (note).
J7 Ice per mix design
Quantity of ICE per 1 m³ of concrete, as specified in the used formula (note).
J8 Additive 1 Total Quantity
Total theoretical quantity of additive as specified in the used formula, calculated multiplying the
quantity per m³ for the total m³ delivered (note).

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J9 Additive 2 Total Quantity

Total theoretical quantity of the second, if any, additive as specified in the used formula, calculated
multiplying the quantity per m³ for the total m³ delivered (note).
K0 Order: requested m³
total m³ requested by the order linked to the production (note).
K1 Order: remaining m³ (balance)
remaining m³ still to deliver to complete the order linked to the production (note).
K2 Client: VAT/Fiscal code
Fiscal code of the client to which the produced material is delivered (note).
K3 Client: Bank Code
Bank Code of the client to which the produced material is delivered (note).
K4 Client: Bank Description
Description of the bank of the client to which the produced material is delivered (note).
K5 Client: Payment Code
Payment code used for the client to which the produced material is delivered (note).
K6 Client: Payment Description
Description of the payment mode used for the client to which the produced material is delivered
(note).
K7 Client: Province
Province of the client to which the produced material is delivered (note).
K8 Order: delivered m³
m³ delivered so far for the order linked to the production (note).
K9 - M1
Asterisk (*). Can be used for printing asterisks, conditioning them to the value contained to other
associated data entries.
M2 - N5
Repeated field. Can be used for repeating the printing of a data entry already placed in another
position in the docket.
N6 % Additive 1
Theoretical percentage quantity of the additive as specified in the used formula (note).
N7 % Additive 2
Theoretical percentage quantity of the second additive, if any, as specified in the used formula
(note).
N8 Batch Report No.
Number of the batch report generated at the end of the automatic production linked to the docket
(note).
N9 - O3
Check . Can be used for placing on the docket the free setting of data like YES/NO (free
usage note). When printing, the ticked check entry is printed as a black square box or like an
asterisk.
O4 Returned m³ from previous load
m³ already in the truck before loading, returned from the previous delivery, possibly used
in production for a new delivery (note).

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O5 Returned Formula Code

Code of the formula used for producing the returned m³ which are in the truck, possibly re-used in
production for a new delivery (note).
O6 Water in Truckmixer
Quantity of water possibly contained in the truck before starting automatic production (note).
O7 Cubic Meters
m³ of produced/delivered concrete. This data entry must be always configured and entered, for
printing the delivery docket.
O8 Fractions Report
Detail of dosed components during automatic production, detailed to every fraction in which the
total load has been split (note).
O9 Components-Report
Detail of dosed components during automatic production, as summary report for all fractions in
which the total load has been split (note).
P0 Start Date
Date of beginning of the automatic production (note).
P1 Start Time
Time of beginning of the automatic production (note).
P2 End Date
Date of completion of the automatic production (note).
P3 End Time
Time of completion of the automatic production (note).
P4 Request
Number of the production line which generated the delivery docket (note).
P5 Cycle
-- (note).
P6 Fraction
Total number of fractions executed in automatic production for this delivery (note).
P7 produced m³
m³ of produced concrete in automatic production for this delivery (note)
P8 Cycles no.
Total number of cycles executed in automatic production for this delivery (note).
P9 m³ per cycle
m³ produced on every cycle executed in automatic production for this delivery (note).
Q0 Loading point
Loading point used on the plant for this production (note).
Q1 Discharge Chute
Mixer discharge chute used on the plant for this production (note).
Q2 Destination Station
Code of the destination bed/station for the produced material (note).
Q3 Aggregates Total H2O
Quantity of water detected in the aggregates in form of moisture and actually present in the final
mix (note).

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Q4 Dosed H2O
Dosed water actually present in the final mix (note).
Q5 Total H2O
Total quantity of water contained in the final mix (note).
Q6 Trim H2O
Quantity of water delivered by the hygrometric control system, for the correction of the mix, in order
to reach the formula W/C ratio (note).
Q7 Not detected H2O
Quantity of water detected by the hygrometric control system, as detection error from the
aggregate moisture measurement system or, in any case as non controlled water (note).
Q8 Design W/C Ratio
Theoretical Water/Cement ratio as specified in the used formula (note).
Q9 A/C difference
% of error allowed for the water/cement ratio, as specified in the used formula (note).
R0 Actual W/C Ratio
Water/cement ratio actually reached in the final mix (note).
R1 Mixer Absorption
Power absorption detected by the wattmeter foreseen on the plant, and connected to the mixers
(note).
R2 Environment Temperature
Environment temperature detected at production start by the thermometer installed on the plant
(note).
R3 Cycle Time
Duration of the production cycle (note).
R4 Plant Cycle
Duration of the plant cycle (note).
R5 H2O Inlet time
Time when the water got in contact with the cement into the produced mix (note).
R6 Discharge Time
Discharge time of the produced mix from the mixer (note).
R7 Mixing time
Mixing time for blending the produced material into the mixer (note).
R8
not used
R9 Limit time to use concrete
Maximum time allowed for pouring the fresh concrete after being produced from the plant, as
specified in the formula (note).
S0 Certified/Certifying corporation
Information related to the certification of the used formula (mix design) (note).
S1 Truck: Driver code
Code of the driver of the truck used for the delivery (note).
S2 Pump: Driver code
Codie of the driver of the concrete placing pump possibly used on the pouring site (note).

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S3 Stay
Time (minutes) of idle waiting of the truck on the pouring site, to be charged to the client (note).
S4 Pump Stay
Time (minutes) of idle waiting of the concrete placing pump on the pouring site, to be charged to
the client (note).
S5 Operator
Code of the operator on duty at the moment of production.
S6 Order: client order date
Date of the order received from the client which is linked to the production for which the delivery
docket is printed (note).
S7 Time of arrival on site
Time of arrival of the truck on the pouring site (note).
S8 Time start unloading
Time when the truck started unloading on the pouring site (note).
S9 Time finish unloading
Time when the truck finished unloading on the pouring site (note).
T0 - T9
Messages that can be freely set for printing any information: click on the data entry description and
type in the text you want to print on the delivery docket. If necessary, apply a condition to some
other data entry.

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Plant's Data configuration

Access to this function could be limited by operator's access rights.

For accessing the plant configuration data, click on the icon from the main menu in
the System group.

Here one can define the accountancy identification data for the production plant, in order to adapt it
to the specific needs of the user.

Available functions: Plant Id - Production - Admin - Save - Exit

Plant id
For entering the accountancy identification data of the plant, in order to print them as header in the

print pages or into delivery docket, click on :

Plant name, etc.: enter the desired informations on these plant identification data.
up

Production
For accessing the automatic progressive counters for dockets, batch reports, etc. and some

general plant operation parameters, click on :

Next order no.: enter the number to be automatically assigned to the next created production
order. Every time an order is created the number is automatically increased.
Next report's no.: enter the number to be automatically assigned to the next generated batch
report. Every time a new automatic production is launched, the number is automatically increased
(not on every recorder batching fraction, but on every completed production cycle).
Next delivery doc. no.: enter the number to be automatically assigned to the next created delivery
docket. Every time a new docket is created/printed (manually or automatically), the number is
automatically increased.
Group water in report: if ticked (enabled), the water quantities in the batch reports are summed
up together, in order to show only a single line for water, normally referring to clean water (the first
water batcher, provided it has been used in the batch). In other words, the detail of other possibly
used waters (i.e. recycled water) will not be shown.
Moisture calc. on DRY weight: if ticked (enabled), configures the Genyx for calculating the
aggregates moisture compensation considering the defined/detected moisture values as referring
to the dry weight of the sample, and not on the wet weight of the sample. See notes for moisture
compensation.
Calculate active moisture: if ticked (enabled), the active moisture will be shown
in the batch reports on the column Moisture % instead of the normally shown detected
moisture. By default, the parameter is disabled (not ticked).

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Fractioning limit: if ticked (enabled), during the calculation of the batching fractions on production,
the maximum number of calculated fractions is limited to 10. In other words, if the plant setup
requires the fractioning of the total requested production quantity in more than 10 fractions, Genyx
signals an error, suggesting to check and trim the plant setup parameters.
up

Admin
For accessing the definition of specific printed information on the delivery docket, in order to abide

various accountancy requirements, click on .

Exterior appearance of goods: list of the available selections for the docket entry "Exterior
appearance of goods" (that is how the produced material looks like, during the transportation;
usually: Bulk, Concrete, etc.)
Carriage reason: list of the available selections for the docket entry "Carriage reason" (that is the
reason for which the produced material is transported; usually: Sale).

In the above mentioned lists:

for modifying an entry in the list, click on the item to be edited then type in the new
information;
for adding an entry to the list, click on then click on the New line and type in the new
information;
for deleting an entry from the list, click on the desired item, then click on .
for assigning the default entry, that is the one automatically assigned when creating a
new delivery docket, click on the box on the right of the entry, in order to tick it .
Defining the default entry is MANDATORY.

up

Exit, saving modifications, returning to the main menu

To confirm the modifications made, exiting and returning to the main menu, click on .
up

Exit, without saving modifications, returning to the main menu

To exit without confirming the modifications made, returning to the main menu, click on .
up

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Alarms History
Access to this function could be limited by operator's access rights.

For accessing the alarm history file, click on the icon from the main menu in the
System group.

Here one can browse the history of the alarms that happened on the plant.

Available functions: All - Filter - Group - Delete - Exit

Alarms information
Alarms are listed in decreasing chronological order, that is the most recent alarm is on top of the
list.
The information available in the list are:
N°: alarm identification code. This is a unique code, useful for reporting a specific alarm in contacts
with Onyma technical service.
Date: date on which the alarm happened.
Time: time on which the alarm happened.
Alarm: description message for the alarm. See alarm types descriptions.
Ack: date on which the alarm was acknowledged, that is either when the operator confirmed the
alarm-paused cycle could continue, or when the alarm condition ceased automatically.
End: like Ack but for the time.
Duration (sec): duration of the alarm situation, that is how many second the alarms was active.

up

All

Clicking on , the complete historical list of all alarms is shown. Useful to restore the normal
list when a filter on the alarm list is applied.
up

Filter

Clicking on , enables a filter to display only part of the information contained in the list, in
order to show only the occurrences of a specific alarm. The filter can be set on the alarm code and
on a date range.

up

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Group

Clicking on , the alarms in the list are grouped by code, and the total number of occurrences

for each is shown. Clicking again , the list shows the normal date/time detail.

up

Delete
For permanently delete the historical record of an alarm, select the line containing the record and

click on , then confirm the deletion.

It is moreover possible to delete more daily records simultaneously from the list, by clicking on

and entering the date range for which to delete the records.
up

Exit and return to main menu

To exit from the list and return to the main menu, click on .
up

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Language selection
Access to this function could be limited by operator's access rights.

For changing the Genyx current language, click on from the main menu in the System
group.

Click on the desired language within the list of the available languages, then confirm by clicking on

For changing the language, you must restart Genyx: on request, confirm the system shutdown,

then start the program again double clicking on the icon from the desktop. After restarting,
Genyx will be set for the selected language.

Reserved access - Operators

Click on the icon to access the reserved access configuration area from System in the
main menu, or from the plant mimic.

Here one can define the operators which can access Genyx, limiting if necessary the functions that
can be accessed: one can define who can do what.

Up to 10 operators can be defined, each one with specifics access rights.

The operators configuration is reserved to the plant supervisor: contact Onyma technical service
to obtain the supervisor password.

Available functions: Operator log-in (access) - Operator log-out (exit) - List - Passwords - Save -
Exit

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Operator log-in (access)

When Genyx starts, unless the compulsory request of the access password is enabled, the
active/current operator is always Operator 1, which is the one defined as Base operator, and does
not require access password.

To access the Genyx with a specific operator code, click on from System in the main

menu, or from the plant mimic, then if necessary click on .

After opening the operators definition page, write the password then click on . If the
password is wrong, an error will be shown.
If the password is correct, the operator identification box shows the operator's data.
To access the Genyx as Base operator, do not insert any password (or remove the one already

inserted), then click on .

Operator log-out (exit)

The inserted operator's password is active until removal. In other words, it is always necessary to
remember removing your own password when you leave the Genyx to some other
operator, in order to avoid giving reserved privileges to somebody else.

To log-out, click on the icon from System in the main menu, or from the plant mimic, then

if necessary click on .

When opening the operators definition page, the password box should contain a series of asterisks
(*) hiding the current access password: delete all asterisks by clicking inside the password box,

then pressing Canc (or Del) o Backspace, then click on . The access as Base
operator is done.

Operator information

Click on to show the available operators list.

Operator 1 is the Base operator, that is the one automatically active when Genyx starts, if no
specific password is entered. Accessing as Base operator does not require any access password.

Click on any operator for defining its password and access rights.

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Access rights

After selecting the operator, click on to show the list of functions that can be protected by
password.

To control the access to a specific function, click on the box beside the function's name:

function can be accessed by the operator,

function cannot be accessed by the operator.

The functions that can be protected by password are:

Formula Formulas for mix design definition

Production Automatic production programming and launch
Components Components/raw materials for mix designs
Fractions Monitor Monitor for fractions calculation for automatic production
Products Products for delivery dockets
Reports Batch reports
Clients/Destinations Clients/Destinations, for delivery dockets
Consumptions Consumptions for components/raw materials
Trucks Trucks used for transportation/delivery, for delivery dockets
Components Exchange the components extractors for batching
exchange
Orders Production Orders
Raw materials INput Recording of raw materials input
Delivery dockets Delivery dockets
Suppliers Suppliers of raw materials
Statistics Statistics and queries on production
Stock Components/raw materials Stock
Assisted backup Procedure for data backup and save
Assisted restore Procedure for data restore
Plant data backup Procedure for saving the plant configuration data: batchers,
weighers, etc.
Plant data restore Procedure for restoring the plant configuration data: batchers,
weighers, etc.
Genyx configuration Configuration for Genyx
Language selection Selection of the language for operating Genyx
Alarms history Alarms history file
Extractors data Setup parameters for batchers/extractors, weighers, belts,
mixer, etc.
Calibration Calibration of weighers/scales and moisture analog inputs, etc.

Exit, saving modifications, returning to the main menu

To confirm the modifications made, exiting and returning to the main menu, click on .
up

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Exit, without saving modifications, returning to the main menu

To exit without confirming the modifications made, returning to the main menu, click on .
up

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Alarms
Alarms
When an alarm situation happens during an automatic production cycle, as well as in any other
faulty situation controlled by the system, Genyx activates automatically the pop-up alarm signal
window.

If more than one alarm is active at a certain moment, the alarm window may contain more lines.
Each line displays the unique alarm identification number and the alarm description. When an
alarm is active, the window cannot be closed.

The available commands on the alarm window, beside the status change commands, are:
Command Effect
acknowledge of all signaled alarms;
if there is an automatic production cycle in progress, it will be continued;
clicking on this icon is the same as pressing the F4 function key
acknowledge of the selected alarm inside the multiple alarm list; for selecting a
specific alarm among the list, click on the alarm description, highlighting it;
if there is an automatic production cycle in progress, it will be continued only for
the batchers for which the alarm has been acknowledged
suspend (pause) the automatic production cycle currently in progress;
the plant switches to SUSPENDED status and the production cycle is paused,
leaving open the chance to restart it
restart the suspended (paused) automatic production cycle;
the plant switches to AUTOMATIC status and the automatic production cycle
which has been pause restarts from the point of interruption
switch to manual operation mode;
the plant switches to MANUAL status, the automatic production cycle is paused,
leaving open the chance to restart it;
in this status, the manual operation commands from the Genyx mimic page or
from the main control panel become available
acoustic alarm signal shut off (on both PC and external plant's siren);
the signaled alarms are not acknowledged, therefore the automatic production
cycle is still paused waiting for the acknowledge

To activate one of the above commands, click on the corresponding icon/button.

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Alarms: description

Description of the alarm conditions that can happen during an automatic production cycle

Every time an alarm is signaled, the message contains the name and the identification number of
the component batcher or scale/meter on alarm. The following, brief, descriptions show only the
main body of the alarm message.
Some alarms refer to anomalies on the batching system for a component: chute, valve, screw
conveyor. Again, for shortness, the alarm message shown here refers always to CHUTE type.

ALARM Description Action

Check the PLC analog card
Error in detecting the analog signal
SCALE: READING ERROR Check the digital display and the
coming from the digital METER
connection to the PLC
Check the actual weight into the
scale and, if necessary, remove
METER is loaded with an excessive the excess
SCALE: OVERLOAD
amount of material
Check the parameter Capacity
defined for this METER
Check the actual weight in the
The material contained in the METER, METER and, if necessary,
SCALE NOT EMPTY BEFORE
LOAD START before production launch, is more than remove the excess.
the Empty meter tolerance Check and, if necessary, increase
the Empty meter tolerance

During automatic batching, more Check electrical connections into

SCALE: MORE THAN components BATCHERS are the main control switchboard
ONE DOSAGE CHUTES OPEN simultaneously active, Genyx cannot Check operation of individual
detect the dosage properly BATCHERS

Check electrical connections into

SCALE: DISCHARGE OPEN The METER discharge chute is open the main control switchboard
WHEN DOSING during the dosage phase
Check sensors for closed METER

Check electrical connections into

Before starting the automatic batching, the main control switchboard
SCALE: DOSAGE CHUTES one component BATCHER is Check operation of
OPEN BEFORE LOAD START active, Genyx cannot detect the dosage individual BATCHERS
properly Check sensors for open/closed
BATCHERS

Check if material is actually

During the automatic discharge phase, discharging from METER
SCALE: DISCHARGE
CLOGGED Genyx is not detecting a proper output Check and, if necessary, change
flow from METER the parameters for Clogging
threshold

Check actual operation

During the automatic batching, Genyx is on BATCHER and electrical
trying to control a component BATCHER, connection into the main control
DOSAGE CHUTE NOT OPEN
but cannot receive the acknowledge of switchboard
batching in progress Check sensors for open/closed
BATCHERS

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ALARM Description Action

Check setup parameters
for BATCHER (Tolerance, Free
The automatic batching of the
fall, Pulse dosage)
TOLERANCE xxx% component ended out of defined
Check and trim the dosage flow
tolerance limits
of the component's batching
system

Check if material is actually

During automatic batching, Genyx does dosing from BATCHER
not detect enough dosage flow from Check and, if necessary, change
component BATCHERIf there are the parameters for Clogging
DOSAGE CLOGGED
more BATCHERS on the specific threshold
METER, most likely a component Check and trim the dosage flow
exchange request will be activated of the component's batching
system

Check actual operation

of BATCHER and the electrical
Genyx is trying to control the discharge connection inside the main
DISCHARGE BLOCKED of a component, but cannot receive the
control switchboard
acknowledge of discharge in progress
Check sensors for open/closed
BATCHERS

Check actual operation of

'BATCHER and the electrical
During the automatic discharge phase
connection inside the main
DOSAGE DURING DISCHARGE of METER one component BATCHER is
control switchboard
active
Check sensors for open/closed
BATCHERS

Check moisture sensor calibration

and moisture parameters for this
During the automatic dosage of an
aggregate
aggregate on which a moisture sensor is
AGGREGATE MOISTURE Check electrical connections from
VALUE NOT VALID foreseen and enabled, the detected
moisture sensors to electric
moisture percentage falls outside the
switchboard then, inside the
valid range
switchboard, between moisture
display and PLC

The dosed quantity for an aggregate on Check moisture parameters for

MINIMUM WEIGHT FOR which a moisture sensor is foreseen and this aggregate
MOISTURE READING NOT enabled, is not enough for properly Check formula for dosed quantity
REACHED covering the sensor and obtaining an
accurate reading

Check the star/delta timer inside

the electric switchboard and, if
necessary, decrease the delay
Genyx is trying to start the mixer,
MIXER IS NOT RUNNING but cannot receive the acknowledge of Check the thermal protection
switches for the mixer's motor
mixer running.
and the electrical connections
inside the main control
switchboard

More than one chute position sensor, for Check chute position and sensors
WRONG MIXER DISCHARGE
CHUTE POSITION the mixer discharge gate, are Check electrical connections into
simultaneously active. the main control switchboard

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ALARM Description Action

Check actual slump and W/C
The W/C ratio of the mix batched in ratio
WATER/CEMENT RATIO
TOLERANCE ERROR automatic production falls outside the Check formula and, if necessary,
formula defined range increase the tolerance on
the W/C ratio

The workability (slump) of the mix Check actual slump, then check
batched in automatic production calibration and defined control
MIX WORKABILITY (SLUMP)
NOT REACHED falls outside the formula defined range, thresholds on the wattmeter
according to the detection from the Check components quantities in
wattmeter connected to the mixer. formula

Check if the mixer is actually

The discharge of the components into empty and, if necessary remove
the mixer cannot start because the all material inside by means
MIXER NOT EMPTY absorption level detected by the of manual commands
wattmeter connected to the mixer does Check and trim the mixer empty
not fall between the empty range. threshold defined in the wattmeter
parameters

Check the actual chute position,

then the sensors
Genyx is trying to open the mixer's Check thermal protection
DISCHARGE CHUTE NOT
OPEN discharge chute, but cannot receive the switches for the unit controlling
acknowledge of chute open mixer discharge, then the
electrical connections inside the
main control switchboard

Check the actual chute position,

then the sensors
Genyx is trying to close the mixer's Check thermal protection
DISCHARGE CHUTE NOT
CLOSED discharge chute, but cannot receive the switches for the unit controlling
acknowledge of chute closed mixer discharge, then the
electrical connections inside the
main control switchboard

Activate the authorization to

mixer's discharge (i.e. truckmixer
The mixer still contains a mix which presence)
MIX READY FOR DISCHARGE
STILL IN THE MIXER completed the mixing cycle, and which is Check the mixer's discharge
ready for discharge enable command from the
Genyx mimic page or from the
main control switchboard

Check actual clogging of the drip

The sensor detecting the build up of
edge and, if necessary remove
material into the truckmixer loading drip the build up
DRIP EDGE CLOGGED
edge is active, the materials discharge
has been paused Check electrical connections into
the main control switchboard

Check actual position of the skip

Genyx is trying to start the aggregate
SKIP NOT IN LOADING then check position sensors
POSITION scale discharge, but the skip is not in
Check electrical connections into
loading position
the main control switchboard

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ALARM Description Action

Check if the skip is actually
moving up, then check position
Genyx is trying to control the ascent of sensors
SKIP BLOCKED WHILE GOING the skip for discharging the aggregates Check thermal protection
UP into the mixer, but cannot receive the switches for the skip motor,
acknowledge of skip going up then the electrical connections
inside the main control
switchboard

Check if the skip is actually

moving down, then check position
Genyx is trying to control the descent of sensors
SKIP BLOCKED WHILE GOING the skip for returning to the aggregates Check thermal protection
DOWN loading position, but cannot receive the switches for the skip motor,
acknowledge of skip going down then the electrical connections
inside the main control
switchboard

During the ascent of the skip for Check the actual position of the
discharging the aggregates into the skip, check the position sensors,
SKIP TIMEOUT WHILE GOING mixer, the waiting position (or discharge) check and modify setup
UP sensor has not been reached within parameters
the maximum time defined in the setup Check electrical connections into
parameters the main control switchboard

Check the actual position of the

During the descent of the skip for skip, check the position sensors,
returning to the aggregates loading check and modify setup
SKIP TIMEOUT WHILE GOING
position, the low position sensor has not
DOWN parameters
been reached within the maximum
Check electrical connections into
time defined in the setup parameters
the main control switchboard

During the ascent of the skip for Check actual position of the skip,
discharging the aggregates into the check position sensors and the
SKIP IN DISCHARGE mixer, the skip did not stop in the waiting electrical connection into the main
POSITION (UP) WITH MIXER position, therefore it started discharging switchboard
STILL FULL into the mixer, while the mixer still Move the sensor of the waiting
contains the mix from the previous position far away from the one of
cycle/fraction discharging (up) position

Check actual position of the skip,

The sensor detecting the wrong roll up of check the pull rope, then check
LOOSE SKIP ROPE the skip's pull rope is active, either during the position/alarm sensors
ascent or descent Check electrical connections into
the main control switchboard

Check actual skip position, check

More than one skip position sensors are position sensors
WRONG SKIP POSITION
simultaneously active Check electrical connections into
the main control switchboard

Check if the hopper is actually

The stand-by hopper contains material, it
closed, then check closed
STAND-BY HOPPER FULL AND is not yet time to discharge it into the discharge chute sensor.
OPEN mixer, but Genyx cannot acknowledge
the closed discharge signal. Check electrical connections into
the main control switchboard

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ALARM Description Action

Genyx is trying to control the opening of Check if the hopper is actually
the component stand-by hopper for discharging, then check the
STAND-BY HOPPER NOT
OPEN discharging into the mixer, but cannot discharge chute position sensors
acknowledge the discharge in progress Check electrical connections into
signal the main control switchboard

Check if the hopper is actually

Genyx is trying to close the component closed, then check closed
STAND-BY HOPPER NOT
CLOSED stand-by hopper, but cannot discharge chute sensor
acknowledge the CHUTE closed signal Check electrical connections into
the main control switchboard

Check if the stand-by hopper is

The sensor detecting the maximum level
actually full, then check level
STAND-BY HOPPER MAXIMUM of material inside the stand-by hopper is sensor operation and position
LEVEL active, but the discharge of the material
from the scale is not finished yet Check electrical connections into
the main control switchboard

Check if there is actually some

material inside the hopper,
then check level sensor operation
When it is time to discharge the and position
component scale into the stand-by
STAND-BY HOPPER NOT Check and, if necessary, increase
EMPTY hopper, the sensor detecting the
the emptying time of the stand-by
presence of some material inside the
hopper , checking the setup
hopper is active
parameters.
Check electrical connections into
the main control switchboard

When it is time to discharge the batched Check actual by-pass position,

BY-PASS NOT ON components into the truckmixer, the check position sensors
TRUCKMIXER POSITION discharge by-pass for dry/wet it is not on Check electrical connections into
dry position the main control switchboard

When it is time to discharge the batched Check actual by-pass position,

BY-PASS NOT ON MIXER components into the mixer, the check position sensors
POSITION discharge by-pass for dry/wet it is not on Check electrical connections into
wet position the main control switchboard

If the warning condition cannot be

true, check operation of the level
The sensor indicating the minimum level
MINIMUM LEVEL sensor, then the electrical
of material into the silo/hopper is active
connection into the main
switchboard

If the warning condition cannot be

true, check operation of the level
The sensor indicating the maximum level
MAXIMUM LEVEL sensor, then the electrical
of material into the silo/hopper is active
connection into the main
switchboard

Check actual filling of the

batcher/tank, check thermal
The maximum allowed time for the protection switch for the motor,
FILLING TIMEOUT
weight loss batcher or for the tank is over check level sensor or load cell
Check electrical connections into
the main control switchboard

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ALARM Description Action

The back-up battery maintaining the data Replace battery following PLC
MEMORY CARD BATTERY programmed in the PLC memory card is user's manual instruction, contact
low Onyma technical service

The back-up battery maintaining the data Replace battery following PLC
POWER SUPPLY BATTERY programmed in the PLC working user's manual instruction, contact
memory is low Onyma technical service

Check the reason for motor's

MOTOR THERMAL At least one of the motors thermal
PROTECTION over-heating/over-absorption,
protection switches tripped off
then re-arm the switch

Check the reason for the

The sensor controlling the transmission
INCLINED BELT SKID skidding, if necessary trim the
CONTROL belts skidding on the inclined belt went
sensor properly, then
off
check control parameters.

Check if the compressor is

The sensor detecting the pressure in the working, if necessary trim the
AIR PRESSURE compressed air circuit signals a low sensor
pressure Check electrical connections into
the main control switchboard

Check grease level and operation

of the automatic lubrication
The lubrication control unit on the mixer system (motor and sensors)
MIXER GREASING
is signaling a problem Check electrical connections into
the main control switchboard
and setup parameters

Check the reason for the alarm

The lubrication control unit on the mixer (sensors, motors, etc.)
MIXER GENERAL ALARM
is signaling a problem Check electrical connections into
the main control switchboard

Check 24Vac power supply to the

PLC and into the main control
switchboard, check analog output
signals from scales digital
PLC is detecting a problem on the displays to the PLC
PLC CARD - BASE RACK specified electronic card on the main
Check, using the technical
connection rack
documents available, if on
the PLC the specified card shows
an error signal (I/O or ERR)
Call Onyma technical service

Check 24Vac power supply to the

PLC and into the main control
switchboard, check analog output
signals from scales digital
displays to the PLC, check
PLC is detecting a problem on the connection between main PLC
PLC CARD - EXPANSION
RACK specified electronic card on the rack and expansion rack
expansion connection rack
Check, using the technical
documents available, if on
the PLC the specified card shows
an error signal (I/O or ERR)
Call Onyma technical service

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ATTACHMENT

HYGROMETER GENERAL PARAMETERS (Click the hygrometer icon on

the desktop):

The Hygrometer General Parameters layout page appears:

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SYSTEM PARAMETERS

• ENABLING: Yes
o enables the hygrometer at the general level
• END OF CYCLE: AUTOMATIC
o If set to AUTOMATIC the hygrometer cycle is automatically closed
o If set to MANUAL the hygrometer cycle awaits closure by the operator (in this
case, at the end of the hygrometer cycle the monitoring window appears, and
the STOP button should be pressed to end the cycle and continue with the
sequence)
o in the mixes which have not yet been studied, for which that is, a memorized
curve does not exist, or in those where the system reads humidity values
achieved outside of tolerance, or where before the end of the check, water is
added manually, the end of the cycle is nevertheless managed in MANUAL
mode to permit the operator to intervene and check the mix.

•
• WATER LOSS CHECK: switch to OFF (turned off)
o if the switch is left to ON (switched on) the system signals a water loss error
(leakage) on the valve if it intercepts counting of litres when it is not dosing)
• PROGRESSIVE TYPE ADJUSTMENT - GAIN: 1,00
o Is used to adjust the type of progressive function (selectable inside every
individual program) which permits the achievement of a humidity value of the
mix for progressive approaches (PROGRESSIVE function type) rather than
with a single dose of water (AUTOMATIC type function) This system (the
PROGRESSIVE one) permits an even more accurate check of the humidity
sought but with longer cycle times. The permitted values arrive at a
maximum of 1.00 which is equivalent to a target approach with dosages

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equal to 100% of the requested amount; in this case, the progressive type
function is equivalent to the AUTOMATIC mode functioning (the missing
water is dosed as a single solution). Lower values adjust how "hurriedly" the
hygrometer approaches the target. For example, a value of 0.80 indicates
that the hygrometer in the PROGRESSIVE mode, doses 80% of the missing
water and carries out a blending of the mix equal to 80% of the time set
before repeating the check. As the value is lowered, the water dosages will
be lower than required allowing for reaching the target in small steps and,
therefore, with greater precision but with an increase of the cycle time. I
personally do not advise PROGRESSIVE type functioning as it requires
more time and there is no constancy between one mix and another. All
hygrometers put into use up till now have been set with AUTOMATIC type
functioning).
• PROGRESSIVE TYPE ADJUSTMENT - HIGHER THRESHOLD: 0
o In the event of working with recipes for which progressive type adjustment is
selected, this works when the probe signal goes beyond the set value. As
long as the probe signal remains below this value, the PROGRESSIVE
function is cancelled (It tends to dose all the water requested until the probe
signal reaches this value, after which it works in PROGRESSIVE mode).
 Indeed, opportunely adjusting the GAIN and UPPER
THRESHOLD values, it is possible to have a PROGRESSIVE
function, that is with a step approach to the target, only
approaching the same, while when the probe signal is less than
the UPPER THRESHOLD the function is equivalent to the
AUTOMATIC type thus optimizing the hygrometer cycle times).
• WORK WINDOW ON TOTAL WATER (%): 40
o indicates on which % of the total formula water the hygrometer works. The
remainder (in this case 60% including inert humidity) is normally reached
before activating the hygrometer control. I do not advise values which are too
low in order to leave sufficient space for the hygrometer to work; values
around 30-40% are optimal.
• READS EVERY (msec): 200
o indicates the probe signal at set times. A value of 200 msec guarantees and
good sampling frequency.
• NUMBER OF READINGS: 20
o adjusts the filter (smoothing) software on a signal from the probe indicating
over how many subsequent readings the average will be carried out. Too
high a value makes the probe reply too slow forcing a notable increase in the
cycle time. Too low a value makes the probe signal too "skittish" and
imprecise.
• MINIMUM ADJUSTMENT (sec): 30
o Is the minimum blending time before accepting the probe signal and deciding
how much water to add. Whether the blending is be set (within the formula)
in FIXED mode (with a time set by the operator) or in AUTOMATIC (with
blending control carried out by the system) the minimum blending time will
nevertheless be the one that is set. The Galletti mixers do not work well with
minimum times less than 30, or better still 40 seconds.
• MINIMUM ADJUSTMENT (sec): 60
o Is the maximum blending time when AUTOMATIC mode is chosen in the
formula, that is with control of blending the mix. As soon as this time elapses,
the system nevertheless considers the mix blended and accepts the probe

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signal. The Galletti mixers do not work well with minimum times less than 60,
or better still 70 seconds.
• SIGNAL ADJUSTMENT (points): 200 / sec: 10
• controls the blend of the mix. If, in the formula, AUTOMATIC is selected instead of
FIXED, the mix is blended before and after the additions of water for a minimum
and maximum time equal o the above settings. Within this interval the system
checks that the probe signal does NOT vary more than the point number set in the
interval of time indicated to be able to consider the mix blended and interrupt the
mixing. In the example indicated, the system considers the mix blended if, having
exceeded the minimum blending time, the probe signal varies by less than 200
points within 10 seconds. If, nonetheless, the variation is greater on reaching the
maximum blending time, the system considers the mix blended and passes to the
next checking phase.

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HYGROMETER PARAMETERS IN FORMULA (click on the hygrometer

button within each individual recipe):

o
• ENABLING: AUTOMATIC
o enables the hygrometer at the formula level. Permits the choice of
AUTOMATIC mode for each recipe (advised), that is with water correction in
a single solution, or PROGRESSIVE, that is with progressive approaches
(see headings PROGRESSIVE TYPE ADJUSTMENT - GAIN - UPPER
THRESHOLD in the general parameters).
• INERT HYDRATION - HYDRATION WATER (Lt): 0,000
o Is used to set the hydration of inert solids (which in any case also includes
humidity) before loading the mixer with cement or other components. Very
useful with very porous inert materials (such as expanded clay) which
requires an initial hydration at least to reach the SSD state (Saturated
Surface Dry) before proceeding with loading the concrete. Unnecessary with
normal inerts; in this case, leave the value at 0 in order to avoid unnecessary
pre-hydration which only causes time wasting.
• HYDRATING INERTS - OK HYDRATION SIGNAL (point): 0
o Indicates a signal threshold (in points from the probe) beyond which the
hydration of inerts only is interrupted to avoid that already excessive humidity
values are reached which will then be impossible to correct. It is perfectly
ineffective if the hydration of inerts is left at 0.
• HYDRATION OF INERTS - ADJUSTMENT TIME (sec): 0 FIXED
o indicates the amount of time for which the inerts should be blended after
hydration. It is possible to set a time in seconds for FIXED or AUTOMATIC,
that is with control of blending by the system (see general parameters). If
hydration of inerts is not used, leave it on 0 FIXED.
• ADJUSTMENT OF MIX HUMIDITY - SIGNAL ADJUSTMENT (sec) 30
AUTOMATIC
o Allows for the decision whether the mix should be blended using fixed times
or with a check of the blend by the system before and after the regulation of
water (see general parameters) It is not possible to set times that are less

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than the MINIMUM ADJUSTMENT time inserted into the general

parameters.
• CORRECTIONS FOR FRACTIONS - 1/1 (Lt) 0.000 - 1/2 (Lt) 0.000 - 3/4 (Lt) 0.000 -
1/4 (Lt) 0.000
o are zeroed when the curve is cancelled (ZEROING button) for a new study.
With the study acquired (the hygrometer calibration curve can be seen in the
illustration) allows an intervention on the correction of the mix for different
cubing cuts (step of 1/4 cubature of the mixer). This allows for the provision
of different readings by the probe with different grades of refilling the mixer
(causes a different pressure of the material on the probe and, consequently,
a slightly different reading for the same level of humidity). With Galletti
mixers and orbiting probe, it is less indispensible and efficient than it is with
other types of mixers which use bottom probes.
• NUMBER ANALYSIS FOR AUTOMATIC: 2
o Indicates how many points (from 2 to 5) will form the hygrometer adjustment
curve. 2 points indicate that the curve will only have one segment. 5 points
indicate that the curve will be divided into 4 segments. For each auto-
identified segment, a dosage of water and a blending will be carried out,
therefore, with a notable loss of time. If the probes are absolutely linear,
there is no sense in dividing the curve into more segments (a straight line will
in any case be obtained). Instead, if the probe has a slightly curved response
(as happened recently with the Hydronix probes) it might be useful to carry
out a study on the points and, therefore, with more segments but, given the
counter-indications (considerable lengthening of research times with
consequent overheating and drying of the mix) it is advised to leave this
parameter at 2 and to reduce the WORKING WINDOW ON TOTAL WATER
(%) in the general parameters: working on a reduced "window", the probe's
reply turns out to be reasonable linear and, therefore, it is no longer
necessary to study the curve over several segments.
• :

Modification

To modify the parameters of a distributor, click on . In the illustration, the standard functions
of data modification are active.

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Monitor

To screen the hygrometer signal in real time, click on . The progress of the value read
by the hygrometer probe appears in yellow on the screen. If there is a mix in progress, the
values relating to it also appear.
The following buttons are present on this page:

• Pause . Suspend the hygrometer cycle.

• Stop. Stop the hygrometer cycle. This button is used when the end of the
MANUAL cycle is selected. In this case, the hygrometer cycle awaits closure
by the operator and this is the button for doing so.

• Reset . Cancel the hygrometer cycle. In this case, from the moment the button
is pressed, the mix is carried out as if the hygrometer cycle was not selected.

• Correction . With this button, a corrective quantity of water can be set,

exclusively valid for the current mix.

• Exit . Exits from the hygrometer cycle monitoring page

Exit and return to the plant summary

In order to exit from the parameters page and return to the plant summary, click on .

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