BLICHMANN 2 BBL Single-Walled Brewhouse Instruction Manual

2 BBL Single-Walled Brewhouse
2 Vessel Assembly, Operation, & Maintenance

Congratulations on your purchase, and thank you for selecting the 2 BBL Hybrid™ Brewhouse from Blichmann Engineering™. We are confident that it will provide you with years of service and many gallons of outstanding beer.

IMPORTANT INFORMATION

PLEASE READ AND THOROUGHLY UNDERSTAND THIS MANUAL PRIOR TO USE FOR IMPORTANT SAFETY INFORMATION!

WARNING:

| Sections labeled “Warning” can lead to serious injury or death if not followed. Please thoroughly read these sections and understand them completely before use. If you do not understand them or have any questions, contact your retailer or our website at www.blichmannengineering.com before use.
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CAUTION:

| Sections labeled “Caution” can lead to equipment damage or unsatisfactory performance of the equipment. Please read these sections thoroughly. If you have any questions, contact your retailer or our website at www.BlichmannEngineering.com before use.

IMPORTANT:

| Sections labeled “Important” should specifically be followed to ensure satisfactory results with the product.

IMPORTANT: Power demand for the brewhouse is 32A at 208V (three phases) or 52A at 240V (single phase). Select the main breaker setting for 20% above the appropriate amperage to avoid nuisance tripping or as directed by your local codes.

ASSEMBLY

Assemble the kettle stands as shown in the images below.

KETTLE PLACEMENT & FITTINGS INSTALLATION

The place stands in the desired location Use a level to ensure that the stand arms are level. Adjust the leveling feet as needed. It is recommended that you allow enough clearance between kettles and also on the sides and rear to allow personnel access for cleaning and service of the ancillary equipment. Although in practical use, the kettles can easily be slid out for any service needs.
Install valves and fittings as shown in the images below. Note that a 6” spool is added to the mash tun drain to allow the valve to swing under the stand so that a spent grain tote can be placed under the manway. It is not necessary to add the spool to the BK.

SPOOL FOR MASH TUN ONLY

Hoses

Construction:
Tube: FDA white EPDM (nonoily transfer applications)
Reinforcement: Multiple plies of polyester tire cord with wire helix
Cover: Grey EPDM
Temperature Range: -40°F to +225°F
Not for continuous steam service
Stainless Steel 1.5 Inch Tri-Clamp ends
Place heating elements (2) into the boil kettle. Ensure the bolts on the element junction boxes are tight to prevent water entry into the heater as shown. Water entry into the element will cause failure.
NEVER immerse the junction box or cord in liquids!

Note: you can easily couple hoses together with a clamp and gasket to make long runs to fermentors etc.
Additional hoses can be purchased.

For the Boil Kettle only install the stand pipe in the drain fitting inside the kettle as shown. To install and remove the standpipe, simply use a hook to lower it into the drain hole and reverse it for removal. This will keep the bulk of the settled hops and break material in the bottom of the kettle and out of the chiller. Use of the standpipe, while recommended, is optional.

BREWERY VENTILATION

Ventilation needs for an electric brewhouse are fairly minimal as only the boil kettle needs to be ventilated. We recommend a traditional commercial kitchen vent hood be installed approximately 32 inches above the kettle. General rules of thumb are in the table below. It is recommended that you consult your local codes and consult with a professional prior to purchasing or installing your ventilation equipment.
The total power for the Boil Kettle is 12 KW.

RULES OF THUMB SUMMARY

Heat Load Factor| 1 CFM per 100 BTU/hr (gas) or 34 CFM per KW (electric)
Hood Velocity Factor| 50 CFM per ft2 of the hood
Room Air Exchange Factor| CFM = Room Volume (ft3) / 6 (you can generally disregard)
Hood Size| Overhang 6” minimum front and sides
Hood Height| 32” above kettles

CONTROL PANEL INSTALLATION
Warning: Always follow ALL local codes and regulations for the installation of this panel. We highly recommend hiring a certified electrician for this work!
The back of the panel has 4 holes for affixing the panel to the wall of the brewhouse or onto a suitable stand. Mounting hardware or stand is not included.
The image below indicates the locations of the main components.

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Main System Power– This panel requires a connection to an appropriate- sized breaker. This needs to be installed before the connection point for the main power cables is connected to the panel. Consult your local codes to determine if you need a main disconnect as well. In any case, we highly recommend a suitable disconnect switch be installed prior to the panel for safe servicing of the panel. Your contractor will need to punch a hole in your panel for the main power cable conduit in your desired location. The power demand for the brewhouse is 52A at 240V (single phase) or 32A at 208V (three phases). Select the main breaker setting for 20% above the appropriate amperage to avoid nuisance tripping or as directed by your local codes.
Your system is supplied with PT100 RTD temperature probes with 30 feet of cable. Insert the Temperature Probe into the cord grip and thermowell until the probe bottoms out. It is important to ensure it is inserted all the way, otherwise, this can cause your temperature readings to be inaccurate.
Tighten the cord grip until the probe cable is locked into place.
Connect the white, red, and blue wires to the control panel listed below.

RTD Wiring Inside Control Panel

Boil Kettle
Blue to BKTS-1
Red to BKTS-2
White to BKTS-3| Mash Tun
Blue to MTS-1
Red to MTS-2
White to MTS-3
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Heating Elements: The brewhouse is supplied with four 6,000 W ultra-low watt density heating elements.
Each heating element will draw 25A at 240V (single phase) or 17A at 208V (three phases). Each single phase element is pre-wired for 240V or 208V operation and has a pigtail with an L6-30P twist lock connector for easy removal for cleaning. Each three-phase element is pre-wired for 208V operation and has a pigtail with an L15-30P twist lock connector for easy removal for cleaning. We recommend SJOOW type cable 10 ga minimum.
Again, your local codes will dictate the cable type and gauge.
IMPORTANT: Always consult your local codes to determine what type of cable is acceptable, what gauge is required, and the maximum lengths of flexible cable allowed.

REMOVE THE RUBBER BAND FROM THE LOW-LEVEL FLOAT SWITCH BEFORE INSTALLATION

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The picture shows the float switch down. In this position, the heating elements will not energize.| The picture shows the float switch up. In this position, the heating elements will energize.| The picture shows blue and brown pre-stripped wires.

Float Switches – float switches are provided to help prevent unintended energizing of the heating elements. It is vital that the heating elements be immersed in liquid prior to energizing them. Failure to immerse the heating elements will cause them to fail and potentially cause a fire! Using the wires included, run the wire from the float switches to the terminal block shown in the panel (Fig. 10). Polarity is not important. Hook your BK float switch blue and brown wires into terminals BKFS-1 and BKFS-2 in the panel. Again, polarity is not important. If jumper wires are installed in the panel remove them when you install the switch wires.
When wiring the float switches to the control panel use a continuity tester on the leads to ensure that the switch is open when in the down (empty) position, and is closed (has continuity) in the up (full) position.
CAUTION: The low water level switches are a backup to an unintended energizing of the heaters. They are NOT intended to be normal shutoff switches and solely relied upon to keep the heaters from unintentionally energizing!
Dry-fired heating elements are not covered under warranty!
Control Panel Operation

Temperature Mode

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Power Mode

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Reference the figures on pages 4 and 5 for locations of components.
PIDs – The PID controllers are pre-set for optimum heating rates and minimum overshoot. The corresponding large green lamp below the PID will indicate when the control is powering the heating elements. As the temperature approaches the set point the controller will automatically begin to cycle the heating elements on and off to maintain the set temperature. Typical stability is about +/- 1F. Note that the MASH PID is displaying temperature only and does not energize heating elements.
To change the set point press the UP/DOWN arrows until you reach your desired setting.
To switch your kettle to Power Control Mode, press the F1 button. To change power % use the up and down arrows. To switch back to Temp Control Mode press the F1 button again.
Heater Control Selector Switch – there are two positions for the power selector switch on and off.
WARNING: Energizing the heaters dry will cause the heaters to fail and potentially cause a fire. Boiling water unattended (if heaters are left in the ON position) will cause a similar failure if the water boils off.
WARNING: Consult your local codes and regulations for unattended operation of your system.
Emergency Stop – this switch disables all heater contactors in the panel and also can be used for ensuring your heaters do not inadvertently power on. For safety, install a padlock through the hole in the switch to prevent unauthorized operation of the panel.
WARNING: Pressing the emergency stop button does NOT cut power from the inside of the panel! All internal components will be live! To service the panel, disconnect the main power to the panel before opening the panel.
Chiller
Sanitize the chiller by either pumping StarSan or similar copper-friendly sanitizer through the chiller. Alternately the chiller may be submerged (fittings up) into a pail of sanitizer. Drain the chiller after the recommended time with the fittings facing down. Connect the chiller per the instructions on the nameplate.
Sanitize the chiller by either pumping StarSan or similar copper-friendly sanitizer through the chiller. Alternately the chiller may be submerged (fittings up) into a pail of sanitizer. Drain the chiller after the recommended time with the fittings facing down. Connect the chiller per the instructions on the nameplate.
Drain off the first gallon or so of wort from the boil kettle to a waste drain to eject any solids in the piping and to ensure only clear wort flows through the chiller to prevent plugging. Then divert the flow to the chiller. Adjust the wort flow and/or the cooling water flow to achieve the desired wort temperature for your fermentor.
IMMEDIATELY after use back-flush the chiller with hot water to eject any solids and wort. IMMEDIATELY soak the chiller fittings up in PBW or other copper-friendly cleaning agents for 30 min or pump through the chiller. Rinse with hot water and then soak in sanitizer. Allow to drain fittings down, and then store with the
chiller horizontally. Following this procedure consistently will give you a very long service life for your chiller.
Pumps: The pumps included with the system are sealless magnetic drive pumps. They MUST NOT be run dry or the impeller-bearing surface will be damaged!
This is NOT covered under warranty. Ensure the hoses and pump head are filled with liquid before turning on the pump. If you hear a loud squeal stop the pump immediately!
Caution: NEVER restrict the inlet to the pump. Always place flow throttling valves on the OUTLET of the pump ONLY. Failure to do this will cause cavitation in the pump possibly leading to failure of the impeller. If you hear any grumbling or grinding in the pump STOP IMMEDIATELY as this is cavitation. Cavitation failures are NOT covered under warranty.
Cleaning Your System:
Mash Tun: Spent grains can easily be removed through the manway in the mash tun. Drain all remaining wort out of the bottom drain and then open the door.
Utilizing a non-marring hoe (available in our maintenance kit) rake out the spent grains into a tub, also available through Blichmann Engineering. Remove the false bottom sections and spray them off with hot water and allow them to dry. Spray excess grain from the sidewalls and bottom of the kettles with a hose.
BK/MT: Due to the easy access through the top of the relatively small tanks, and the small size of the chiller and pumps, it is usually fastest to scour the kettles with a scrub brush mounted on a pole and spray them out with a hose. Optional cleaning tools are available through Blichmann Engineering to make this a fast and thorough job. Alternately, you can utilize one of the heated vessels to heat and hold your CIP (clean in place) chemicals and use one pump to recirculate through the CIP ball and the second pump to return back into the chemical kettle. It is recommended that you turn off all heaters while running the CIP system to avoid dry firing them. Tip your kettles forward so that all water drains out of the bottom valve, leave the lid open, and allow the kettles to dry thoroughly.

Tip: A spray of StarSan on the interior surfaces after cleaning will help prevent mildew between uses.
Tip: Place your chiller in line with the pump to clean it at the same time.

Helpful System Data
Typical heating rates are 0.8-1.5 F/min.
Expect about a 5% boil-off rate
Temperature loss in MT – less than 1F/hr
Temperature stability of control system approximately +/- 1 F

Blichmann Engineering Product Warranty

A. Limited Warranty

1. Blichmann Engineering warrants to the original purchaser that this product will be free from manufacturing defects in material and workmanship for a period of one (1) year from the date of purchase by the customer. Proof of purchase is required. Blichmann Engineering’s obligation to
   repair or replace defective materials or workmanship is the sole obligation of Blichmann Engineering under this limited warranty.

2. The limited warranty covers only those defects that arise as a result of the normal use of the product and does not cover any other problems, including, but not limited to, those that arise as a result of:
   a. Improper maintenance or modification;
   b. Damage due to incorrect voltage or improper wiring by the customer;
   c. Operation outside of the product’s specifications;
   d. Carelessness or neglect to operate the product in accordance with instructions provided with the product;
   e. Damaging the tamper label on the product;
   f. Damage by over-tightening the fasteners;
   g. Failure to follow cleaning and/or maintenance procedures; or
   h. Exceeding published operational temperatures.

3. Blichmann Engineering reserves the right to request delivery of the defective component for inspection before processing the warranty claim. If Blichmann Engineering receives, during the applicable warranty period, a notice of a defect in any component that is covered by the warranty,
   Blichmann Engineering shall either repair or replace the defective component with a new or rebuilt component at Blichmann Engineering’s option.

4. Blichmann Engineering must be notified within seven (7) days of the delivery date of any shipping damage. The customer is responsible for shipping damage outside of this time period. Approval for return must be provided by Blichmann Engineering prior to any return. The customer is responsible
   for keeping all original packaging material for warranty returns. Blichmann Engineering is not responsible for damage from improperly packaged warranty returns, and these repair costs will be the sole responsibility of the customer. Shipping costs for warranty returns are covered only for
   the contiguous United States.

5. Blichmann Engineering’s limited warranty is valid in any country where the product is distributed.

B. Limitations of Warranty

1. Any implied warranty that is found to arise by way of state or federal law, including any implied warranty of merchantability or any implied warranty of fitness, is limited in duration to the terms of this limited warranty and is limited in the scope of coverage to this warranty. Blichmann
   Engineering disclaims any express or implied warranty, including any implied warranty of fitness for a particular purpose or merchantability, on items excluded from coverage as set forth in this limited warranty.

2.  Blichmann Engineering makes no warranty of any nature beyond that contained in this limited warranty. No one has the authority to enlarge, amend, or modify this limited warranty, and Blichmann Engineering does not authorize anyone to create any other obligation for it regarding this product.

3. Blichmann Engineering is not responsible for any representation, promise, or warranty made by any independent dealer or another person beyond what is expressly stated in this limited warranty. Any selling or servicing dealer is not Blichmann Engineering’s agent, but an independent entity.

C. Limitations of Liability

1. The remedies provided in this warranty are the customer’s sole and exclusive remedies.
2. Except for the obligations specifically set forth in this warranty, in no event shall Blichmann Engineering be liable for direct, indirect, special, incidental, or consequential damages, whether based on contract, tort, or any other legal theory and whether or not advised of the possibility of such damages.
3. This warranty does not cover, and in no event shall Blichmann Engineering be liable for, travel, lodging, or any other expense incurred due to manufacturing defects in material and workmanship, or any other reason.
4. Any performance of repairs after the warranty coverage period has expired or performance of repairs regarding anything excluded from coverage after this limited warranty shall be considered goodwill repairs and they will not alter the terms of this limited warranty, or extend any warranty coverage period.
5. The venue for any legal proceedings relating to or arising out of this warranty shall be in Tippecanoe County, Indiana, United States, in which courts will have exclusive jurisdiction.

D. Local Law

1. This warranty gives the customer specific legal rights. The customer may also have other rights that vary from state to state in the United States or other countries.
2. To the extent that this warranty is inconsistent with local law, it shall be deemed modified, only to the extent necessary to be consistent with such local law.

This product uses food-grade materials anywhere the product touches the beverage.
Warning: This product contains or may contain chemical(s) known to the State of California to cause cancer, birth defects, or other reproductive harm.

2 BBL Single-Walled 2 Vessel Brewhouse V3© Blichmann Engineering, LLC 2021
For replacement parts, visit: blichmannengineering.com

Documents / Resources

| BLICHMANN 2 BBL Single-Walled Brewhouse [pdf] Instruction Manual
2 BBL Single-Walled Brewhouse, Walled Brewhouse, 2 BBL Single Brewhouse, Brewhouse
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References

• Blichmann Engineering: Industry-Leading Brewing Equipment
• Blichmann Engineering: Industry-Leading Brewing Equipment

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