Hitech ZycoTherm User manual

ZycoTherm Pump
In-Line Blend Pump
User Manual
Hi - Tech
H
i -
i -
T
TechT
ech
TechT
ech
ech
ASPHALT SOLUTIONSASPHALT SOLUTIONS www.HTAS.com
[phone]
6055 Mechanicsville Turnpike
Mechanicsville, VA 23111

Page 1
In-Line Blend Pump
Install & User Manual
Plan a suitable location for the pump and the ZycoTherm material tote. The In-Line Blend Pump should
be located within 15 feet of the injection site, the closer the better. Typical injection location of
material is in the AC strainer before the AC Pump. Because this is the suction side of the system this
alleviates any potential back pressures into the Blend Pump and causes the greatest amount of mix
time to properly blend into the AC. The separate control box should be placed inside the control
house.
The Blend Pump requires 120VAC on a 20amp circuit. It is recommended to hard wire the pump. In
addition to power, the pump also requires a cable run from the Control House to the pump location.
This cable is for communication, and CAT5 Ethernet cable is typical because it is easy to find. CAT5
cable not supplied with pump.

Page 2
1.) Run the CAT5 from the electrical box at the pump to the control box located in the control
house. Insert the communication wires from the CAT5 cable into the Green 5 Pin Connector and
insert it on the top of the Touch screen. You will wire both the touch screen at the pump and
the touch screen in the control house with the CAT5 cable the same way. Take care to leave
the resistor and any existing wiring in place. Unused wires from the CAT5 can be cut or taped
back. NOTE: incorrect wire placement can burn the resistor.
+V – Blue wire
H – Brown wire
PE – Green wire
L – White wire with Brown stripe
-V – White wire with Blue Stripe
2.) Plug in or hard wire the pump power.
3.) Turn on the pump electrical box and the control box in the control house and look for a green
“Comm” in the upper right corner of the touch screen. If red “No Comm” is showing there is no
communications between the pump and the controller, and wiring should be checked.

Page 3
4.) Connect supply hose (yellow) to material Tote using supplied connectors. The plastic male cam-
lock should be transferred from old tote to new tote when replacing the material totes.
5.) Remove Center Cap from top of material tote. Pull rubber plug, punch out center plastic piece
with #2 philips screwdriver and place rubber plug back. A reusable vented cap may also be
purchased and can help keep moisture out of the product.
Prime and Calibrate
6.) The pump must be primed prior to being put into service. This is to fill the hose with product
and to displace any air that may be in the lines. Attach the quick connect with ball valve on the
end of the red hose and place it just inside the tote. This is for initial priming only and needs
only to be done at install.
NOTE: these are NO FLOW quick disconnects. Without mating them together no flow will
occur and will likely result in pump damage.
After prime and calibrate, close the Tote lid and place Ball Valve onto the Injection site.

Page 4
Prime and Calibrate should be done at the pump.
Cut off metal straps and unscrew the lid.
With the pump power on and the installation section complete the output hose should be in the
top of the Tote with the ball valve or at least the mating quick disconnect, connected.
Controller Calibration
The Touch Screen ------ all highlighted items are buttons on the touch screen
Press Settings, Calibration
Press PID ON --- This will change to PID OFF
Press to the right of VFD% and type in 100 and Press enter
Press Back
Set Start Delay to 0
Set Time out of Tolerance to 0
Press Back
Set all options to a typical plant run. Ideally Target Flow Rate should be greater than 0.04
Press Start
Flow should begin shortly. Do not run for more than 3 min.
Once Steady flow is achieved
Press Stop ----- same location as start
Press Settings, Calibration
Press to the right of VFD% and type in 50 and Press enter
Press PID OFF --- This will change to PID ON
Press Auto Tune? --- This will change to Auto Tune On Next Run
Press Back, Back, Start
The frequency drive will go from 0 to 60 several times.
Once the Flow rate stabilizes (Less than 5 min on average) the Pump can be stopped and connected
as a typical run would be. Close the Tote lid and place Ball Valve onto the Injection site.

Page 5
Running Screen
This is the Running Screen. From this screen you can start a run, navigate to the settings
menu, view faults, and see information about the current run.
START - This button will begin a run and start the timer. Once pressed will change to STOP,
and once the timer has ended the Red light above will turn green indicating pump is in motion.
COMM - This button indicates if there is communication between the pump and the controller.
If it says NO COMM then there is no communication between the pump and the controller.
SETTINGS - This button will take you to the settings menu.
FLOW RATE - Indicates the current flow rate of a run. It will constantly adjust depending on
the liquid moving through the pump.
TARGET FLOW RATE - This is the target flow rate derived from the material %, TPH, and
AC% - These parameters must all be inputted manually. When an Analog signal is present
either Plant TPH or AC TPH can be tracked depending on setup - see Tie-In Options for
details.PUMP SPEED - This is the output % that the controller is sending to the pump. This
will constantly adjust depending on the current flow rate and need.

Page 6
MATERIAL % - This is the percentage of ZycoTherm to be added to the AC.
AC% - Your AC% is manually typed in. This button may alternatively say “AC TPH” if an
analog signal is connected. AC TPH can only be achieved using an analog signal from the
plant and can not be manually entered from this screen.
THP – This button is the plant Tons Per Hour target. It can either be manually entered here or
entered through the use of an analog signal with proper setup. It is recommended to set up the
analog signal to represent the AC TPH and not use the manual option.
SUB – T & TOTAL – This is a running tally of the material that has been run. They can be set
independently depending on the needs of the plant.
NO FAULTS – This button will indicate if there are any faults with the pump. Faults include:
High/Low/No Flow – Drive Fault – E-Stop @ Pump – E-Stop @ Control – No Disk @ Pump –
and Replace Tote. All warnings will turn this button red with Yellow lettering describing the
warning.

Page 7
Settings Screen
TOLERANCE – This button shows the percent allowance of tolerance before the audio alarm
will begin to count down.
TIME OUT OF TOLERANCE - Shows the amount of time out of tolerance before the audio
alarm will sound.
VOLUMES – This button can be set to gallons or liters. When it is set to gallons, all math will
use U.S. tons in the equations. When it is set to liters, all math will use metric tonnes for
factoring equations. All targets and flow rates will also be reflected as either the selected
gallons or liters.
FLOW RATE PER – This button can toggle between a rate of Gallons per hour/Liters per hour
and Gallons per minute/Liters per minute. Per hour or per minute will depend on the volume
selected and the calculated time needed to run the volume.
START DELAY – This button will allow you to set the delay of the start of the pump in seconds
once the start button has been pressed (Zero is an option). When you press START from the
RUNNING SCREEN this timer will count down before the pump actually begins. This is
implemented so that if plant issues occur with the AC pump, the ZycoTherm pump will not turn
on and off with every attempt of the AC pump.
CALIBRATION – This button is only available at the pump.

Page 8
TIE IN OPTIONS SCREEN
NO ANALOG – ANALOG INPUT 4-20mA – ANALOG INPUT 0-10V – These are all the same
button in the top left of the screen. You can press the button to cycle through the different
options.
ANALOG SIGNAL REPRESENTS – This will determine what the analog signal represents.
Either Plant Tons Per Hour or AC Flow Tons Per Hour. Press the button to cycle through the
two options.
HOW LONG OUT OF TOLERANCE – Set in seconds, this button will allow you to adjust the
number of seconds the pump can be out of tolerance before the “No Flow Output” is triggered.
The right hand side of this screen deals with the actual input of the analog signal. It displays
the present voltage, voltage (0-10V), or current(4-20mA), and the representation of the signal.
The linearization maximum can be adjusted to match up with what the plant displays as TPH
or AC TPH. "Multi point" button will let you into an advanced method of analog scaling.

Page 9
Print Options Screen
This is the Print Options screen. It will allow you to adjust the printing options for reports should
you have a printer attached.
You can set the date and time here, set how often a report will be printed, and print a test
print to make sure the printer is working.
BAUD RATE – This is the rate at which the controller communicates with the external printer.
The rate on the controller must match the rate on the printer to obtain a readable printout. The
controller can communicate with any printer through a serial RS232. Please note that all
reports and information are also being sent to the micro SD card at the rear of the touch
screen. This information will be recorded on the SD card with or without a printer attached. By
default it will record to the SD card in one minute intervals.

Page 10
Tote Screen
This is the Tote Screen – From here you can change the number of gallons per tote (Totes are
shipped by default with 264 gallons of product)
You can adjust the percentage at which the pump will alert you when your tote is getting low.
Once your tote has reached this level, an alarm will sound after each run until the tote is
changed and reset.
You can turn the audio warning alarm on or off here.
When a new tote is installed you will need to reset the counter so that the system can keep
track of how much product has been used and how much is left.
This screen is where you will reset the counter when a new tote has been installed.

Page 11
Pump Only Calibration Screen
VFD % - Here you can manually input how fast to run the pump. If the pump is already running
when you adjust the % it will immediately be overridden by the PID.
PID ON – PID OFF - Turns the PID on and off. The PID is what controls the speed of the pump
depending on need. This should only be turned off when first installed and attempting to prime.
AUTO TUNE? – AUTO TUNE ON NEXT RUN – This will allow the PID to self-adjust its
settings to get the best possible flow rate. Should only be done at factory and at plant
installation.