Conversion from BCS462 to Brucontrol

[brewvet]

Looking for advice.

Last year my father and I built a new 2 vessel, 30Amp control panel using BCS 462. After using it twice, I let is sit for a number of months as life got in the way. In November I planned on brewing a batch and noticed 2 of the temp probes were reading extremely high, 300+ degrees so I sent it off for repairs. I recently heard that the board was shot and it couldn't be fixed as there are no more BCS 462's anywhere.

So in looking for a replacement, and researching my options it looks like Brucontrol would be the best solution.

My system as built consists of:

2 Vessel 15 Gallon kettles
Boil Kettle - Spike brewing containing a 4500 Watt element, SS Float Switch to ensure the element remains submerged when it's heating.
MT - Brew Boss w/Cofi Filter
4 - 2 Way SS 12v Ball Valves
3 - 3 Way SS 12v Ball Valves
2 - SS Flow Sensors
2 - Chugger Pumps
6 - BCS Temp Probes
Auber Instruments Control Panel w/2 LCD displays (1 for 120V, 1 for 240v), 12 Led's for monitoring the valves, pumps and heating element(s). I emergency stop switch and 1 keys switch for the 240v side(the panel is wired so that there is always 120v for the BCS, the 240v for the heating element is separated for safety and expediency reasons(using a spa control panel off the dryer circuit). All of the valves, pumps, etc are running off the 120v leg.

Brucontrol should have no issues with reusing any of the existing equipment, although the challenge for me is having to rewire this (thinking of using prototype headers?). My control panel as built is pretty full.

So has anyone done something similar and can offer any tips or recommendations?

Thanks,

 

[BrunDog]

Hi @brewvet. Because the BCS’s I/O (input/output) is +5V in an “active high” (+5V means ON vs. ground means ON) format, an Arduino MEGA makes for a fairly straightforward conversion. There are a few considerations:
1. Power supply: the BCS uses a 6V power supply, which can be used to power the MEGA through the Vin pin. Alternatively, you can power the MEGA through the Vin pin or power jack with the 12V power supply. It is important that a quality switching supply is used, no matter which you use.
2. Thermistor probes: The MEGA can read the thermistors, but a voltage divider (and noise filter) circuit needs be added. This is a passive circuit of resistor and capacitors. We have a schematic on the website for a build-your-own or we offer a turnkey board with screw terminals for up to 6 thermistor probes.
3. Wiring: I would suggest a screw shield to make wiring easier. The MEGA does not have very good native physical connections. The BCS has pluggable connectors, so you would need to re-wire each I/O line individually. Use the BruControl Interface Wiring Map for the MEGA to decide which I/O line to wire to which pin. The relays (mechanical or SSR) and flow sensors can be directly wired to Digital I/O pins just like with the BCS. Its a good idea to make sure that each pin must not be expected to provide more than 10mA per pin, but that shouldn’t be an issue as you are using likely SSRs for the elements and relay boards for the valves and pumps.
4. Connection: one of the major differences between BC and the BCS is that BC uses a host computer. While this admittedly adds a layer of hardware, that gives the user essentially unlimited storage and capacity. Plus BC can control multiple micro-controller interfaces simultaneously if you like. That said, the connection needs be planned. If the host computer (laptop, mini-PC, etc. is going to be used next to the control box, you can use a Serial connection over a USB port. If you want to have the interface remotely connected, you can use a network connection such as Ethernet or Wi-Fi. These are accomplished via the addition of a shield board stacked on top of the MEGA.

It sounds like one of your concerns is wiring. I would assume that since you and your Dad built this system, you have the capability to make the wiring changes. If you don’t, you would need to find someone with basic skills to help you.

We are happy to help with any specific wiring questions!

 

[Brewsit]

I’m in the process of converting from a BCS-460 to BC, and I did what BrunDog suggested to you for setting up the BC. It was actually easier to set up than the BCS initially, and if you can find a tiny bit more space than where the BCS is in your control panel it should work out great. I actually simplified some pieces of my system by rethinking how to control some of the automation, since you can use a ton of different arduino compatible devices. I think the options are so limitless its hard to pin down any single way to go.