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Hookup 240v to existing 120v BCS Setup

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horric29

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Feb 18, 2011
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Lebanon
Hi All,
I have had a few issues with my new brew stand and have decided to convert my BK and HLT to electric. I have the 240v 5500W elements ready to go, in the pots. I need to however get these hooked into an existing BCS unit.

The box that the existing gear is in is equipped with 120v gear, the bcs, etc for pump power, temp control, etc. It also has some SSR's and such for the Honeywell thermostats and so forth present on the rig. I'm thinking the easy solution is just to purchase another box, bring 240 into that box and then bring back some CAT6 to the BCS for the on/off temp control, process functions.

If you take a peak through my threads, you'll see the brew rig has a control panel on the front face so that makes the wiring a bit different from my perspective in that I'll come out into that panel with all knobs, switches, etc. I'd like to have a selector for HLT, BK, Off and then switches for the BK and HLT that perform on/off/auto functions. I've seen a few threads out there that are similar but, not exact in that people generally stick with 240v and break off legs for 120v to their BCS etc. I think it would just be easier to wire up a second box and attach it to the brew rig.

I saw a few switches that light up when powered which seem like a nice way to condense the number of switches/LED's. I'm hoping someone can help me with a wiring diagram as I'm not the quickest there. I've had the stand now for several months with no ability to brew... Any help would be appreciated from a parts/wiring diagram prospective!

I appreciate the help! My head is starting to spin.
 
What is everyone using to do the electrical schematics that I see floating out and about? It might be easier if I draw that out and post it here to see if it's feasible/take suggestions?
 
I suggest reading the electrical primer sticky at the top of this forum.

Converting from gas(24vac assumed) to 240 really just comes down to adding the wiring for the other 120V leg.
It could be as simple as adding a 240V contactor(for e-stop), swapping to a 40A SSR to switch one leg, adding fuse or CB for each leg, and making sure you e-stop works.
 

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