The Electric Brewery: Phase 1

So, in an effort to assist Brewmaster Jay with his move and advance our brewing system, I have decided to move the brewery to my house.  Unfortunately, the only permanent location for the brewery is in my basement.  I say unfortunately because using a gas burning turkey fryer appliance in an enclosed area can be particularly dangerous due to the toxic chemicals (CO) and exhaust fumes.  Fortunately, this gives us the perfect opportunity to advance our brewing methods and system.  The design is fairly simple: replace the gas heat with electric heat.  However, the equipment though safer during normal use, can be a bit more dangerous and complicated to install.  The plan is to use the output of a proportional-integral-derivative controller (PID controller) to drive a solid-state-relay (SSR) connected to a hot water heater heating element (5500 Watt, extra low density (ELD)).  The pulse width modulated (PWM) wave coming from the PID controller will turn on and off the SSR a number of times per second.  The ratio of low voltage to high voltage (off/on) will depend on the feedback from the thermocouple connected to the kettle.  The end goal is to be able to set a temperature on the PID and have the element reflect that temperature in the kettle.  This, hopefully, will be a more efficient, safer way to brew.  According to our calculations, the only difference in this system may be the time it takes to heat liquids as the gas burner can, most likely, put out many more than 5500 Watts of power.  We will only really know the answer to this once the equipment is installed.

So far, the PID and element have been ordered.  I believe it will only take some low gage electrical wire and a dryer wall plug to finish the job, electrically.  Physically, I will need to have the ports welded into the kettle, which I will do as soon as all of the parts have arrived and I have figured out how they will all fit together.  I should have the element today and the PID should arrive in the next few weeks as it's on its way from China.

Electrical Heat Calculations: Electric Heat