50a hlt/boil controller

I helped out a forum member with this build. I am not so good at documenting this stuff but here is what I have. We tried to be frugal and still use decent components.

The circuit borrowing PJ's GFCI shunt circuit and Walkers PWM:


Walkers PWM:


Parts List - http://www.mediafire.com/?9ceb9jjbd55ocyq - Not entirely complete. I can update it if there are any items not on there that anyone is interested in. I really like the fuseholders but could not find the 10x38mm fuses at a reasonable price so I used a different fuse block.
Element:


Guts:


Panel:

nice build! I like the fusing down the elements to reduce cord size... I may have to borrow some of your ideas.

project box from home depot?

runningweird said:

project box from home depot?

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Actually the box had been sitting on my shelf for years. I searched the number but it seems to be discontinued. It's fiberglass.

jtsims21 said:

nice build! I like the fusing down the elements to reduce cord size... I may have to borrow some of your ideas.

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Thank you. Sorry I missed your post somehow. Borrow away...that is why we post these builds.

What size cord grip did you use for that range cord?
Is it from McMaster?

This is the one I used: http://www.hubbellcatalog.com/raco/RACO_datasheet.asp?PN=4803-9

The range cord I used is a little over 3/4-in. I suppose cords could vary so you may want to measure before you buy one. The cord just fit in the 3/4-in hub version.

Here is the complete list available from Appleton: http://www.hubbellcatalog.com/raco/compprod.asp?cid=10135&cat=6542&cls=7716

I got mine from my electrical supply.

Nice panel – can’t wait to see it hanging on my wall! Thanks Lschiavo for helping me out with this one. You have a great mind for this stuff and your work and ideas really added to the functionality of the panel . It’s going to be tough to decide what to brew with it first!

sredz said:

Nice panel – can’t wait to see it hanging on my wall! Thanks Lschiavo for helping me out with this one. You have a great mind for this stuff and your work and ideas really added to the functionality of the panel . It’s going to be tough to decide what to brew with it first!

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Thank you, glad I could help. I hope it makes your brewing a little easier and safer. You should start a thread on your build or keep us posted here.

lschiavo, I just placed a $100 order with ElecDirect yesterday for switches, a lamp, terminal blocks, and a few other random things for my build after reading thru your parts list.
Thanks for sharing that site - the switches and rubber boots a bit cheaper than elsewhere.

bigljd said:

lschiavo, I just placed a $100 order with ElecDirect yesterday for switches, a lamp, terminal blocks, and a few other random things for my build after reading thru your parts list.
Thanks for sharing that site - the switches and rubber boots a bit cheaper than elsewhere.

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I do like that site. They have a good selection of decent stuff and pretty good prices. Free shipping over $100 helps too.

sredz said:

Nice panel – can’t wait to see it hanging on my wall! Thanks Lschiavo for helping me out with this one. You have a great mind for this stuff and your work and ideas really added to the functionality of the panel . It’s going to be tough to decide what to brew with it first!

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I like the looks of the control panel! That's really cool. I don't understand all of it, though!

I see you have 20amp toggles for your elements but 30amp fuzes... I'm no ee so I don't know much but that doesn't seem quite right to me. If my math is accurate, a 5500w element will pull almost 23 amps at 100%...

flanneltrees804 said:

I see you have 20amp toggles for your elements but 30amp fuzes... I'm no ee so I don't know much but that doesn't seem quite right to me. If my math is accurate, a 5500w element will pull almost 23 amps at 100%...

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In the diagram, you can see all the toggles are placed after a 15A fuse. The only element switching is done by the 40A SSR.

We'll I've made a little progress on my brewery build using the panel lschiavo helped me with. I finally had a chance to fire up the elements and I'm happy to report it's working flawlessly. It's really nice to be able to fire both elements at the same time. I still have to put an order in for some disconnects, tubing and a March pump, but things are coming together nicely. Here are some photos of the progress so far - https://skydrive.live.com/?cid=771c77abe31dc509&Bsrc=Photomail&Bpub=SDX.Photos&id=771C77ABE31DC509%21129&sff=1

sredz said:

We'll I've made a little progress on my brewery build using the panel lschiavo helped me with. I finally had a chance to fire up the elements and I'm happy to report it's working flawlessly. It's really nice to be able to fire both elements at the same time. I still have to put an order in for some disconnects, tubing and a March pump, but things are coming together nicely. Here are some photos of the progress so far - https://skydrive.live.com/?cid=771c77abe31dc509&Bsrc=Photomail&Bpub=SDX.Photos&id=771C77ABE31DC509%21129&sff=1

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that link asks for a password and login. try imgur

Sorry about that. Thanks for the tip runningweird. I'll try this again.
Here's the panel

Ventilation



HLT Stirrer


Immersion chiller

Water line

Boil in action

Whole system

what did you use for the stirrer motor?

I used one of these for the stir motor: Herbach & Rademan, electric motor, power supplies, timing motor, solar panels, fans, transformers, H: 63 RPM Rotation CCW, Torque 10 lb-in.

Glad you have been finding some time to work on it. It's looking great, nice work! What's the first brew gonna be?

I've got a pretty straight forward American Amber recipe I'll probably start with. I figure it's going to take a few sessions to get everything dialed in. The PID was holding the HLT temps within 1 degree so it seems to be pretty spot on. I fired it up and ran the auto tune.

sredz said:

I've got a pretty straight forward American Amber recipe I'll probably start with. I figure it's going to take a few sessions to get everything dialed in. The PID was holding the HLT temps within 1 degree so it seems to be pretty spot on. I fired it up and ran the auto tune.

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I am drinking my amber right now...good choice! I have a feeling you will be pretty well dialed-in after one session. The PID is your friend. Keep me posted.

After 5 months of piecing my system together it’s finally ready for an inaugural brew! I just finished installing the March pump as well as the disconnects and final plumbing. Here are the completed pics:

sredz said:

After 5 months of piecing my system together it’s finally ready for an inaugural brew! I just finished installing the March pump as well as the disconnects and final plumbing. Here are the completed pics:

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Looks great! Hope the first brew goes well.

Really looks like you got it together. Nice build

Thanks Guys, took it on a trial run today with just H2O to test the pump. All is working well. Plan to brew next weekend.

sredz said:

Thanks Guys, took it on a trial run today with just H2O to test the pump. All is working well. Plan to brew next weekend.

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Document it with some pics or video. We all appreciate that.