I dont understand the question about your "infusion mash spigot upgrade"...
Here is the email I sent to them when they asked for more pics and a more detailed description. Hopefully it holds thier interest.
XXXXX,
Thank you (and your magazine) for your interest in my rig! It has been an ongoing evolution from a simple 5 gallon Rubbermaid AG system that I used in my kitchen, with water heated on the stove... to an all electric HERMS that utilizes 10 gallon Rubbermaid coolers and a 15.5 gallon Sankey for the BK.
Here is a brief description of the major components:
HLT: 10 Gallon Rubbermaid beverage cooler converted to HERMS HEX with a 1/2" ball valve bulkhead (custom as many commercial models leak). It consists of a 1500W 120VAC heating element that is controlled by a Johnson A419 controller that is mounted to the cooler itself. I fashioned my own stopper/thermo well that passes through the lid and sourced parts for a 120VAC HLT stirrer. The HLT HEX contains 25' of 1/2" copper tubing (a modified pre-chiller) that is outfitted with brass QDs. It also sports a custom through the wall digital thermometer (my solution to leaky commercial models). ALL plumbing on my rig is 1/2", the flow rates are far superior to 3/8" plumbing. This vessel is used for strike water, sparge water, HERMS re circulation to hold mash temps and used to heat the mash to mashout temps.
MLT: 10 Gallon Rubbermaid beverage cooler converted to a MLT with a 1/2" ball valve bulkhead (custom), SS false bottom, through the wall digital thermometer (custom) and a HERMS/FLY sparge return line that is plumbed through the lid for superior heat retention. Mash temps are maintained within .5F during any length of mash.
BK: 15.5 gallon (legal) Sankey keg that has been converted to an E-Keggle. It is outfitted with a 1/2" ball valve, custom pick-up tube, 5500W ULWD heating element and thermocouple.
Software: This rig, as in any rig, has specific temperature differentials, fluid loss, heating times etc. In order to manage all of these aspects I created a spreadsheet that asks the brewer for specific information about the brew. Strike temps, volumes etc. are entered and crucial values are computed for the brewer to manage the system during the brew session. This allows the brewer to effectively plan HLT water quantities, temps and view resultant heating times that may be of concern when step mashing.
All of the components are powered through a custom 240VAC control panel that I built. It consists of a PID and SSR for the E-Keggle heating control. It also contains switched outlets for the HLT and March 809 pump on my rig. It also contains a "kill" switch that will kill both legs of power to the E-Keggle heating element regardless of what the PID and SSR command.
The E-Keggle heating element is my own design, with a fully insulated collar and entirely potted electrical connections, making it safe for use on a boil kettle where boil overs can happen. It can be submerged in water with no voltage leak.
All liquid connections are made with brass QDs.
My design philosophy all along has been simplicity, efficiency, affordability and repeatability. I have built my own bulkheads and through the wall thermometers for affordability and reliability reasons. When possible I have sourced components to build items needed for this rig in lieu of purchasing commercial components when cost and design allowed.
I am a member of Homebrewtalk.com and have posted loads of information about my build over the past couple years as it evolved. (instructions, part numbers, suppliers, design philosophy, cost etc) Currently there are several other members building exact replicas of my system, one is actually brewing on it already. I have been tech support for these guys and provided them with the software to run this rig effectively in their own garages.
I will attach some photos, AND a link to my Photobucket account where you can see many more pictures. Please let me know if you have continued interest and if there is anything else you would like!
If you have a minute, can you help me understand some basic construction issues here?
1) Re: heat exchange coil, does one really need to cut it? Or can one unscrew the garden hose connection and connect the QD to the existing pipe fitting? (I don't have tools to cut copper.)
Why wouldn't they be ok?2) Are the white rubber stoppers OK? Or should one use silicon? I would think rubber is not desirable in direct contact with hot water/wort.
JB Weld "sticks" two metal pieces together. It's like glue/epoxy for metals.3) What is the JB Weld for? Does one need to have advanced electrical skills to put this together? (Probably should have asked this first before getting interested in this system.)
Many people use 3/8, but 1/2 just flows better.4) Can you confirm you need a 1/2" elbow nipple from false bottom in mash tun? Right now I have 3/8", but thought that would restrict the flow too much.
Tried to put all parts in, including valve assemblies and pump valves, maybe you can use this for the magazine. I know it's not exactly right, as I see you have an elbow connector at the top of the HLT. I have it in Excel, for Qty * Amt for a total cost:
Qty Item
1 Stand?
1 Megapot 10 gallon brew kettle, with spigot
1 Hurricane burner
2 10 gallon coolers
1 Johnson controller (A419)
1 March pump (809HS-PL)
1 25 foot 1/2" copper tubing coil
1 1" Thermowell stopper (or crimped corny pickup tube)
2 1" Solid stoppers
2 Thermometers
1 120v 1500w water heater element
1 JB Weld
1 Wire and plug for water heater element
1 1x SS 1" nut
1 1" PVC tubing (2"?)
1 1.25" hole saw
12 12 ft heat resistant tubing (1/2 ID)
6 [1/2"] stainless hose clamps
2 50915K328 2 Each Standard Brass Compression Tube Fitting, Adapter For 1/2" Tube Od X 1/2" Nptf Male Pipe
3 50785K94 3 Each Med-pressure Extruded Brass Thrd Pipe Fitting, 1/2" Pipe Size, Hex Coupling, 1-3/16" Length
7 6739K59 High Flow Hose Coupling For Coolant, Plug, 1/2" Nptf Male, 3/8"
6 6739K64 High Flow Hose Coupling For Coolant, Sleeve-lck Sckt X Barb, 3/8"cplg Sz,1/2"hose Id
1 6142K49 Ac Gearmotor W/fan, Face Mnt, 100 Rpm, 7 In-lbs Torque, 115 Vac
1 34935K66 Polypropylene Propeller With Shaft U-shaped Blade, 2-1/2" DIA.
1 6099K22 Stainless Steel One-piece Set-screw Coupling 5/16" Bore, 1" Length, 5/8" Od, Without Keyway
2 10095K12 Loc-Line Any-Which-Way Coolant Hose 1/2" ID, 12" Length W/ Connectors & Round Nozzles
2 1/2" x 1/2" FPT x Barb female adapter
2 A-836 1/2"MIP x 1 1/2" Brass pipe nipple
4 3/4" SS flat washer
4 1 1/8" OD x 5/8" ID rubber grommets
4 1/2" threaded ball valve
2 1/2" x 1/2" MPT x barb Male adapter
1 Teflon Tape (for all threads)
1 1/2" elbow barb with nut for false bottom
If you have a minute, can you help me understand some basic construction issues here?
1) Re: heat exchange coil, does one really need to cut it? Or can one unscrew the garden hose connection and connect the QD to the existing pipe fitting? (I don't have tools to cut copper.)
2) Are the white rubber stoppers OK? Or should one use silicon? I would think rubber is not desirable in direct contact with hot water/wort.
3) What is the JB Weld for? Does one need to have advanced electrical skills to put this together? (Probably should have asked this first before getting interested in this system.)
4) Can you confirm you need a 1/2" elbow nipple from false bottom in mash tun? Right now I have 3/8", but thought that would restrict the flow too much.
For infusion mashes, you get 2F per minute? Do you find that adequate? Looking to start buying parts now that I have a pretty good list.
Sorry, looks like I missed a couple posts here.
#1. The downwside of placing your temp probe in the MLT, or anywhere too far down line in the process form the HEX is that you increase the chance of an overshoot. People generally have excellent results when placing the temp probe in the HEX, or at the outlet of the HEX. There is really no reason to have the temp probe in the MLT, it is not as accurate at measuring wort temp there.
#2. You still want a way to stir the HLT water. If you do not, you will have a less conrollable HEX. You will have hot and cold spots and temperature stratification that you cannot control. When the temp is homogenous, you KNOW that there is even heating and you KNOW that the heat from the element is being effectively transferred to the coil. Otherwise the coil will create a cold spot, the element a hot spot... this reducing your level of control in the system. IMHO
#3. You could use a "t" and a compression fitting or something to get the probe into the output flow of the HEX. There is really little reason to measure the temp of the MLT output, if you are controlling the temp of the input.
#4. I dont know anything about the Ranco, but I did get my JC A419 pre-wired. I would suggest not hard wiring anything into anything. My A419 PLUGS into my control panel and my element PLUGS into my A419. This helps to make the parts more user friendly when cleaning, repairing, updating, moving, anything.