3.5 BBL Hybrid Brewhouse
Assembly, Operation, & Maintenance
2 Vessel
Congratulations on your purchase, and thank you for selecting the 3.5 BBL Hybrid
Brewhouse from Blichmann Engineering™. We are condent that it will provide you
years of service and many gallons of outstanding beer. This manual will familiarize
you with the use, assembly, and the sanitation procedures for the product.
IMPORTANT INFORMATION
PLEASE READ AND THOROUGHLY UNDERSTAND THIS MANUAL PRIOR TO USE
FOR IMPORTANT SAFETY INFORMATION!
WARNING:
CAUTION:
IMPORTANT:
IMPORTANT: Power demand for the brewhouse is 55A at 208V (three phase) or 79A at 240V (single phase). Select a main breaker setting
for 20% above the appropriate amperage to avoid nuisance tripping or as directed by your local codes.
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 Blichmann Engineering (www.BlichmannEngineering.com) before use.
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 Blichmann Engineering
(www.BlichmannEngineering.com) before use.
Sections labeled “Important” should specically be followed to ensure satisfactory results with the product.
What’s In the Box?
Item Number Description Quantity
BEPS-MLT-3.5BBL 3.5 BBL Mash Tun 1
BEPS-BK-HLT-3.5BBL 3.5 BBL Boil Kettle 1
BEPS-LIFTSTAND-3.5BBL Kettle Stand 2
Control Panel - Single Phase 1
Sanitary Heater Set of 3 - Single Phase 1
BEPS-PUMP-15HP 1/5hp Brewery Pump 1
BEPS-CHILLER-2.0SQM Chiller 3.5 BBL 1
BEPS-HoseKit-3.5-2V 3.5 Hose Assembly Kit 1
BE-000957-00 CIP Spear 1.5” Tri Clamp 1
BE-000859-00 Cap 2.5” Sanitary 2
Item Number Description Quantity
BE-000868-00 Clamp Gasket 1.5” 11
BE-000633-00 1.5” Tri Clamp 11
BE-000863-00 Tri Clamp Elbow 1.5” 4
BE-001356-00 1.5” Multi Position Valve Tri Clamp 3
BE-001084-00 CIP Spray Ball 1
BE-001186-00 1.5” Sanitary Pipe 6” 1
BE-000630-00 Cap 1.5” Sanitary 1
BE-001132-01 3.5 BBL Stand Pipe 1
BE-000866-00 Clamp Gasket 2.5” 2
BE-000861-00 2.5” Tri Clamp 2
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
1
Assembly
Assemble the kettle stands as shown in the images below.
Attach the lifting arm to the holes in the mash kettle strand. Use the
included allen wrench to tighten in place.
Kettle stand walls
Kettle Placement & Fittings Installation
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 ttings 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
Length (1 inch ID) Quantity
5 Feet 2
10 Feet 1
Construction:
Tube: FDA white EPDM (non oily 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
Note: that you can easily couple hoses together with a clamp and gasket to make long runs to fermentors etc.
Additional hoses can be purchased.
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
2
Place heating elements (3) into the boil kettle. Ensure the nuts on the element junction
boxes are tight to prevent water entry into the heater as shown. Water entry into the element will cause failure.
For the Boil Kettle only install the stand pipe in the drain tting inside
the kettle as shown. To install and remove the standpipe, simply use
a racking cane to lower it into the drain hole and reverse for removal.
This will keep the bulk of the settled hops and break material in the
bottom of kettle and out of the chiller. Use of the stand pipe, while
recommended, is optional.
Install the false bottom through the manway in the mash tun (MT)
one segment at a time starting with the center section. Install the
U-shaped securing clips between the sections to secure them as
shown.
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 6.5 ft from the nished oor. 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.
Total power for the Boil Kettle is 18 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 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 – approx. 6.5 ft from oor
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
3
Control Panel Installation
Warning: Always follow ALL local codes and regulations for installation of this panel. We highly
recommend hiring a certied electrician for this work! We offer this panel in both single phase and three
phase options.
The back of the panel has 4 holes for afxing 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.
IMPORTANT: Power demand for the brewhouse is 55A at 208V (three phase) or 79A at 240V (single phase). Select a main breaker setting
for 20% above the appropriate amperage to avoid nuisance tripping or as directed by your local codes.
Kettle Temperature
Controllers (PID’s)
Heaters ON
Indicator Lamps
Heater Control
Selector Switch
Heating Element
Selector Switch
Emergency Shutoff
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
4
Panel pictured is a single phase controller. Locations of the components in the three phase panel will be
the same.
Main GFI Breaker
DC Control Power Supply
Heating Element Breakers
System Ground
Heating Element Contactors
Main Power GFI Breaker – this industrial grade GFI (ground fault interrupting) breaker is the connection point for main power cables connected to
the panel. Consult your local codes to determine if you can utilize this breaker as 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. Power demand for the brewhouse is 150A at 240V (single phase). Select a main breaker setting
for 20% above the appropriate amperage to avoid nuisance tripping or as directed by your local codes.
RTD’s – the brewhouse is equipped with two durable high precision PT100 temperature probes. The sensors come prewired to your controler panel.
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
5
RTD Wiring Inside Control Panel
Boil Kettle
Prewired to - 3021, 3031
Fig. 10
Mash Tun
Prewired to - 3221, 3231
Heating Elements: The brewhouse is supplied with three 6,000 W ultra-low watt density heating elements. Each heating element will draw 25A at 240V
(Single Phase) or 17A at 208V (3 phase). Each single phase element is pre-wired for 240V 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 L14-30P 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 maximum lengths of exible cable
allowed.
CAUTION – ensure the heater junction box is tight to keep any water out of the box. NEVER immerse the junction box or cord in liquids!
Boil Kettle
Temperature Probe
Mash Tun
Temperature Probe
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
6
Float Switch – A oat switch is 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 re! Wire from the oat switch to the terminal block shown in the
panel (Fig. 10). Wire to terminal 1 and 2 on the oat switch. Polarity
is not important. Use suitable 2 wire cable (18 ga recommended) for
connection.
When wiring the oat switch 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.
Low level oat switch wires hook into the control panel terminals 2063
and 0VDC. If a jumper wire is installed in the panel, remove it when
you install the switch wires. (Fig. 10)
WARNING - DO NOT twist the oat
switch apart. This is NOT covered
under warranty.
CAUTION: The low water level switch is a backup to an unintended energizing of the heaters. They are NOT intend-
ed to be normal shutoff switch and solely relied upon to keep the heaters from unintentionally energizing! Dry-red
heating elements are not covered under warranty!
The indent should be pointed up for proper
oat switch operation.
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
7
Control Panel Operation
Reference the gures on page 4 for locations of components.
PID’s – 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 for a short period approximately every 30 seconds 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.
Heater Control Selector Switch – there are three positions for the power selector switch.
ON -
OFF -
AUTO -
Heater Power Selector Switch – the heater selector switch is used to select the total power input to your kettle. Each switch controls
3 heating elements. You may select, for example, element 1 only (1/3 power), element 1-2 (2/3 power), or 1-2-3 (full power). This is
particularly helpful during the boil to control the boil intensity.
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 main power to the panel before opening the panel.
Energizes the corresponding heating elements.
De-energizes the heating elements in all cases and prevents heater from energizing. Select this
position as you begin to frain a tank or wish to prevent unitended powering of the heaters.
Allows the PID to automatically turn on the heaters to maintain the desired set temperature.
Brewhouse Operation
The hybrid design combines the conveniences of a traditional brewhouse with the simplicity, familiarity, and lower start-up cost of a
homebrew system. This allows a fast and easy transition into commercial brewing with very few sacrices! As such, startup and the
learning curve is quite simple.
IMPORTANT: This manual is not intended as a brewing guide. If you are not intimately familiar with all grain brewing techniques we
highly recommend the following texts from the Brewers Association:
How to Brew (Palmer)
Water (Palmer & Kaminski)
Yeast (Zainasheff and White)
Malt (John Mallet)
For the Love of Hops (Stan Hieronymus)
Brewing Classic Beer Styles (Zainasheff & Palmer)
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
8
Your mash tun, even though uninsulated, will lose less than 1 F/hr. Rarely do commercial
breweries perform step mashing. Modern malts are highly modied and very little is to be
gained by step mashing. Homebrew kettles, on the other hand, are so small that they lose
heat quickly so temperature maintenance is common (RIMS/HERMS).
Lautering (sparging) and vorlauf are both performed using the CIP ball included with the system to gently distribute liquor or wort over
the top of the grain bed. See the image below. Take care to avoid too fast of a runoff which may stick the mash. Note that the level
gauge also acts as a manometer that measures the suction pressure on the grain bed. If the level in the gauge is more than 1/3 lower
than the level in the tank you are drawing too quickly and will soon stick your mash.
IMPORTANT: Do NOT sparge or vorlauf at full pump ow or you are very likely to stick your mash, and your efciency will suffer severely!
TIP: Your pumps are equipped with sanitary diaphragm valves that make easy work of balancing your ow rates.
Boiling: Once the level of the wort in your BK has reached your oat switch, turn the corresponding heater control selector switch to
ON
TIP: If the boil is too aggressive use the heater selector switch to de-energize one of the heating elements. Note that a proper boil is
between a simmer and a surging boil. Shoot for a 3-5% boil off rate per hour.
IMPORTANT: To drive off DMS ALWAYS boil with the lid open!
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
9
Chiller
Sanitize the chiller by either pumping StarSan or similar copper friendly sanitizer through the chiller. Alternately the chiller may be
submerged (ttings up) into a pail of sanitizer. Drain the chiller after the recommended time with the ttings facing down. Connect the
chiller per the instructions on the nameplate.
Drain off the rst 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
ows through the chiller to prevent plugging. Then divert the ow to the chiller. Adjust the wort ow and/or the cooling water ow to
achieve the desired wort temperature to your fermentor.
IMMEDIATELY after use back-ush the chiller with hot water to eject any solids and wort. IMMEDIATELY soak the chiller ttings 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 ttings down, and then store with the chiller horizontal. Following this procedure consistently will give you a very long
service life for your chiller.
Pumps: The pumps included with the system are seal-less 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 lled 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 ow 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 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 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 pumps to recirculate through the CIP ball and the second pump
to return back into the chemical kettle. Tip your kettles forward so that all water drains out the bottom valve, leave the lid open, and
allow the kettles to dry thoroughly.
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 3-5% boil-off rate
Temperature loss in MT – less than 1F/hr
Temperature stability of control system approximately +/- 1 F
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
10
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 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 modication;
b. Damage due to incorrect voltage or improper wiring by customer;
c. Operation outside of the product’s specications;
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, 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. Customer is responsible for shipping damage outside of this
time period. Approval for return must be provided by Blichmann Engineering prior to any return. 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 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 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 other 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 good-will repairs and they will not alter the terms of this limited warranty, or extend any warranty coverage period.
5. Venue for any legal proceedings relating to or arising out of this warranty shall be in Tippecanoe County, Indiana, United States, 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 necessar y to be consistent with such local law.
3.5 BBL Hybrid Brewhouse 2 Vessel V1 © Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
11
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