Kill-A-Watt Brewery Build Compilation

[Zulu]

Glad you are up and running.

I love the BCS, was one of the beta testers and have had a lot of fun in last 18 months. While I typically only use it now for the basics of running the RIMS, I have programmed and played with many other settings and arrangements but not got the time to implement them yet !!!

Your whole project looks like fun.

As for wireless, man I tried a number of routes in early days , including bridges, and kinda gave up , I now run a seperate old linksys router with own wifi network for the brewery, and just toggle between wifi networks on my laptop if I need internet. It is rather nice being able to mash in and sit at breakfast table and monitor the brewery in warmth.

have fun , shout if you need help

Rick

 

[The Pol]

Well, I wanted to upload a parts list, but... well after saying the upload was a success, there is nothing there. So I guess... I cant get it up on here

 

[cashbrewing]

Pol, Quick question about your pumps, ok maybee three. How do you like them compared to the march 809? Where did you get them? And how much?

 

[The Pol]

Pol, Quick question about your pumps, ok maybee three. How do you like them compared to the march 809? Where did you get them? And how much?

Havent used them yet.

Already like them more than the March 809.

Ebay $89 free ship

 

[The Pol]

Labeled all of my SSRs tonight... with 10 of them I thought I may want to lable them instead of chasing wires down later. Getting the casters installed as well.

Tomorrow I will have the mechanicals finished... the wiring will come in a few days when I get my rigs wireless bridge (WGPS606) in house.

 

[churdbird]

Not working today? With IAD shut down, im not supprised. Got screwed a little w/ DCA an PHL closed as well.
System looks great. Brew on!

 

[The Pol]

Not working today? With IAD shut down, im not supprised. Got screwed a little w/ DCA an PHL closed as well.
System looks great. Brew on!

Oh man, I am OFF... I come home from a trip a few days ago. I paid my dues last week.

Held TWICE going into IAD on the same leg with an RVR of 1000', had to swap alternates to free up enough fuel to hold out 25 miles south of IAD for the approach.

Then on the next leg, we had to wait 1:40 to get released to the de-ice pad... I am running on the verge of 30-7 all month. I hope to get enough time in the coming week to get this thing together!

Got my LOW profile casters mounted... they are so low you cannot even see them under there, it just seems to glide about .5" above the floor...

 

[bakins]

So, you're mashing at a "normal" water/grain ratio, then adding more water and doing a "recirculating" sparge? Would it be easier to just do the full boil volume of water (plus losses) at the beginning? Don't have to move an hoses. This is what I do now, with the brew-in-a-bag-in-a-basket. Just wondering... I hate to move hoses mid-brew, so I don't any more.

Both RIMS elements are ran at 240V, right? I'm contemplating re-wiring mine to 240V or just getting rid of it and using the BK element to control mash temps. I already use it for steps and have had no issues, but with the $$$ I spent on the RIMS, I feel obligated to use it.

 

[The Pol]

So, you're mashing at a "normal" water/grain ratio, then adding more water and doing a "recirculating" sparge? Would it be easier to just do the full boil volume of water (plus losses) at the beginning? Don't have to move an hoses. This is what I do now, with the brew-in-a-bag-in-a-basket. Just wondering... I hate to move hoses mid-brew, so I don't any more.

Both RIMS elements are ran at 240V, right? I'm contemplating re-wiring mine to 240V or just getting rid of it and using the BK element to control mash temps. I already use it for steps and have had no issues, but with the $$$ I spent on the RIMS, I feel obligated to use it.

Cant fit a full grain bill and a full compliment water in the MLT. The idea crossed my mind, but the numbers wouldnt work 16 gallons of water and then... well, grain... more than 15 gallons.

All elements will be run at 240VAC, 9000W in the RIMS and 9000W in the kettle. I think it will make quick work of heating 5-10 gal. batches.

 

[bakins]

Cant fit a full grain bill and a full compliment water in the MLT.

If you are recirculating the entire mash, the "excess" water can be in the BK. The starch and enzymes are quick to get into solution, so it is all working at the same time. So you can have grain and water up to, say, the 16-17* gallon mark in the MLT, and the rest in the BK and recirculate. Heck, the RIMS is not needed, as you could use the BK element to maintain temps.

Just thinking out loud...

*or whatever level you want - use the autosparge for this.

 

[The Pol]

If you are recirculating the entire mash, the "excess" water can be in the BK. The starch and enzymes are quick to get into solution, so it is all working at the same time. So you can have grain and water up to, say, the 16-17* gallon mark in the MLT, and the rest in the BK and recirculate. Heck, the RIMS is not needed, as you could use the BK element to maintain temps.

Just thinking out loud...

*or whatever level you want - use the autosparge for this.

I considered all of that, but saw it as tying my hands. Then I would have no choice but to mash with all of my water needed and I would have to use the BK to provide heat for the recirc. I didnt want to do that, I wanted to leave some options for myself and whoever else may own it.

I could have built a lot of things...

The MLT is 15 gallons FWIW

 

[The Pol]

Finally able to roll it around... my wife awoke to it in the kitchen this morning

 

[Brewmoor]

That is awesome. Morning honey would you like some coff....... Beer maybe!

 

[The Pol]

That is awesome. Morning honey would you like some coff....... Beer maybe!

She is still resisting my push to keep it in house... it is a battle of wills at this point!

Today I may get everything mounted, I also bought all of my wire... so maybe I will do some of that? Hard to tell what the day will bring. Typically when I think I will get a lot accomplished, I get nearly nothing done. Days when I dont plan to do much, I end up getting 6+ hours in the build.

My "goal" is to fire it next week. Until the WGPS606 arrives, I can connect my PC directly to the BCS, but it has already shipped, so it should be here when I get home from my next trip.

 

[bendavanza]

where'd you hide all the guts?

 

[The Pol]

where'd you hide all the guts?

They arent mounted yet, so they are in the formal dining room, since we dont have many formal dinners anyway

I have about 5 boxes of small parts that need to be assembled yet and about 65' of wire...

 

[HarkinBanks]

Anything up your sleeve to assist with the dumping of the grains Pol?

 

[beerocd]

where'd you hide all the guts?

Angled mirrors cleverly conceal the innards and give the appearance that you can see through the cabinet. It's an old magician's trick.

 

[jfkriege]

If it is a battle of wills, you should bribe her with shoes. Shoes can sway many arguments.

 

[The Pol]

Got the work surface mounted today, the SS plumbing panel/valves mounted today, installed the pumps today AND drilled the access holes for the wiring conduit to run between the wet and dry sides of the rig.

This thing is really compact in the "mechanical" bay... really, but it should work nicely.

Gone for 2 days to fly, when I get home my electronics will go in, the wireless bridge has shipped... should be ready to rock after one more day!

I will get photos up later of what I did today.

After mounting the protected SS plate to the work top, I laid out the hole locations:

After drilling pilots, used a hole saw to open up the back side to accomodate nipples that run to the valves and the hoses for the triclamp pump inlets:

You can see here the different hole sizes, necessary to use the nipples to tighen the valves to the plumbing panel:

The topside, holes deburred and pretty like:

After valve mount, you can see the nipples that will connect to the silicone plumbing:

After mouting valves, here is what people will see. Valves are for the pump outlets, the holes are to accomodate the 1/2" barb Tri's that will have silicone hoses attached for the pump inlets:

This took a very long time. This, along with mounting the pumps, took about 6 hours.

 

[The Pol]

Build on hold now for two days while I work. I appreciate your questions/suggestions. I have already implemented some from this thread.

 

[Dog House Brew]

It is amazing the time that it takes to plan, measure, cut, and install. It took me 3 hours just to get my HERMS coil installed. You were not kidding when you said the stainless was hard to work with. Great work! After my limited experience, this piece is really appreciated.

 

[jfkriege]

That is looking really slick. I like the way that you have mounted the ball valves for the two pumps. I can also sympathize with marking and cutting taking way longer than you would think; it always takes forever.

Will you have a way to drain the fluid out of the pumps easily? or will you just leave some water in there and brew enough that it will never grow anything?

 

[remilard]

Anything up your sleeve to assist with the dumping of the grains Pol?

From a practical stand point, a shop vac is the best way to deal with spent grain. Sure it ain't blingy but when I read about doing that (no, I wasn't smart enough to think of it myself) I stopped wanting a tippy dump that minute.

So I'm guess The Pol covers a shop vac in diamond plate or something.

 

[Layne]

Dude!
*speachless*
That's beautifull. And well thought out and engineered.
Well, maybe I'm speachless after all, but impressed indeed!

 

[Cliff897]

Hey Pol, What is this coil:
http://s1002.photobucket.com/albums/af143/zydaco/?action=view&current=Whatisthiscoil.jpg&newest=1
that you have in your cabinet?

 

[klyph]

That's the HEX, it's not in the cabinet, but behind it. It goes in one of the pots when in use.

 

[Cliff897]

That's the HEX, it's not in the cabinet, but behind it. It goes in one of the pots when in use.

What's a hex?
In this context I mean.

 

[The Pol]

It is amazing the time that it takes to plan, measure, cut, and install. It took me 3 hours just to get my HERMS coil installed. You were not kidding when you said the stainless was hard to work with. Great work! After my limited experience, this piece is really appreciated.

Yah, stainless is pretty, but hard to work with. Time, so much time to lay things out, to make them clean, to make them logical. This whole thing would be so much easier if I just built it to build it. The hard part is taking all of the parts and assembling them in a thoughtful manner.

Thanks, I am home now since my NYC and DC trips this week were all cancelled due to the pending storm. So, I am home now laying out my Ebay.

 

[The Pol]

From a practical stand point, a shop vac is the best way to deal with spent grain. Sure it ain't blingy but when I read about doing that (no, I wasn't smart enough to think of it myself) I stopped wanting a tippy dump that minute.

So I'm guess The Pol covers a shop vac in diamond plate or something.

Shop Vacs are awesome!

 

[klyph]

What's a hex?
In this context I mean.

Heat Exchange. In most contexts.

 

[The Pol]

That is the SS cooling coil, HEX, heat exchanger... it was sitting behind the cabinet. As soon as I get the tedious task of wiring the thing finished, the back will have a vented panel installed.

Laying out the electronics now, trying to keep everything as hidden as I possibly can.

 

[Cliff897]

Heat Exchange. In most contexts.

Why does he have a heart exchanger there? I mean since he's got one in the BK.

 

[klyph]

Why does he have a heart exchanger there? I mean since he's got one in the BK.

In case his heart gets broken, he can use his heart exchanger.



That IS the one that goes in the boil kettle :fro:

 

[The Pol]

In case his heart gets broken, he can use his heart exchanger.



That IS the one that goes in the boil kettle :fro:

Yeah, that IS the exchanger in the BK, it is just OUT of the BK at the moment while I am finishing the adjustable recirc arm.

Got all the holes drilled for running wires and hoses tonight. Tomorrow I will start wiring up the elements and getting things set up. Maybe 2 days of work to wire it thoughtfully and get it running. Maybe... I will say 4 days since everything takes 2x as long as I hope.

 

[The Pol]

Here are a few photos from my limited time today. I really hate measuring and drilling holes in the proper locations. AHHHHHH.

 

[Dog House Brew]

Looking good You ain't a kidding it takes a long time to plan. I didn't do such a great job this time a round. I think you have to have a system under your belt to get the next one the way you want it. Kind of like building a house the second time. You could have picked a smaller foot print to make it easier to build. I can see you snarled in there drilling.

 

[The Pol]

Laying the stuff out is crazy, drilling all of the holes from BOTH sides adds to the work too (to eliminate splitting) Keep in mind, I drilled all of those holes BEFORE the pumps were bolted down.

Tomorrow I will have the WGPS606 wireless bridge installed, BCS, SSRs, distribution block etc. MAYBE get a little wiring done? Having all of my flights cancelled has its perks!

 

[Dog House Brew]

Snow is everywhere. We had 8" here with another 1" today. Not that many flights come into Louisville. Will be looking for the pics tonight.

 

[The Pol]

Snow is everywhere. We had 8" here with another 1" today. Not that many flights come into Louisville. Will be looking for the pics tonight.

Yah I am running out to the DD for coffee and then to Lowes for a SS wall plate. Then I begin again. I like being able to start accomplishing things before noon, then I can get ramped up, so after noon I am really accomplishing things.

There is no reason that I cant nearly finish it today. Then I have the next couple to mess with it.