Pandemonium's 3 Vessel, Single Tier, eHERMs Build!

[Mountainsax]

I know, I know, we need another build thread like we need more macro breweries! Hopefully I'll be able to come up with some useful tidbits that others can use. But if not, at least we all like pictures!

So here's the story, the Christmas bonus came, SWMBO is awesome, and the build begins!

I'm planning a system based on Kal's design using keggles.

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The progress so far. The stand is pretty budget right now. Eventually I want to weld one out of stainless!

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The whole thing slides under my existing work bench. It does have wheels on it now.

 

[Mountainsax]

Here is the control panel.
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I thought I had it mostly wired (except for the safe start relay) so I plugged it in this morning... Nothing! [emoji37] Grrrr! Time to start trouble shooting.

 

[hungry4hops]

Looking good so far, keep up the good work!

 

[ampsman]

Hope you get it figured out!!! Love to see the progress!

 

[FuzzeWuzze]

Looks good, good luck with the electrical debug we may be able to help ....

 

[Mountainsax]

Thanks FuzzeWuzze! First question, are these bars in the terminal blocks supposed to have screws in all the holes?
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[BrunDog]

Oh yes, most definitely.

 

[Mountainsax]

I got the trusty volt meter out and found that there are 240 volts to the left side (main power in) of the main contactor and 0 volts on the right. Maybe it has something to do with how I wires in the key?
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Main power coming from plug on the left (black and red), second 10AWG wire on the left from the key, black wire w/ yellow connector is the other key wire.

 

[FuzzeWuzze]

Can you get a wider shot or do a quick MS paint of how its connected?

When your key is turned on you should see 120V going into your black w/ yellow end cable going to your contactor coil. When its off there should be 0V.

 

[Mountainsax]

I got 0 volts with the key on or off across the contactor coil. I'll try to get you a wider shot tonight. Basically looks like this...

 

[BrunDog]

0 volts referenced to what? Neutral?

Walk your probes backwards and see where the disconnection is occurring.

 

[Mountainsax]

It's alive!!!!
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Turns out it was just that the screws were missing in the connector bars on the blocks. Gotta love easy fixes!!

One benefit to all this was that I learned how the contactor coil functions as the switch for the contactor. Gotta love feeding by the brain!

 

[poptarts]

I so want to fire up my panel already. Jealous.

 

[Mountainsax]

I hear ya!!! It was insanely gratifying to see those lights come on this morning!!

 

[Mountainsax]

Finished the stand today and got some stain on.
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The next thing is to figure out how to mount the panel to the side of the stand, but be able to remove it for storage under my existing work bench.

 

[FuzzeWuzze]

It's alive!!!!
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Turns out it was just that the screws were missing in the connector bars on the blocks. Gotta love easy fixes!!

One benefit to all this was that I learned how the contactor coil functions as the switch for the contactor. Gotta love feeding by the brain!

Good work, one question though what are the blue lights for the BK/HLT? I assumed it was for "Selected" and the Orange/Yellow as for "Is Powered"...Im curious why both are on if that is the case...

Actually in any case im wondering what purpose those two lights would have being on at the same time. Or are those the power lights for the PID's?

 

[Mountainsax]

I knew someone would notice that! [emoji12] The top white lights are 220v and show the elements heating. The lower yellow lights are 110v and are supposed to show the selected element. I'm not sure why both white lights are coming on. I'll have to look into it.

 

[Mountainsax]

Here is the wiring diagram that I used, in case anyone is interested.
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[Mountainsax]

Hose parts and ball valves! Sweet!
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[Mountainsax]

Made some progress on the house wiring yesterday. The breakers in the main panel are installed and wired, the 110v outlet is working, and I should be able to finish the 220v wiring today.
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I had some good help!
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[Mountainsax]

Finished the 220v outlet!
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[Mountainsax]

Cleaning paint off one of the kegs. I'm not sure what kind of paint this was but it was tough stuff!!
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All gone!
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I also removed some of the dis-coloring from the previous owners burners.
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[Mountainsax]

Building temperature probe cables, per Kal's instructions. I got the DIY kits from www.theelectricbrewery.com. Since my bench is 6 ft long, I got a 6ft, 8ft, and 12ft cable. Probably a little overkill but better too long than too short!

Here is what comes in the kit. Plus the detachable probe tip (not pictured).
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I don't have a heat gun for the shrink tube, but I've found that a soldering iron works good if you just keep moving it on the shrink tube.

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Here is a finished cable.
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[Mountainsax]

Installed the weldless bulkhead with compression fittings from BrewHardware on the HERMs coil. I really like these fittings! They are super solid and well built, definitely worth the couple extra bucks! When you figure in the cost of the stainless compression fitting, adaptor, and weldless bulkhead it's about the same cost.
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In case anyone was wondering, a properly sized HERMs coil for a keggle fits nicely around a 7 year old!
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I don't recommend using the 7 year old to wrap the tubing though, they wiggle too much!!

 

[Mountainsax]

Mounted the pumps and built the plug cords.
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[Mountainsax]

Started working on the boxes for the heating elements.

Punched holes on outlet box covers.
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Punched hole in keggle.
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Learned how cheap Harbor Freight bits are!! This 1/8" bit just bent and snapped when I was trying to drill the pilot for the knockout punch. I didn't think I was pushing that hard but once it started bending I leaned more on it as I lost my balance and, SNAP!!
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[Mountainsax]

I fab'd up the mount for the control panel today. The basic design uses 1" OD pipe inside 1-1/4" ID square tube to allow the panel to turn and for the mount to fold flush with the side of the stand.

The rusted "I" is where he control panel will be mounted.
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The panel will come off for storage and the mount folds in.
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I did all the welding myself and I am definitely not a welder!

 

[Mountainsax]

With the panel...
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[BrunDog]

Cool!

 

[Mountainsax]

Made some more progress this weekend. Got the heating element boxes built and installed, and installed the HERMs coil and some other various fittings.

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The temp probe in the boil kettle seems a little close to the heating element (about 1/2"). I'm wondering if this is going to create an issue with inaccurate readings?
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