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Old 08-24-2011, 04:48 AM   #1
fumbles
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I've started to make my control panel. I'm working mainly from Kal's design, but with less bells and whistles. I'm using the BCS 460 and a single pump. Looking for input on what fuses to use. The selector switches are in the green and blue. They are illuminated but I can't wire them separately for switching and light. So the HLT and Boil can only display the coil circuit status. This should only be an issue if the relay fails. Should be okay; I think? And I plan to make the SSRs a second safety with programming since I'm not using the 3-selector. I was thinking that if I insulate the HLT. I could reduce the heating element wattage and run both elements. Or have one heating element to heat to strike and another to maintain while sparging. The blue switch/light will be wired in series with the pump. I don't have grounds or a netural to pump or power to the BCS shown. I haven't got a good way to power the BCS. I'm looking for a single plug outlet that I could mount inside with no luck so far.
http://i1094.photobucket.com/albums/i457/Dr_fumbles/wiring-ver1.jpg
Would love to get some feedback on things
Did I forget about something?

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Old 08-24-2011, 01:49 PM   #2
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What is your power source for this? 30A? 50A?

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Old 08-25-2011, 12:59 AM   #3
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40A so I couldn't run two 5500W elements at the same time

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Old 08-25-2011, 01:06 AM   #4
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Quote:
Originally Posted by fumbles
40A so I couldn't run two 5500W elements at the same time
No, two 5500 watt elements at ~240 pulls like 48 amps. I did not do the math, might be like 46.
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Old 08-25-2011, 01:45 AM   #5
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i did the math 45.8333333

yea im a nerd... i was looking at this today... i am wanting to power 2 elements per pot... 4 total and power them both at the same time... i will need to pull 100A line into the box... im gona need a bigger box then i can put breakers on each element... might be an option for you? or are you running off a dryer plug/ not want to run a dedicated line?

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Old 08-25-2011, 03:23 AM   #6
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I'm in an apartment using a range outlet

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Old 08-25-2011, 01:39 PM   #7
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Quote:
Originally Posted by fumbles View Post
I'm in an apartment using a range outlet
fumbles: if you are on 40A and want to run two kettles at the same time, you are going to have to keep total power at 9000W or less, and you can't really power anything else except the elements unless you drop down further.

9000W will pull 37.5A when both elements are running ... IF you actually have 240V available.

240V is not a guarantee. It could be higher or lower than this, which is going to affect the amount of current you pull.

If you are only getting 220V instead of 240V, then a "4500W/240V" element (for example) is really only acting as a 3780W element and will pull 17.2A... so two of those will pull 34.4A and your 40A breaker would handle things fine.
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Old 08-28-2011, 04:25 AM   #8
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"I plan to make the SSRs a second safety with programming since I'm not using the 3-selector" The primary safety being don't turn them both on.
Can I not do this? Program the BCS where it does not allow both to be on at once?

Should I wire my indicator lights to the coil loop or on output that goes to the elements. I'm using incandescent lights so the constant switching done by the SSRs could burn them out quickly. However, I'd like to see if the element is actively heating. What are people doing? Should I have gone for LEDs instead?

Which fuses can I use for the march 809? slow blow? I couldn't find data on the insush current.

pictures of current progress
http://dl.dropbox.com/u/21491289/wiring-ver1.jpg
http://dl.dropbox.com/u/21491289/IMG_6468.JPG
http://dl.dropbox.com/u/21491289/IMG_6460.JPG
http://dl.dropbox.com/u/21491289/IMG_6459.JPG

thanks for the responses

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Old 08-28-2011, 04:43 AM   #9
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Quote:
Originally Posted by fumbles
Should I have gone for LEDs instead?

I did. LED, resistor, diode or two. You can monitor for cheap.

Which fuses can I use for the march 809? slow blow? I couldn't find data on the insush current.

I never understood the fusing issue. Fuse it for the wire. Did your pump come with a cord/plug? If so fuse it at 20A. The motor should have built in thermal protection. My (not March) does.
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Old 08-28-2011, 08:15 AM   #10
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I don't have a code book on me right this second, but I believe for Inrush current you only need to upsize your breaker by 125%, you can also get time delay breakers that will consider inrush because theyre meant for motors. I think your bigger problem is going to be where to get 100 amps unless you live in a Fresh Prince ass house.

As far as making a safety so you can't turn two things on at once, wire your first load in series with a Normally Closed contact on your second Control Relay. Wire your second load in series with a Normally Closed contact on your first relay. When CR1 coil is energized it'll open up that contact and you won't be able to turn the second load on no matter how hard you push the button!

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