PRABHAKAR, P.

Liquid Technology Application Specialist

Bentoli Agri Nitrition India P Ltd,

No.3f2 Third Floor, Front Block,

Building No: 115, Metro Tower,

Poonamallee High Road,

Chennai – 600084.

CUSTOMER RESPONSIBILITY
The customer in applying the applicator described in this documentation accepts that the applicator is a
programmable is fully automatic system which is inherently complex and which may not be completely free of
errors.in doing so the customer therefore undertakes responsibility to ensure that the applicator and
accordance with any instructions or safety precautions made available or good engineering practice and to
thoroughly verify the use of the applicator the particular application.

ERRORS IN DOCUMENTATION

The applicator described in this documentation is subject to continuous development and improvement. All
information of a technical nature and particulars of the applicator and its use including the information and
particulars contained in this documentation are given by Bentoli in good faith.
welcomes comments and suggestions relating to the applicator and this documentation please send this
mail id: prabhakarp@bentoli.com

Bentoli is dedicated to providing our customers with the highest quality products, services and consultative solutions
that will tangibly improve their operational and financial performance.
Contents
1 SAFETY INFORMATION ...................................................................................................................... 3
2. PRODUCT INFORMATION: ..................................................................................................................... 4
2.1 OVERVIEW OF THE APPLICATOR:..................................................................................................... 4
2.2 APPLICATIONS ...................................................................................... Error! Bookmark not defined.
2.3 PRODUCT SPECIFICATION .............................................................................................................. 10
2.4 SCHEMATIC DIAGRAMS: ................................................................................................................. 11
3. INSTALLATION ................................................................................................................................... 13
4. OPERATION INSTRUCTIONS ................................................................................................................. 14
5. MAINTENANCE ................................................................................................................................... 19
6. TROUBLESHOOTING ............................................................................................................................ 19

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that will tangibly improve their operational and financial performance.
1 SAFETY INFORMATION

Your Applicator should be operated according to the instructions in this manual. In particular
electrical specifications should be followed and met. It is important to use this equipment as specified
in this manual. Using this equipment in a different manner may impair the safety precautions of the
System.

THIS ATTENTION symbol is used to

refer to instructions in this manual
that need to be done carefully.

Other safety symbols

Electrical Equipment Safety WARNING!

Non-electrical workers may use electrical equipment, but must be
trained to know the hazards of the equipment and how to use the
equipment safely.
The hazards involved in it use, stop work and get the required training.
The Electrical safety precautions involve the risk of electrocution.
This may result in personal injuries, burns or death.
Always lock the door of the control panel to protect unauthorized
persons against electric shocks.

Chemical Liquid Safety

When handling the product, avoid direct contact with the skin and
inhalation of any dust, by wearing protective clothing, gloves and dust mask,
skin sensitization may occur when handling the product.
Contact with corrosive liquids may itch, irritate or burn the skin.it may
cause severe eye irritation and burn or irritation of the mouth and the
gastrointestinal system in case of oral intake.

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that will tangibly improve their operational and financial performance.
2. PRODUCT INFORMATION:

2.1 OVERVIEW OF THE APPLICATOR:

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that will tangibly improve their operational and financial performance.
OPERATING PANEL

Emergency Button
Spray Button

Touch Screen HMI

MACHINE CABINET

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CENTIFUGAL PUMP

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SOLENOID VALVES

Wiring Details

Phase Safety
CONTACTOR
MCB Relay Card

CONTACTOR

Level Transmitter

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LEVEL SENSOR

PLC

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TOWER LIGHT AND REMOTE WITH LIGHT

Emergency/Alarm

Buzzer
Spraying

Batching

Spray Button

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2.2 APPLICATIONS
Following are applications of Applicator.
This can be used to mix two Liquid nutrients or water etc.

2.3 PRODUCT SPECIFICATION

Automatic Applicator
Range – Up to 60Ltrs
Tank SS
Capacity 60L
Frame finish Epoxy Painted
INSTRUMENTATION
Electrical Control Panel
Type Automatic
Finish Epoxy Painted
PLC Advance PLC model
HMI 3.5 “ Touch screen
Weight transmitter Load cell.
Range 0-100 kg
Level sensor No type
Counter Digital Counter
Type Inbuilt in HMI (Programmable)
Timer Digital Timer
Type Inbuilt in HMI (Programmable)
Pump 1)Spray-1HP,415V,1.8A 3 phase, 2900 RPM
(Centrifugal) 2)Water-0.50HP,220V,2.5A,1 phase,2800RPM
3)Nutrient-0.16/0.12HP,230V,1A,1 phase,2900RPM
Weight Input Device Inbuilt in HMI (Programmable)
Solenoid Valve 1).14W size-15MM 2 nos
2)0.5-12bar
Tower Light & For Indicating Batching, Spraying and Emergency
Remote control with
light indicator
Other Supportive Nut, Nipple, Adopters, Solenoid valves, MCB, Bulb,
Accessories Switches etc.

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that will tangibly improve their operational and financial performance.
2.4 SCHEMATIC DIAGRAMS:

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that will tangibly improve their operational and financial performance.
WIRING DIAGRAM

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3. INSTALLATION

1. Fill the Pumps with liquid. Ensure that it should not run dry.
2. The Tank is equipped with Weight Gauge and level sensor.
3. Pumps and inlet Oil supply are connected with Mesh filter, so dirt will not go into the work piece
during operation.
4. Check the calibration set the limits.
5. Connect all the pumps and valves to all specified connections.
6. Connect the proper phase connection to main power supply.

WARNING! The equipment must be connected to a grounded main

Socket. The mains power switch must always be easy to access. And never run pump dry.

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that will tangibly improve their operational and financial performance.
4. OPERATION INSTRUCTIONS
Following steps should be follow carefully during operation :-

Screen Navigation
Password Protected

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that will tangibly improve their operational and financial performance.
 HMI Operation
1. Welcome Screens / Logo Screens

When the PLC program starts up, Welcome / Logo screens appear on the HMI. These screens unload
automatically after a few seconds and lead to the next screen. Among them are logo screens of Fermex
and Bentoli. User has the option to unload these screens as soon as they appear i.e. without any delay
by touching the area of the screen just below the logo.

2. Home Screen

The automatic navigation of screens ends when the Home screen comes up. This screen informs user
about the basic status of the Applicator. It displays the current operational mode of the applicator
marked as STATUS. Status displays one of the following information:

OFF = When the Batching control is enabled & Spray control is off.

BATCHING = When the Batching is going on.

BATCH OVER = When the batch is READY for spraying & Spray control is off.

SPRAYING = When Spray control is ON.

Just below the STATUS, information appears when high level alarm condition for tank is present.
Buttons that lead to ‘Last Batch’ and ‘Settings’ screen are located at the bottom of the ‘Home’ Screen.

When the user is on any screen other than ‘Home’, there is an icon at the top left corner of all
screens which leads directly to the ‘Home’ screen.

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that will tangibly improve their operational and financial performance.
2. Last Batch

This Screen gives information about the last successful batch. At the bottom left corner of the screen,
there is a batch counter which increments by one after every successful batch. There is also a RESET
button at the bottom right to reset the counter to zero.

Touching the icon located at the top right corner of this screen leads back to the ‘Home’ screen.

3. Settings

This screen has buttons to access sub-menu of settings. Process settings, Calibration settings, Delay
settings and Alarms settings are the sub-menu of settings.

Touching the icon located at the top right corner of this screen leads back to the ‘Home’ screen.

4. Process Settings

On this screen, process parameters can be edited to suit the required batch. There is also an option to
enable/disable the Batching control (just above the ‘water’ label). Under the heading ‘SV’, the Set
Value of Water or Amonex can be edited by the user. Information about whether water and amonex
pump/valves is presently ON or OFF is displayed under the ‘Status’ label.

It is highly recommended that the Batching control be DISABLED before disconnecting the
applicator power connection. This is to avoid any possible fluctuation on the process values during
switchgear start up.

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that will tangibly improve their operational and financial performance.
Touching the icon located at the top right corner of this screen leads back to the ‘Settings’ screen.

5. Calibration Settings

This is a password protected screen. During FAT of the applicator, the optimum values of X1, X2, Y1,
Y2 are calculated. Value calculation is a onetime exercise. In case of master reset, these values have to
be entered again to enable weight calculation. Other than master reset, these values don’t require
editing by the user (in most of the cases).

TARE is an option that is required by the user to set the present value of the weight as zero. Tare
should be done at regular intervals but it should only be done when the tank is empty and the
batching control is disabled.

If after spraying, the spray control goes OFF but the batching does not begin (given the
batching control is enabled), then it means that TARE has to be done to set whatever is left in
the tank as zero. This is a part of fine tuning and may be required for several batching cycles after
installation or movement of the applicator (or anything that disturbs the previous load cell values).

If TARE is still required after every single batching cycle for more than 6 cycles after
installation/movement , then adjustment of ‘Tank Min Load’ may be required. Please check point no
8 for further information.

Touching the icon located at the top right corner of this screen leads back to the ‘Settings’ screen.

6. Delay Settings

Under this sub-menu of the settings, Delay timings can be entered by the user. These values may be
set to zero if no delay is required, except for the spray pump. Spray Pump has been given a minimum
delay of 2 secs to allow the system to check incoming power before supplying it to the spray pump.
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that will tangibly improve their operational and financial performance.
Touching the icon located at the top right corner of this screen leads back to the ‘Settings’ screen.

7. Alarm Settings

Here we have the MRT or the Maximum Run Time of each pump. This is a protective feature and
should be used wisely by the user. If the MRT is more than required, it may not protect the pump
during dry run. If the MRT is less than required, it will frequently generate MRT alarms.

MRT Alarms are condition when Maximum Run Time of a pump is reached. During this alarm, a
window pops up to inform the user about the issue. During this period the PLC controls get frozen and
pump stops immediately.

Touching the RESET button on the alarm window resumes the system for another MRT cycle.

Touching the icon located at the top right corner of this screen leads back to the ‘Settings’ screen.

8. Master RESET & Tank Min Load

This option is password protected and comes under service/maintenance. It should NOT be used
unnecessarily. If required, it should be used by our service engineer or trained user (under the
guidance of our service engineer).

This ‘Master RESET’ screen can be reached by touching the screen area just above the FERMEX logo.
This will lead the user to a password screen. If correct password is entered, it will lead to the ‘Master
RESET’ screen

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that will tangibly improve their operational and financial performance.
Master RESET is used in case of any error in PLC address values or when PLC enters an unending
loop error. Using this option clears all values in the PLC program and sets them as zero and turns OFF
all controls. After Master RESET, all sub-menu under Settings need to be re-entered before using the
Applicator again.

Tank Min Load is a value in KG which the PLC considers as the allowed leftover liquid weight in the
tank. When the Total weight of the liquid in the tank decreases to this value, Batching restarts
(Ignoring the leftover liquid weight). Ideally, this value should be between 0 to 0.3 KG. If TARE is
required after every single batching cycle for more than 6 cycles after installation/movement, then
increasing the Tank Min Load by 0.1 or 0.2 values may solve the issue.

5. MAINTENANCE

1. Check tank before the start of the operation of the machine every time.
2. Check the Outlet and Inlet connection regularly.

6. TROUBLESHOOTING

1. If Batch ratio is not as per requirement, then go to HMI panel in setting in process enter the
required amount.
2. If any pump doesn’t work properly. Then,
a. Go to HMI panel setting in process check the status and
b. Check the solenoid valve coil connected to the Hydro pump. It might need a
replacement.
3. Calibration can be checked under Settings in calibration Screen to ascertain which valve is set
for dry and maximum filled tank.
4. If still problem persists; contact us.
5. For any other electrical or electronic fault; contact us.

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that will tangibly improve their operational and financial performance.
NOTES: