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Old 10-10-2013, 11:25 PM   #1
luhrks
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Dec 2011
Posts: 340
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So I've been brewing with the BCS 460 for a while, and when I upgraded my current rig I knew that I wanted to be able to go fully automated on the burners (eventually the pumps too).

I started with an Email to Ryan over at Ebrewsupply who was tremendously helpful in assembling a DIY Kit, and schematic.

Cost and complexity was simplified by keeping everything attached to the panel (pumps, solenoids) on 110v.

Key features:
4x Unswitched 110v outlets for accessories (Monitor, Wifi, Laptop, etc)
5x E-stop 110v outlets for Solenoids/pumps
2x Internal 110v outlets for BCS-460 and 6v "manual mode" powersupply. With interrupt for resetting the BCS without opening the panel.
5x Cat-5 jacks for temp probes, and external network.
File Type: pdf Visio-15a-Karl-Luhr.pdf (132.8 KB, 274 views)

 
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Old 10-10-2013, 11:30 PM   #2
luhrks
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Dec 2011
Posts: 340
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I already had an old "cart" around that I got from a neighbor that I had been using for my brew station. So with that in mind I ordered the 600x400x200 enclosure off ebay. As I wanted to fit the panel to the stand. Thant and I just wanted the extra room internally.

I ordered the parts from Ebrewsupply, and the 110v outlets from jameco. The rest came from the usual suspects (Home Depot, Lowes, etc).

Once things came in I went to go mock things up.

Sharpie and Painter's tape for the win. Once I had the controls laid out on the front the way I wanted. I used a drill press and a 22m drill to cut the holes.
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Old 10-10-2013, 11:34 PM   #3
luhrks
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Dec 2011
Posts: 340
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For the side/square cuts I was fortunate enough to be able to get them plasma cut at our LBS, and then finished with a Jig Saw.

I also decided to go with the nice hammered black color.
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Old 10-10-2013, 11:36 PM   #4
luhrks
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Dec 2011
Posts: 340
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I then laid out the backboard and the internal DIN components made sure I had enough room for everything and went to getting all the internals mounted.
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Old 10-10-2013, 11:40 PM   #5
luhrks
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Dec 2011
Posts: 340
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Once that was all done, I started on the 110v wiring.

The one or two questions I had were answered by Ryan in short order.

The whole wiring/testing process took about a week of evenings after work (and a few beers).

Then came the 5v wiring. Found out I had a bad switch, and a bad SSR. Ryan had the replacements in the mail ASAP.
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Old 10-10-2013, 11:48 PM   #6
luhrks
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Dec 2011
Posts: 340
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I test fit the panel to the case. Then cut out the top deck to receive it. It fits very snug. I drilled a hole on each side of the stand, and panel and then used a carriage bolt on each side. The bolt is secured with a nut/washer inside the panel and outside the panel - it's not going anywhere.

I then painted the stand to match the panel and... voila!
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Old 10-10-2013, 11:49 PM   #7
luhrks
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Dec 2011
Posts: 340
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And the finished product.
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Old 10-12-2013, 01:50 AM   #8
mike_in_winchester
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Jan 2012
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Very nice.


I am inspired.

 
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Old 10-15-2013, 03:18 AM   #9
Clawson
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Apr 2013
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This is pretty much exactly what I'm trying to do. Thanks for leading the way on the build! Did you need that large of a enclosure?

Matt

 
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Old 10-18-2013, 06:25 PM   #10
luhrks
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Dec 2011
Posts: 340
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No, not really.

I could have easily gotten away with the 16x16 panel, but I wanted the extra space, and the 24" fit right into the pre-existing stand just perfectly.

Contacted a friend at Seattle Engraving and had her make up some nice bronze plates made up for e switches.

 
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