Fiori BATCH CONTROLLER User manual

FIORI GROUP S.p.A.
Via per Ferrara, 7
41034 FINALE EMILIA (Modena Italia)
Tel. [phone] - Fax [phone]
http://www.fiorigroup.com
uk_EN
TRANSLATION FROM
ORIGINAL LANGUAGE
USE AND MAINTENANCE MANUAL
RIF. 9304444428 ed. 03
id.:
FIORI BATCH CONTROLLER
REV. 01 24/03/2015

3REV. 00 02/01/2015
id.:
CONTENTS
1 WARNINGS ..................................................................................................................................................7
2 SYSTEM DESCRIPTION .............................................................................................................................9
2.1 SETTING UP ..........................................................................................................................................9
2.2 COMPONENTS ....................................................................................................................................10
2.3 KEY FUNCTIONS .................................................................................................................................11
2.4 PRINTER FUNCTIONS AND PAPER ROLL REPLACEMENT............................................................ 12
2.5 TECHNICAL FEATURES .....................................................................................................................13
3 FBC MODE FUNCTIONS ..........................................................................................................................15
3.1 TURN ON .............................................................................................................................................15
3.2 ACCESSING THE FUNCTIONS ...........................................................................................................15
3.3 MAIN PAGE DESCRIPTION ................................................................................................................15
3.4 ADJUSTING THE DISPLAY BRIGHTNESS .........................................................................................15
3.5 TURNING OFF THE SYSTEM .............................................................................................................15
3.6 WATER MANAGEMENT ......................................................................................................................16
3.7 AUTOMATIC WATER LOADING .........................................................................................................16
3.8 MANUALLY LOADING A COMPONENT .............................................................................................16
3.9 LOADING COMPONENTS THROUGH WEIGHING ............................................................................17
3.10 LOADING PROGRESS INDICATORS .................................................................................................17
3.11 CANCELLING LAST WEIGHING .........................................................................................................17
3.12 TIP-OFF (DYNAMIC WEIGHING) ........................................................................................................18
3.13 BAG-COUNTING FUNCTION............................................................................................................... 19
3.14 RESETTING MEASURED WEIGHTS ..................................................................................................19
3.15 COMPLETING WATER LOADING .......................................................................................................20
3.16 PRINT MENU .......................................................................................................................................20
3.17 HELP PAGE .........................................................................................................................................21
3.18 ALARMS PAGE ....................................................................................................................................21
3.19 CALIBRATING THE TARE ...................................................................................................................22
3.20 ADDITIONAL FUNCTIONS ..................................................................................................................24
3 CBV STANDARD MODE FUNCTIONS .....................................................................................................25
3.1 TURN ON .............................................................................................................................................25
3.2 ACCESSING THE FUNCTIONS .......................................................................................................... 25
3.3 MAIN PAGE DESCRIPTION ................................................................................................................25
3.4 ADJUSTING THE DISPLAY BRIGHTNESS .........................................................................................25
3.5 TURNING OFF THE SYSTEM ............................................................................................................25
3.6 SELECTING A RECIPE ........................................................................................................................26
3.7 MOISTURE OF AGGREGATES ...........................................................................................................26
3.8 SELECTING THE VOLUME .................................................................................................................27
3.9 AUTOMATIC WATER LOADING .........................................................................................................27
3.10 LOADING COMPONENTS THROUGH WEIGHING ............................................................................28
3.11 MANUALLY LOADING A COMPONENT .............................................................................................28
3.12 LOADING PROGRESS INDICATORS .................................................................................................29
3.13 CANCELLING LAST WEIGHING .........................................................................................................29
3.14 TIP-OFF (DYNAMIC WEIGHING) ........................................................................................................29
3.15 AUTOMATICALLY LOADING THE ADDITIVE .....................................................................................30
3.16 WATER LOADING ................................................................................................................................31
3.17 BAG-COUNTING FUNCTION............................................................................................................... 32

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CONTENTS
3.18 VIEWING THE MIXING STATUS .........................................................................................................32
3.19 POURING THE MIX .............................................................................................................................33
3.20 RESETTING THE VALUES OF THE WEIGHTS MEASURED ............................................................33
3.21 PRINT MENU .......................................................................................................................................34
3.22 HELP PAGE .........................................................................................................................................36
3.23 ALARMS PAGE ....................................................................................................................................36
3.24 CALIBRATING THE TARE....................................................................................................................36
3.25 WATER MANAGEMENT ......................................................................................................................38
3.26 FUNCTION MENU ................................................................................................................................38
3 CBV ADVANCED MODE FUNCTIONS .....................................................................................................41
3.1 TURN ON .............................................................................................................................................41
3.2 ACCESSING THE FUNCTIONS .......................................................................................................... 41
3.3 MAIN PAGE DESCRIPTION ................................................................................................................41
3.4 ADJUSTING THE DISPLAY BRIGHTNESS .........................................................................................41
3.5 TURNING OFF THE SYSTEM ............................................................................................................41
3.6 SELECTING A RECIPE ........................................................................................................................42
3.7 MOISTURE OF AGGREGATES ...........................................................................................................42
3.7.1 Manually enter the humidity percentage................................................................................................42
3.7.2 Use of the Mikrolab...............................................................................................................................43
3.7.3 Use of the moisture probe..................................................................................................................... 44
3.8 SELECTING THE VOLUME .................................................................................................................44
3.9 AUTOMATIC WATER LOADING .........................................................................................................44
3.10 LOADING COMPONENTS THROUGH WEIGHING ............................................................................45
3.11 MANUALLY LOADING A COMPONENT .............................................................................................45
3.12 LOADING PROGRESS INDICATORS .................................................................................................46
3.13 CANCELLING LAST WEIGHING .........................................................................................................46
3.14 TIP-OFF (DYNAMIC WEIGHING) ........................................................................................................46
3.15 AUTOMATICALLY LOADING THE ADDITIVE .....................................................................................47
3.16 WATER LOADING ................................................................................................................................48
3.17 BAG-COUNTING FUNCTION............................................................................................................... 48
3.18 VIEWING THE MIXING STATUS .........................................................................................................49
3.19 POURING THE MIX .............................................................................................................................49
3.20 RESETTING THE VALUES OF THE WEIGHTS MEASURED ............................................................50
3.21 PRINT MENU .......................................................................................................................................50
3.22 HELP PAGE .........................................................................................................................................52
3.23 ALARMS PAGE ....................................................................................................................................52
3.24 CALIBRATING THE TARE....................................................................................................................52
3.25 WATER MANAGEMENT ......................................................................................................................54
3.26 FUNCTION MENU ................................................................................................................................55
3.27 DATA SENT TO GPS AND GPRS SYSTEMS ..................................................................................... 56
4 FBC MODE FUNCTIONS FOR THE FOREMAN ONLY ............................................................................57
4.1 MENU SETTINGS ................................................................................................................................57
4.2 MENU FOREMAN ................................................................................................................................57
4.3 COMPONENTS AND RECIPES ...........................................................................................................58
4.4 SYSTEM CONFIGURATION................................................................................................................ 59
4.5 DIAGNOSTICS .....................................................................................................................................59
4.6 SYSTEM DIAGNOSTICS .....................................................................................................................59
4.7 PASSWORD CHANGE ........................................................................................................................59

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CONTENTS
4.8 SETTING THE CLOCK .........................................................................................................................60
4.9 PRINTING THE PARAMETERS ...........................................................................................................60
4 CBV STANDARD MODE FUNCTIONS FOR THE FOREMAN ONLY ......................................................61
4.1 MENU SETTINGS ................................................................................................................................61
4.2 MENU FOREMAN ................................................................................................................................61
4.3 COMPONENTS AND RECIPES ...........................................................................................................62
4.3.1 Entering the components .......................................................................................................................62
4.3.2 Creating mixes .......................................................................................................................................63
4.3.3 Downloading components and recipes ..................................................................................................64
4.3.4 Uploading components and recipes ......................................................................................................64
4.4 SYSTEM CONFIGURATION................................................................................................................ 65
4.5 MACHINE DIAGNOSTICS ...................................................................................................................65
4.6 SYSTEM DIAGNOSTICS .....................................................................................................................65
4.7 PASSWORD CHANGE ........................................................................................................................65
4.7 SETTING THE CLOCK .........................................................................................................................66
4.8 PRINTING THE PARAMETERS ...........................................................................................................66
4 CBV ADVANCED MODE FUNCTIONS FOR THE FOREMAN ONLY ......................................................67
4.1 MENU SETTINGS ................................................................................................................................67
4.2 MENU FOREMAN ................................................................................................................................67
4.3 COMPONENTS AND RECIPES ...........................................................................................................68
4.3.1 Entering the components .......................................................................................................................68
4.3.2 Creating mixes .......................................................................................................................................69
4.3.3 Downloading components and recipes ..................................................................................................70
4.3.4 Uploading components and recipes ......................................................................................................70
4.4 SYSTEM CONFIGURATION................................................................................................................ 71
4.5 MACHINE DIAGNOSTICS ...................................................................................................................71
4.6 SYSTEM DIAGNOSTICS .....................................................................................................................71
4.7 PASSWORD CHANGE ........................................................................................................................71
4.8 SETTING THE CLOCK .........................................................................................................................72
4.9 PRINTING THE PARAMETERS ...........................................................................................................72
5 ALARM LIST ..............................................................................................................................................73
5.1 OPERATING ALARMS .........................................................................................................................73
5.2 SYSTEM DIAGNOSTICS ALARMS .....................................................................................................73
5.2 ALARM TABLE .....................................................................................................................................74
6
6 CBV STANDARD ADDITIVE FEEDER
.....................................................................................................
.....................................................................................................
77
77
6.1
6.1 TECHNICAL DATA
...............................................................................................................................
...............................................................................................................................
77
77
6.2
6.2 REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES
.......................................................
.......................................................
77
77
6.3
6.3 FILLING THE ADDITIVE TANKS
..........................................................................................................
..........................................................................................................
78
78
6.4
6.4 SCHEDULED MAINTENANCE TABLE
................................................................................................
................................................................................................
78
78
6.5
6.5 CHECKING AND MAINTAINING
..........................................................................................................
..........................................................................................................
79
79
7
7 CBV ADVANCED DOUBLE ADDITIVE FEEDER
.....................................................................................
.....................................................................................
81
81
7.1
7.1 TECHNICAL DATA
...............................................................................................................................
...............................................................................................................................
81
81
7.2
7.2 REFERENCES AND DESCRIPTIONS OF THE MAIN DEVICES
.......................................................
.......................................................
81
81
7.3
7.3 FILLING THE ADDITIVE TANKS
..........................................................................................................
..........................................................................................................
82
82
7.4
7.4 SCHEDULED MAINTENANCE TABLE
................................................................................................
................................................................................................
82
82
7.5
7.5 CHECKING AND MAINTAINING
..........................................................................................................
..........................................................................................................
83
83
REV. 01 24/03/2015

7REV. 00 02/01/2015
id.:
WARNINGS
1
- Carefully read this manual for proper use of the system.
- Before cleaning the system, turn off the vehicle.
- Use only a clean moist cloth to clean the system. Do not use liquid products or aerosols.
- Do not spray water directly or indirectly onto the device with a hose or use pails of water or similar.
- Do not let the system come into direct contact with:
- Ammonia
- Acetone
- Benzene
- Hydrocarbons
- Perchlorethylene
- Trichlorethylene
- Methanol
- Dishwasher detergents
- Washing machine detergents
- Dichloromethane
- Ethyl ether
- Toluene
- Do not insert any objects in the system or the printer casing as they may damage some parts vital for proper
functioning.
- Do not operate on the system in any way except for the maintenance operations described in this manual.
- For any problem not indicated in this manual contact the supplier.

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SYSTEM DESCRIPTION
2
2.1 SETTING UP
The system is made up of one of the following modes; each version calls for a specific configuration which is
described in the diagram in which we include all the available options.
A sensor kit is provided for each mode.
FBC Weighing
Component Archive Management
Setting up preset values
Print receipt
Water pump automatic management
Standard USB port (for software upgrade only)
CBV STANDARD Component Archive Management
Setting up preset values
Advanced weighing with angle compensation (proximity),
Recipe Archive Management and components ratio recalculation
Water compensation in hygroscopic components
Advanced USB port for upgrading the software, downloading receipts, and uploading/
downloading components and recipes.
Automatic management of the water pump and additive pump
Mixing quality control
CBV ADVANCED Component Archive Management
Setting up preset values
Recipe Archive Management and components ratio recalculation
Advanced weighing with angle compensation (tilt sensor),
Machine tilting safety check
Water compensation in hygroscopic components
Advanced USB port for upgrading the software, downloading receipts, and uploading/
downloading components and recipes.
Automatic management of the water pump and additive pump
Mixing quality control
Moisture Probe and Mikrolab management
Data transmission management towards a GSM/GPRS communication device
The system has been designed to operate on a concrete production vehicle.
It allows to set up different mix and visualize and record the quantity of components (cement, water, gravel,
sand, etc.) used
After storing the components and the recipes, the electronic system allows monitoring the correct quantity of
each component of each recipe during loading.
The recipe complete with a list and weight of the components can be printed using the printer unit FPR282
(optional) and stored in electronic format on a pendrive so that you have a record of the operations performed
and can keep track of the compositions made.

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SYSTEM DESCRIPTION
2
2.2 COMPONENTS
1 - Operating panel
2- Display
3- Keypad
4- Printer connector
5- System wiring connector
6- USB
7- Buzzer
8 - Printer
9- Thermal paper roll
3 412
567
8
9

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SYSTEM DESCRIPTION
2
2.3 KEY FUNCTIONS
Key Function when weighing Function when editing
Print receipt Alphanumeric input
Access the mixing page Alphanumeric input
Start and stop (hold down for 3 secs.) Alphanumeric input
Alphanumeric input
Alphanumeric input
Access the “short manual” (hold down for 3 secs.) Alphanumeric input
Accessing the bag-counting function Alphanumeric input
Alphanumeric input
Access the diagnostics page
Activates the “reset weight” function (hold down for 3 secs.)
Activates the “boom calibration” function (hold down for 3 secs.) Alphanumeric input
Access the FUNCTIONS menu Alphanumeric input
Exit editing
Cancel the last weighing
Access the water management menu
Activates the tip-off mode Alphanumeric input
Activates the component manual loading selection Alphanumeric input
Confirms selection
Navigation keys Navigation
Adjusts screen brightness Navigation

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SYSTEM DESCRIPTION
2
3
4
12
2.4 PRINTER FUNCTIONS AND PAPER ROLL REPLACEMENT
The printer is used to print the the record (of each single load).
1Button to open the cover to replace the paper roll and a
status LED:
a - When it is on fixed it means that there is no error.
b -
When it flashes slowly it means that the paper has run out.
c - When it flashes fast it means that there is an error
(head overheating or power supply fault).
2FEED button (paper feed).
3Paper outfeed.
4Paper roll.
To replace the paper roll:
Press the key “1” to open the cover.
Remove the used paper roll and insert the new one (paper
width 57 mm)
Closing the cover insert the border of the paper roll in the
suitable opening “3”

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SYSTEM DESCRIPTION
2
2.4 TECHNICAL FEATURES
Control unit dimensions 160 x 120 x 80 mm
Printer dimensions 120 x 120 x 80 mm
Supply voltage 10 ÷ 35 Vdc
Allowed ambient temperature during the operating phase -20°C) / +60°C
Allowed ambient temperature during the non-operating phase -30°C) / +80°C
Maximum front tilting (Y axis) of the machine during weighing (**) ± 10°
Paper type for printer Thermal
Maximum number of recipes (*) 16
Maximum number of components for each recipe 8
Maximum number of components available in the data storage 32
Languages 9
Selectable unit of measurement kg / lb
Water compensation in the components (*)
Compensation of the machine’s front tilting (Y axis)
during the weighing phase (*) within the ± 10° range
(*) not available in FBC mode
(**) ± 2.5° in FBC mode

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FBC MODE FUNCTIONS
3
3.1 TURN ON
Press and hold the key until the start page is displayed.
The start page is displayed for a few seconds,
3.2 ACCESSING THE FUNCTIONS
Enter the user identification code (max. 4 digits).
Press the OK key to confirm.
Press ESC to skip.
3.3 MAIN PAGE DESCRIPTION
1 - Recipe components
2 - Preset weights
3 - Measured weights
4 - Displays loading progress of the selected com-
ponent
5 - Zoom of PRESET and MEASURE values of the
selected component
The yellow colour and the yellow arrow highlight the
selected component
Use the navigation keys to select the product
you want to upload
3.5 TURNING OFF THE SYSTEM
From the main page: press and hold the key until it turns off.
3.4 ADJUSTING THE DISPLAY BRIGHTNESS
From the main page press the indicated keys to increase or reduce the brightness.
12
3
4
55

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FBC MODE FUNCTIONS
3
Press the key to access the water management menu.
There are two different modes available for using the water:
A) Washing water
Normally used to wash the machine. The system does not count the amount of supplied water.
To activate the supply of washing water:
- Select “WASHING MODE”
- Press or
To stop the water supply:
- Select “WASHING MODE”
- Press again or
First stop threshold during the
water loading phase
B) Recipe water
You may set the threshold (%) at which the system will stop loading water during the first loading phase.
3.6 WATER MANAGEMENT
3.7 AUTOMATIC WATER LOADING
Select the “WATER” component
Press OK (a message is displayed)
Press OK again to confirm or ESC to
return to the previous step.
When the OK key is pressed, the water loading phase
starts; the loading progress is visible.
The water loading phase may be started through an
external device (Mix control); the device automatically
turns the pump off as soon as the preset value is
reached.
The water loading phase is carried out until the
set threshold is reached (e.g. 70%).
The remaining water will be loaded at the end of the loading phase by repeating the automatic water
loading operation.
3.8 MANUALLY LOADING A COMPONENT
Press the navigation keys to select the
desired component. Manually insert the
component in the drum .
Press the manual loading key.
A
B

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FBC MODE FUNCTIONS
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3.9 LOADING COMPONENTS THROUGH WEIGHING
The required engine speed is 2000 revs/min
- Select the desired component
- Load the component into the bucket.
- Withdraw the bucket (A)
- Lift the bucket maintaining a constant speed.
- Repeat the operation until the preset value is reached.
During the first weighing a lower
value has been reached and
therefore the operation
The preset value has been exceeded
The red bar indicates an overload
The following alarm message is displayed:
excessive load
3.11 CANCELLING LAST WEIGHING
If the preset weighing value is exceeded, before pouring the material you may:
Press the indicated key to cancel the weighing, then lower the bucket to pour some material and
repeat the loading operation of the component through weighing.
3.10 LOADING PROGRESS INDICATORS
The loading progress for each individual component is displayed by means of:
- loading progress bar (from 50% to 100%)
- progressive acoustic signal (from 50% to 100%)
A screen will be displayed, in which the user will input
the amount of material to be loaded: the number in
green represents the recipe PRESET, whereas the
number in yellow indicates the total amount of material
to be loaded. Input the desired amount and press OK
to confirm.
A

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FBC MODE FUNCTIONS
3
3.12 TIP-OFF (dynamic weighing)
If the preset weighing value is exceeded, before pouring the material you may:
Press the indicated key to shift to the dynamic reading, then open the pouring door located on the
bucket and pour the material until the preset value is reached.
Once the preset loading progress value is reached, as
long as it falls within the set tolerance limits, the bar
becomes green
press OK to confirm the end of the TIP OFF and pour the product from the drum.
Continue loading the other components by completing the recipe.
Complete the mixing of the final product and pour it.
Press the button (A) on the joystick and shift it to the
left to open the hydraulic loader hatch and unload the
quantity of material necessary to reach the required
weight.
Shift the joystick to the right to close the hatch.
N.B.: Do not move the arm during tip-off; take into
accountthe weightshown inposition ‘1’,always moving
the bucket to the same point where it was at the time of
activating the tip-off function.
N.B.: the precision of the weight in “Tip-Off” mode is
usually less than the one in standard conditions
A

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FBC MODE FUNCTIONS
3
3.13 BAG-COUNTING FUNCTION
Select the component CEMENT and press the key .
Lower the arm.
Lift the arm back up until the STOP signal is displayed.
Input the weight value of each single bag (25, 30, 42.5,
…...).
Press OK .
The system will indicate the number of bags to be
loaded.
After reaching the number of bags indicated, press OK
and load the material.
Number of bags
to be loaded Number of bags
loaded
3.14 RESETTING MEASURED WEIGHTS
To start a new recipe
Press and hold the C key until the cancellation message is displayed.
Press OK to reset
All values have been reset
You may now start loading the components for a new
recipe.

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FBC MODE FUNCTIONS
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3.15 COMPLETING WATER LOADING
Afterloadingall therecipecomponents, thewatercycleneedstobecompleted byrepeatingthe stepsdescribed
in paragraph 3.6.
3.16 PRINT MENU
Press 1 to access the print menu.
Press SELECT to select the mixing you want to print.
Press 0 to deselect
press the SELECT key + Arrows for multiple selections,
Press 0 + arrows for multiple deselections,
select all items by pressing and holding down the SELECT key,
deselect all items by pressing 0 and holding it down.
List of mixings performed: (Date and time of beginning
of mixing cycle)
The dot indicates that the recipe has not been printed
yet
Progressive number
Once you have selected the recipe you want to print,
press OK or printing key 1 .
If multiple selections have been made, printing will be
performed in succession.
Press ESC to return to the recipe page