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Old 02-09-2009, 11:37 AM   #1
jcdillin
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Default My Weldless Electric HERMS build

So over the last couple months i've been slowly collecting parts and planning and building my HERMS system. I've been trying to do everything stainless and silicone wherever possible. Of course that increases the time because i've been trying to do it on a budget.

I'm hoping that this systems first brew will be controlled by the BrewTroller controller that we are working on. Eventually I hope to have parts of it a bit more automated.


First off I wanted to have the nicest holes I could possibly make without a plasma cutter in the top of my kegs. So I built a simple jig to help me do that. I had some spare 80/20 extrusion laying around from my CNC machine build so I just used some of that.

Pretty ghetto but makes darn nice circles



That little stubby piece just fits right into the hole in the top of the keg and with the help of a little olive oil spins right around.




The other tough part of this project is the fact that I had to do everything weldless, for some reason it's pretty much impossible to find anyone down here that is willing to do the welding correctly.

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Current Rig
4.5KW E-HLT
5.5KW E-Kettle
MasterFlex Peristaltic Primary Pump
March Secondary Pump
Therminator for Chilling

Planned
Automated Grain Drop
Automated Hop Dropper


System controlled via BrewTroller


Last edited by jcdillin; 02-09-2009 at 11:51 AM.
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Old 02-09-2009, 11:42 AM   #2
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First off we have the HLT

I decided to go bottom drain on everything but the boil kettle. I think it makes it look nice and keeps me from having to make pick up tubes for everything.

Looking down into the HLT, here the coil is missing but you can see the 1650W water heater element.




Here is the coil, it's installed now I will have to take a couple more pictures. It's 30ft of 1/2" OD copper water tubing.




Here is the element connection, I still have to build a cover for it.





And here are the QD connections for the HEX coil.




So that is pretty much it for the HLT, I still have to drill the hole to mount the temp probe, but i'm waiting to finish up my probe builds for the BrewTroller for that.

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Current Rig
4.5KW E-HLT
5.5KW E-Kettle
MasterFlex Peristaltic Primary Pump
March Secondary Pump
Therminator for Chilling

Planned
Automated Grain Drop
Automated Hop Dropper


System controlled via BrewTroller

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Old 02-09-2009, 11:42 AM   #3
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Here is the picture of the HLT drain.

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Current Rig
4.5KW E-HLT
5.5KW E-Kettle
MasterFlex Peristaltic Primary Pump
March Secondary Pump
Therminator for Chilling

Planned
Automated Grain Drop
Automated Hop Dropper


System controlled via BrewTroller

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Old 02-09-2009, 11:44 AM   #4
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Looks nice... I assume the rig is going to be all 120VAC? I have never seen a 1650W folded element.

Are you using gas for the BK?

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Old 02-09-2009, 11:45 AM   #5
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Then we have the MLT, i'm waiting for the false bottom to come in. But the drain, temp probe and sight glass will all be under the false bottom so the chances of grain clogging things up are slim.


Here is the bottom drain with the temp probe compression fitting




Here is my new copper DS18B20 temp probe installed into the fitting.




Inside looks like all the others

Here they are together.




I still have to paint the stands to keep the from getting ruined from all the water.

__________________

Current Rig
4.5KW E-HLT
5.5KW E-Kettle
MasterFlex Peristaltic Primary Pump
March Secondary Pump
Therminator for Chilling

Planned
Automated Grain Drop
Automated Hop Dropper


System controlled via BrewTroller


Last edited by jcdillin; 02-09-2009 at 11:48 AM.
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Old 02-09-2009, 11:47 AM   #6
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Quote:
Originally Posted by The Pol View Post
Looks nice... I assume the rig is going to be all 120VAC? I have never seen a 1650W folded element.

Are you using gas for the BK?
Yeah everything is 120V since i'm only heating the HLT with electric I wasn't too worried about it being crazy fast.

The boil kettle is heated by propane, it's the only one with a side drain and a pickup tube.
__________________

Current Rig
4.5KW E-HLT
5.5KW E-Kettle
MasterFlex Peristaltic Primary Pump
March Secondary Pump
Therminator for Chilling

Planned
Automated Grain Drop
Automated Hop Dropper


System controlled via BrewTroller

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Old 02-09-2009, 11:48 AM   #7
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Ahh cool, looks like a nice build, thanks for the pics.

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Old 02-09-2009, 12:05 PM   #8
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Are you using flat gaskets under your weld less sets?

Great looking gear!

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Old 02-09-2009, 12:18 PM   #9
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Thanks!

yup, mcmaster part 99604A129

I was having a lot of trouble getting the O-Rings to seal properly, these silicone sealing washers make a seal even with just a bit more that finger tight. Works really good on uneven surfaces too.

__________________

Current Rig
4.5KW E-HLT
5.5KW E-Kettle
MasterFlex Peristaltic Primary Pump
March Secondary Pump
Therminator for Chilling

Planned
Automated Grain Drop
Automated Hop Dropper


System controlled via BrewTroller

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Old 02-09-2009, 05:40 PM   #10
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This is really cool, I've been planning a similar setup but was planning on using welded connections. I haven't tried to find someone local yet who could do the welding, but I might just go all weldless. My concern with going weldless is having to break it all down often for cleaning. Any thoughts? I'd also love to see a breakdown of some of the connectors you've chosen. I'm thinking about doing a HX in my boil kettle for chilling like the one in your HLT.

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