BI Series Manual BM-ICS-100-01 -...


0BChapter 1 1.1 Product Introduction

Thank you for choosing BlackWorks®. We fully appreciate that you have a choice when it comes to purchasing your black oxide equipment. We have made every effort to provide you the highest quality products available in the industry so that the next time you need additional equipment or supplies; we will hopefully be the first ones on your list. 1.2 Package Contents

Check your itemized packing slip and compare with the following items. Controller 1 x 200 Series Control, pre-programmed for 290°F

UOR 1 x 400 Series Control, pre-programmed for 290°F

Tank 1 x Black Oxide Tank 1 x Electric heating element, pre-installed 1 x k-type thermocouple, pre-installed 1 x Table top tank stand

Documentation Controller user manual

If any of the above contents are missing or damaged, contact your dealer. You may have additional items on your packing slip depending upon your specific order build.

1.3 Special features

1.3.1 Product highlights

• Electrically heated black oxide tank

The entire control system including the heating and water control is electrically operated, eliminating the need for propane or natural gas connections.

• Fully self-contained electronic control cabinet

All of the electronics are completely contained in a single housing, making it safe, secure and easily mountable.

• Completely portable system, featuring Quick-Disconnect plugs The control box and tanks are easily portable, featuring quick-disconnect power plugs and thermocouple from the tank to the controller.

• 120 Volt and 220 Volt AC configurations are available

Depending upon your needs and power availability, both 120 Volt and 220 Volt AC controls are available to provide full flexibility in your installation.

• Wide range of available wattages for heating elements Choose anywhere between 1500 watts and 6000 watts of power.

• Automatic water replenishing system add-on capable

The innovative Fully Automated Water Supply System (FAWSS) which can be added at anytime before or after initial purchase; providing additional system flexibility.


• U.S. Made with a full 1 year warranty parts & labor

Proudly made in the United States using only the highest quality components. A full 1 year warranty on parts & labor, 2 years on parts. The best warranty in the industry, period.

1.3.2 Innovative Blackworks® features

• Revolutionary & Patent-Pending IntelliControl System™ (ICS) Featuring an entirely revolutionary advancement in the control of black oxide processing systems. A custom programmed, artificially-intelligent “Fuzzy-Logic” control using advanced mathematical algorithms to maintain proper temperature and water addition to your black oxide tank solution under any environmental conditions.

• Non-Volatile Memory

The ICS™ Controls programming and operating parameters are fully protected with non-volatile memory storage. Turning the power off on the control has no effect on its memory so you will never have to worry about memory loss due to power failure.

• Plug & Play ready

Quickly and effortlessly plug in the heating tank and the K-type Thermocouple into the ICS™ controller and turn on. Everything automatically configures for you and is immediately ready to run.

• K-type Quick-Disconnect Thermocouple

Industry-standard Quick-Disconnect highly precision K-type thermocouple. Providing extremely accurate temperature monitoring and extreme ease of assembly and disassembly for setup and mobility.

• Modular Heating & Water Control System

Both the tank heating elements and the fully automatic water supply system (FAWSS) is a self-contained modular unit. Allowing easy assembly and providing future add-on capability after the initial purchase if desire without any additional cost to the buyer.

• Extreme Versatility to Varying Element Wattages

Ability to vary element wattages depending upon your needs or power restrictions without having to re-program or modify the ICS™ controller. Fully plug & play feature.

• Over 700% Energy Savings Using Electricity Compared To Propane

Compared to the average cost of Propane at $2.75/gallon and electricity at 7¢ per kWh, using standard gas burners provides over a 700% savings in energy consumption. Not to mention in the tremendous advantages of heat and water control compared to using gas heated tanks.


1BChapter 2

2.1 Installation

To ensure a proper and professional installation of your new automatic black oxide system, please read all of the requirements contained in the installation instructions. You will have a more enjoyable experience as well as a safe one.

2.2 Space Requirements

You need to insure you have ample free space around your black oxide processing area. The black oxide tanks use a caustic solution which is an extreme oxidizer, which will cause severe burns if directly exposed.

Find an area that you can 100% dedicate to this operation. You will preferably want an area that has fresh water access and a drain or utility sink which you can use to wash and rinse your parts before and after running them through your black oxide tank. You should have at least 3-4 feet of open space around your operating tanks. You should have ample room to move around your area without the fear of tripping or running into objects while you are processing your parts.

The caustic fumes which come off of the heated black oxide solution are extremely corrosive. Because of this, make sure anything which might be effected such as steel, zinc coated sheet metal and especially ALUMINUM be completely absent from this area.

Because of the caustic and potentially life-threatening burns the black oxide solution can cause, keep ALL CHILDREN AND PETS AWAY FROM THIS AREA. Children and pets are curious and this is no place for either. Make sure there has been adequate precautions taken to prevent children and pets from gaining access to your work area at anytime, regardless of whether you are operating your system or not. 2.3 Electrical Requirements

Depending upon your specific model and specifications will determine your exact power requirements. We do not recommend using extension cords on any of the BI Series Controllers. Using an extension cord will cause a drop in line voltage resulting in loss of power and overheating of the controller. If you must use an extension cord, use the shortest length possible and use a Wire Gage size no smaller than the Wire Gage designated below for each BI Controller Series models.

• ELECTRICAL GROUND FAULT CIRCUIT INTERRUPTER

A ground fault circuit interrupt (GFCI) protection should be provided on the circuits or outlets to be used. Receptacles and/or breakers are available having built in electrical fault circuit interrupter protection and may be used for this measure of safety. If you have any questions regarding proper electrical installation, please consult a licensed electrician


• Electrical Connection To Controller

Depending upon your model, your controller will be configured for either 120 Volt AC or 220 Volt AC power. All of the controllers that are designed for 120 Volts AC come already wired with a standard 120 Volt household grounded 3-prong plug with an integrated GFCI. The controller models that are designed for 220 Volt AC do not come with an attached plug. Due to the various plug configurations that are possible in the industrial workplace, you will need to purchase the proper mating male plug that matches your existing female wall plug. If this procedure is beyond your scope of expertise, always refer to a license electrician for proper and safe installation.

BI 200-M120 System requirements:

Voltage: 120 Volts AC, 60 Hz AC Amperage: 15 Amp Ground Circuit minimal, (20 Amp Circuit recommended) American Wire Gage: 12 awg BI 400-A120 System requirements: Voltage: 120 Volts AC, 60 Hz AC Amperage: 15 Amp Ground Circuit minimal, (20 Amp Circuit recommended) American Wire Gage: 12 awg BI 400-A220 System requirements:

Voltage: 220-240 Volts AC, 60 Hz AC Amperage: 30 Amp Ground Circuit minimal, (40 Amp Circuit recommended) American Wire Gage: 10 awg

2.4 Water Requirements

If you have purchased a BI 400 Series controller, then you will also need to insure where you setup the black oxide tank has water plumbed to that area. The water needs to be clean, cold tap water. If you have an extremely hard water or sedimentary contaminated water such as a natural spring, you may have to install a filtration system to eliminate contamination in your black oxide finish.

• Water Pressure

Your incoming water pressure must not exceed 100 psi. Your FAWSS comes with a water pressure reducing regulator. It reduces your incoming water pressure down to a workable pressure of 5 psi to for your black oxide tank.

• Hook-up Connections

Do to the vast array of possibilities for different sizes and types of connections to our system; we have not included those items. Typically, it will only involve some simple pipe threaded connectors or water valves which can be easily obtained at your local hardware store. If you don’t feel comfortable with connecting the water system yourself, always consult a licensed professional plumber.


2.5 BI Series Controller Placement

First, determine what kind of incoming power your specific control is going to require. Ensure that you place the control in an area which has easy access to the power requirements of your specific controller. If you have a BI 400 Series Controller, then also make sure you have access to a water source.

• Easy Access To Control

Place the controller in an area which allows easy and unobstructed access. It is preferable that it be placed at or slightly below eye level, providing easy view of the temperature control readout and the LED lights on the front of the panel. It must also be within 6 feet of the black oxide tank to allow cable hook-ups between the tank and the controller.

• Cool And Dry Location

The controller needs to be in a dry location, free of water spray and possible contamination. Insure the controller is placed in location which is not in direct sunlight, full shade highly recommended. The controller gets warm during normal operation and needs to have proper ventilation and cooling to dissipate the produced heat inside.

• Mounting The controller has four mounting holes inside the control cabinet, one in each corner. The two (2) holes at the top are key-holes, allowing easier installation. Using a minimal of a #10 wood or metal screws, depending upon your surface you are mounting too, first mount the control using the top (2) key-holes. Once you have the control mounted in the location of your preference, proceed to install the remaining two (2) screws in the holes provided at the bottom of the control cabinet. ALWAYS SECURELY MOUNT THE CONTROL CABINET USING ALL FOUR (4) HOLES PROVIDED IN THE CABINET.


2BChapter 3

3.1 Unpacking your system

The IntelliControl System™ (ICS) from BlackWorks® comes in multiple boxes within a single crate. DO NOT USE A BOX KNIFE when opening the individual boxes. Doing so may inadvertently damage items within the boxes.

3.2 Boxed Labeled - CONTROLLER

The ICS™ controller is a complete, self-contained system. Along with the controller in the box you will find a paper template with the proper hole spacing for mounting the controller to a hard, solid structure. Using the template provided, install the two (2) screws at the top as shown in the template. This will allow you to mount the controller using the provided key-holes in controller cabinet first. Once you have the controller mounted using the two (2) top screws, proceed to install the reminder of the two (2) screws in the bottom holes. 3.3 Boxed Labeled - STAND

All of the black oxide tanks come with a standard table top tank stand. The tank stand provides 2” of air space between your table top and the bottom of the black oxide tank. The operating temperature of the black oxide tank reaches temperatures exceeding 300°F, so you must place the tank stand on a surface which is highly resistant to heat, preferably a steel table top. Refer to Chapter 2, “Installation” as to the proper placement of the tank stand.

3.4 Boxed Labeled - TANK

The black oxide tank comes completely assembled from factory. The complete tank consists of the steel tank, an electric heating element with a 6’ quick-disconnect cable and a K-type stainless 6’ cabled thermocouple with a quick-disconnect 2-prong plug.

The heating element cable attached to the tank has a male twist-lock connector on the end. This twist-lock plug mates with the female plug on the left-side of the controller labeled (HEATER) as in Figure 1.

Figure 1


The K-type thermocouple has a 2-prong plug on the end of the stainless cable. The plug has two (2) prongs; one is larger than the other. Match the plug orientation to the female plug which is on the left-side of the controller labeled (TEMP) as in Figure 2.

Figure 2

3.4 Boxed Labeled - FAWSS (Optional)

Inside the box labeled “FAWSS” contains the pre-assembled Fully Automated Water Supply System (FAWSS). The assembly consists of the water valve solenoid, solenoid mounting bracket, water pressure regulator, a 6’ water-proof conduit and the tank mounting hardware for the water feed into the tank. On the end of the “GRAY” water-proof conduit is a 4-pin male round Amphenol cannon plug. The round cannon plug has a large index pin which mates with the female plug on the left-side of the controller labeled (WATER) as is shown in Figure 3. Insert the plug into the matting female receptacle and rotate the ring on the male plug 180 degrees until it fully engages and locks onto the mating receptacle threads.

Figure 3

Next, located the plastic bag labeled (TANK FITTINGS). Inside the bag consists of a 6’ length of white polypropylene tubing, 6”x ¼” steel tubing with compression fittings on one end and tank clips to attach the steel tubing on to the black oxide tank. Please refer to the specific instructions and/or drawings inside the plastic bag for detailed assembly.

3.5 Boxed Labeled - SAFETY

All of your operating safety gear is included within this box. Included are an apron, face mask and gloves. All of these items are specifically designed for withstanding exposure to the chemicals in the black oxide processing. All of these items above MUST properly fit and protect you when worn. If any of the safety items do not properly fit, DO NOT proceed until you obtain the correct size for your individual needs.


3.6 Congratulations, You’re Almost Ready

Now you have your entire system assembled and almost ready to go. Please proceed to Chapter 4 (Operation). Please DO NOT PLUG IN YOUR CONTROLLER YET.

Completely go through all of the provided instructions before plugging in or turning on your controller. Doing so can potentially damage or destroy your new system without proper instructions.


3BChapter 4

4.1 Operation

The proper and safe operation of the IntelliControl System™ (ICS) is very straight forward. We have taken great care in providing you a simple yet feature-rich controller that allows you to enjoy the financial rewards performing your own black oxide finishing without the common headaches which are customary in the black oxide industry.

WARNING – THE TANK MUST BE PROPERLY FILLED WITH SALT SOLUTION BEFORE

TURNING ON THE CONTROLLER

4.2 Plugging In the Controller

First, REFER TO THE BLACK OXIDE PROCESSING INSTRUCTIONS BEFORE TURNING ON THE CONTROLLER. OPERATING THE BLACK OXIDE TANK EMPTY WILL DAMAGE THE HEATING ELEMENT. Next, plug in your IntelliControl System™ (ICS) controller into the appropriate outlet, either 120 Volt AC or 220 Volt AC, depending upon your specific model. Once you have plugged in the controller, you are ready to begin. Again, make sure the black oxide tank is filled to the proper level of black oxide salt solution as described in the Black Oxide Processing Instructions. Also insure that all of the appropriate plugs, depending upon your model and purchased accessories are plugged in to their appropriate matting plugs. Always refer back to Chapter 3 in this manual if in doubt.

4.3 Powering Up the Controller

In the upper right-hand corner of the IntelliControl System™ (ICS) controller is the main power, which is a black rocker-style switch. Press the switch down to turn on. At the bottom of the rocker-style switch is a lighted “RED” LED light shining. This let’s you know there is now power to the control unit. If the small red LED light does not come on, re-check your incoming power connections.


Soon as you turned on the main control switch you will notice several things. One, the ICS™ control lights up and within a couple of seconds will begin to display the actual temperature inside the black oxide tank on the top of the two digital displays. The bottom display on the

controller will be displaying 290.0290.0290.0290.0, which is your pre-set temperature from factory of your working salt bath.


Secondly, you will notice four (4) LED’s on the control panel. Two (2) of the LED’s are green and the other two (2) or red. Both the green LED’s should be lit. The lighted LED’s are letting you know that you have power to both the heating control system circuit and the water control system circuit. IF AT THIS TIME, YOU DO SEE BOTH GREEN LED LIGHTS ON, STOP AND CONTACT YOUR DEALER IMMEDITELY.

4.4 Black Oxide Tank Powered On

At this time, your black oxide tank is now heating at full capacity. If you notice, the red LED under the HEATER label will be lit. This is letting you know that power is being applied to the black oxide tank element. The time is takes to bring your salt bath up to operating temperature will depend upon the model and wattage of the system you purchased. It can take from 15 minutes to 45 minutes, depending upon the model. As you can clearly see at this point from watching the digital readout of the controller, the temperature inside the tank is rising. The controller has detected the salt bath is cold and way below proper operating temperature so it’s running full 100% power to the heating element. As the salt bath temperature begins to reach its operating temperature of 290°F, you will begin to notice it starts turning on and off the heating element. This is one of the

unique abilities of the ICS™ controller, it knows it is reaching its pre-set temperature and begins to control the heat output so that it doesn’t overrun the 290°F that has been established. If you have your salt bath concentration correct, as described in the Black Oxide Processing Instructions, you should begin to see the salt bath start boiling at around 270°F. Keep in mind though, it will only begin to boil at 270°F when you first start-up a new batch of black oxide salts in our Midnight Black™ solution. Once you have ran the salts up to full operating temperature once, then your salt bath should be beginning to boil at about 287°F the next time you turn on your tanks.

4.5 Monitoring Your Boiling Point & Water Level

Anytime you start heating a new batch of black oxide salts, you will need to watch closely the

boiling point of your salts. Even with the sophisticated ICS™ controller, it can’t measure the salt to water ratio you have in your tank and as you remember, that is what determines the

solution’s boiling point. When setting up with a brand new batch Midnight Black™ salts, you’re boiling point will be around 270°F because of the extra water in the solution. The controller will take care of everything for you; the salts will continue to boil vigorously until the extra water in the salt solution evaporates due to boiling. Remember, the only way for the temperature to increase at this point is for the salt concentration to increase and the water to decrease, thereby increasing the boiling point of the solution.

4.6 Adding Water to Control Salt Solution Boiling Point

Below are the instructions for both the FAWSS and the normal manual water adding techniques. Please take great care and wear the appropriate safety equipment when adding water to the heated black oxide solution. When adding water to the heated solution it will cause spattering and can even cause violent eruptions of the heated solution if you do no add the water correctly. We should also mention, by using the FAWSS, you are greatly reducing the possibility of injury to you and others due to the normal spattering of the salts when adding water to the solution. Not only does it make your system totally automatic but it also provides a far safer environment in which to work within.


4.6.1 For those with the FAWSS, please read here.

As your new black oxide solution continues to boil, the temperature will slowly rise. If your

controller is at the factory pre-set temperature of 290.0290.0290.0290.0, then it will begin monitoring the

heating and UcoolingU of the tank temperature at 290.3°F (.3°F above the pre-set control setting). The controller begins calculating the proper heating and cooling (water addition) and when the temperature reaches 291.1°F, it then turns on the cooling cycle. The cooling cycle activates the automatic watering control and begins adding water to your black oxide tank. It’s sophisticated temperature monitoring algorithms can detect how much cooling is taking place based upon the amount of water that is being added and then determines how long to continue adding water for it to reach the pre-programmed temperature of .3°F below the pre-set control setting, which would in this case be,289.7°F. When the cooling cycle begins you will notice that the “Red” LED directly below the panel label (WATER) will be lit. This lets you know that the automatic watering system is working and is in water-add mode. Once the salt bath has reached the pre-set “LOW” limit temperature of 289.7°F, the cooling cycle will turn off. The water will stop running into the tank and the “RED” LED will no longer be lit on the control panel. You will now notice the heating cycle is running and the tank is vigorously boiling. It will continue to due so until the water evaporates from the salt solution and again reaches the pre-set “High” limit of 291.1°F. This cycle is repeated over and over for the entire time your controller is powered on.

4.6.2 Those without the FAWSS, please follow these directions. We would recommend that you read the directions above relating to the system running fully automatically. It will provide you some insight as to how the system determines when to and when not to add water. As above, assuming you are starting with a brand new batch of Midnight Black™ solution, you will have to wait awhile as the extra water in the solution boils down, allowing the temperature to rise. When your salt bath temperature reaches the preset “HIGH” limit of 291.1°F, it will stop heating the salt solution and turn on the “RED” LED light, which is above the “HEATER” label on the front of the controller. When the “RED” LED turns on, that is your indicator that you need to carefully and slowly add water to your salt bath. You will need to add water until the “RED” LED turns off on the controller. This process of adding water to the salt bath in this manner is the same as if you were operating a gas heated black oxide tank except that you have a digital readout of the tank temperature and a LED indicator to tell you when to add water. However, a huge advantage over a gas heated system is that if you don’t add water as indicated above on time, your salt bath won’t overheat and destroy your salt bath, as would occur in a gas heated tank system. You always want your salt bath to be at a rolling boil when you place your steel parts in the black oxide solution. With an FAWSS, it will maintain the temperature and water for you automatically, however with the manual system; you must keep an eye on the “RED” LED above the HEATER label on the controller to let you know when to add water. The biggest problem that everyone has who operates a typical gas heated black oxide tank is maintaining the proper temperature and adding the correct amount of water at the correct time. As you can quickly tell, this system even in manual mode, without an automatic water system is greatly advanced over a gas heated system. It is the “Norm” for most people to allow their gas heated tank solution to vary up and down in temperature by as much as 10°F, due too not paying close attention to the dial temperature gauge or just don’t want the hassle of having to add water as often. However, if you properly maintain the temperature of your


salt bath by adding water as the controller directs, you will find that you will have constant beautiful parts coming from your system each and every time.

4.7 Maintaining Black Oxide Solution Level In Tank

Through the normal operation of using your black oxide tank, you will gradually consume the black oxide solution. The largest loss of the salt solution is from what is referred to as “Drag Out”. It is when you remove the basket or parts from your salt bath and then transfer to your rinse tank. A small portion of the salt bath solution adheres to the parts and or basket and is lost in your rinse water. The other salt solution loss is from the evaporating process. The solution doesn’t actually evaporate, but is carried out in very small quantities in the rising water vapor.

In typically smaller operations, this is not a great concern through the day’s black oxide processing. It is standard practice to add additional black oxide solution to your tank either before you start up your tank at the beginning of the day or after you shut-off the tank at the end of the day.

We recommend that you add the salt solution at the end of the day, if you are using our

liquid Midnight Black™. It allows the salt solution to blend into the existing solution as it cools. If you are using a powder form of salt solution, then we would highly recommend that it be added before you shut-off the tank. This will allow the powder/crystal to dissolve within the solution and be ready next time you power on the tank.

Remember; do not overfill your black oxide solution tank. The Blackworks™ tanks are deeper than standard black oxide processing tanks. They are deeper to allow more room between the salt solution level and the top of the tank because of the increased agitation that occurs in an electrically heated tank. The salt solution should always be 3” below the top of the tank when the tank is COLD. Filling the tank more than 3” from the top will cause the salts to boil out of the tank, creating a mess and a potential hazard.

4.8 Advanced User Settings / Programming

WARNING: DO NOT CHANGE SETTINGS AS SHOWN BELOW UNLESS YOU ARE 100%

CERTAIN THEY NEED TO BE MODIFIED FOR YOUR SITUATION.

Your IntelliControl System™ (ICS) controller comes pre-programmed and under most user conditions doesn’t need to be altered. However, there are times when you may have to adjust the controller temperatures higher or lower to accommodate different alloy steels. If you’re finishing application involves black oxiding high-nickel content steel, you may find it necessary to adjust the upper temperature of your control.

We wish to stress that you only change the programming as described below if you are absolutely certain this is necessary for your situation. If you are having difficulties in any of your black oxide processing, always feel free to contact your dealer whom you purchased your system from and they will be happy to assist you in your application. You may also call us directly with your technical questions as well. If you modify the control programming parameters and inadvertently disable the control from proper functioning you may be required to send in the control box for re-programming. If you choose to have the control modified by your dealer, there is no cost to you other than the shipping fees to and from you’re your dealer, if applicable.


4.8.1 Parameter Setup Mode

1. Press the SET soft key button on the control and hold for about 2 seconds until the parameter setup menu is displayed as is shown below.

2. Press the SET soft key repeatedly to scroll through the available parameters.

3. Use V (Down) and ^ (Up) keys to modify the digits and the A/M key to select which digit to modify. Hold down (A/M) and press SET to exit parameter setup mode. The controller will also exit if no key is pressed for 10 seconds.

4. The changed parameter(s) will be automatically registered without pressing the SET key.

5. If the controller is locked, only the parameters marked “Field Access” can be viewed or changed.


4BChapter 5

5.1 Storage

1. Ideal storage temperature range is 32-104°F.

2. Store and use the IntelliControl System™ (ICS) controller in a cool, dry place with adequate ventilation for all-around air circulation.

3. Avoid locations that are exposed to high heat areas, direct sunlight or excessive humidity.

5.2 Fuse Replacement

The IntelliControl System™ (ICS) controller is equipped with multiple fuses. Normally, these fuses will not “blow” unless there is a serious problem inside the unit. Internal fuses are replaceable, however, only trained personnel should attempt fuse replacement. If the unit is damaged during fuse replacement, the warranty may be voided.

5.3 ACCESSORIES

Recommended accessories for use with your controller are available from your local dealer. If you need assistance regarding the purchase or installation of any of these accessories, please call Toll Free 1-888-925-8464. WARNING: The use of any accessory not recommended for use with this controller could be hazardous.

5.4 SERVICE INFORMATION

All Blackworks® authorized dealers are staffed with trained personnel to provide customers with efficient and reliable black oxide processing equipment service. Whether you need technical advice, repair, or genuine factory replacement parts, contact your Blackworks® authorized dealer. To find your nearest service dealer, refer to our website at HUwww.blackworksusa.comUH or call 1-888-925-8464.

5.5 FULL TWO-YEAR WARRANTY ON PARTS / ONE-YEAR LABOR

Blackworks® (U.S.) LLC warrants this product for two years against any defects in material or workmanship of the original owner. Proof of purchase may be required. The defective product or components will be repaired or replaced at no charge for the first one year. After the first year and until the second year, the defective product or component(s) will be repaired or replaced at no charge, except for the cost of direct labor for the replacement. To initiate a claim under your warranty, please take or send your component(s) in question to your nearest dealer for repair or replacement. This warranty gives you specific legal rights and you may have other rights which vary from state to state or province to province. Should you have any questions, contact your nearest dealer or call Toll Free 1-888-925-8464.

This manual and all of its contents are copyright protected 2009, and may not be reproduced without written permission from Blackworks, LLC.

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