Blichmann Engineering Power Controller 120VAC, Power Controller 240VAC Assembly Operation Maintenance Manual
Power Controller
Assembly, Operation, & Maintenance
Congratulations on your purchase, and thank you for selecting the Power Controller 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
WARNING:
CAUTION:
IMPORTANT:
FOR IMPORTANT SAFETY INFORMATION!
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?
240V Controller 120V Controller
Power Controller V1© Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
1
The Power Controller is an ideal means to control the power output for your electric kettles. Note: this controller does not control
temperature. The pulse width modulation linear control is superior to highly nonlinear “dimmer switch controls”. It allows the user to
easily set the desired % power output in an intuitive and fast manner. In addition, the Power controller design is modular. If your kettle
requires multiple elements, optional Relay Modules can be added to accommodate up to 5 total elements (One power Controller
plus 4 Relay Modules), all driven by a single Power Controller. Units can easily be wall mounted or table mounted, and can also be
connected together using optional off-the-shelf DIN rails.
The Power Controller is available in either 120VAC or 240VAC. They are available pre-wired with a short “pigtail” power connectors
or unwired for the user to install their own preferred cables.
WARNING: It is recommended to hire a certied electrician to do the wiring if you are not condent that you can perform this work
yourself. Always use cable and wire gauge suitable for the power of your heater.
All units must be connected to the appropriate sized GFCI circuit. Refer to the chart to determine the appropriate breaker required
for your circuit. If you are uncertain about the power requirements or your server location, contact a licensed and qualied electrician
familiar with National Electrical Code standards and requirements.
Each Unit
Maximum Heater
Power (Watts)
GFCI Breaker Size
(minimum)
120VAC 2400 20A
240VAC 7200 30A
WARNING: The 240V model of the Power Controller is rated for use with electric heaters up to 7200 watts. The 120V model of Power
Controller is rated for use with electric heaters up to 2400 watts. Never exceed 30 amps with the 240V model and 20 amps with the
120V model. It is recommended to have a dedicated circuit to power your heater(s).
WARNING: The Electric Power Controller is only to be used in conjunction with a Ground Fault Circuit Interrupter (GFCI) protected
power source. If you are uncertain about the status of your power source contact a licensed and qualied electrician familiar with
National Electric Code standards before proceeding. Operating the Electric Power controller in any fashion other than described in
this manual can result in personal property damage, injury, electrocution, or death.
WARNING: DO NOT immerse or spray the controller with water.
NEVER:
• NEVER leave this equipment unattended.
• NEVER allow children near this equipment.
• NEVER heat cooking oil with this equipment.
• NEVER use near or with combustible chemicals, gasoline, or other ammable vapors or liquids.
• NEVER operate any equipment with frayed or damaged power cables.
• NEVER expose electrical connections to moisture.
• NEVER modify or alter the supplied electrical cables or connectors.
• NEVER operate controller with higher than rated voltage or current.
• NEVER unplug heater when energized.
• NEVER energize the heater without the heating coils fully submerged.
Power Controller V1© Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
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ALWAYS:
• ALWAYS unplug controller when powered off.
• ALWAYS connect to a GFCI circuit.
• ALWAYS check power cables and connectors for signs of damage or wear prior to each use.
• ALWAYS check that all fasteners are properly tightened prior to each use.
• ALWAYS use genuine Blichmann Engineering™ replacement parts.
• ALWAYS wear appropriate personal protective equipment, such as gloves, clothing, and footwear to prevent burns
and scalds.
Figure 1
Wiring the cables through the bottom of the controller
You can wire the cables through the bottom of the controller housing to allow you to wall
mount your power controller.
Follow these steps to wire your controller.
1. Remove the screws from the front and back of the controller and remove the bottom
housing. (Figure 1)
2. Place the cords through the grommets .
3. Mount the ground cables to the ground screws.
4. Mount the black wires to the terminals on the circuit board. Mount the male cables
black wire to the T1_BLK_IN terminal (Figure 2) and mount the female cables black
wire to the T2_BLK_OUT terminal (Figure 2).
5. Connect the three white wire (one from each cable and the one coming from the
circuit board) with the included wire nut.
6. Reattach the bottom housing to the controller.
IN Terminal
Ground
Out Terminal
Ground
Figure 2
Power Controller V1© Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
3
Relay Module
ONLY TO BE USED WITH THE BLICHMANN ENGINEERING POWER CONTROLLER.
120V Relay Module 240V Relay Module
What’s In the
Wiring the Relay Module to the Power Controller
The Relay Module is used to control multiple heating elements.
Your control relay will come with a blue jumper cable (Figure 6). This cable will
need to be wired to both the Power Controller and the Relay Module. Separate
the jumper cable at the connection.
1. Remove the “CONTROL WIRE CONNECTIONS ONLY” label on the Relay
Module (Figure 7).
2. Connect the blue/white cable to terminal 3 (+) and connect the blue wire
to terminal 4 (-). (Figure 7)
3. Run the jumper cable out the side of the controller as shown in Figure 9
and attach the bottom housing on the Relay Module.
4. Remove the “CONTROL WIRE CONNECTIONS ONLY” label on the
Power Controller. Install the blue jumper wires to the labled terminals
(Figure 10). Connect blue to T4, connect blue/white to T3.
5. Attach the bottom housing on the Power Controller and run the jumper cable
out the side of the controller.
6. If desired, mount both controllers to the DIN Rail (sold separately) shown in
Figure 11.
Figure 6
Figure 8
Figure 7
Blue
Take off
sticker
Blue/White
Figure 9
Cut the DIN Rail with a saw if required.
Power Controller V1© Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
Figure 10
Figure 11
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DIN Rail Installation
Attach the DIN rail with the included bolt and square nut in the kit. Put the bolt and nut on the controller loose. Slide the DIN rail into the back
of the controller and tighten the bolts when the controller is in place. Do not overtighten. This will hold the controller onto the DIN rail.
Operation
Warning: Before use, ensure that the Power Controller knob is in the OFF position. The OFF position is engaged by turning the
power control knob fully counterclockwise. It is harmful to the power cable connections to install/remove them under power as the
connections will arc and will quickly fail. In addition, inadvertent energizing of the elements can cause equipment damage and possible injury.
Connect the heater cord to the electric immersion heater (BoilCoil™). Next, connect the male end of the heater cord to the female
terminal on the Power Controller. Repeat this step if using Relay Modules for multiple heating element setups. Connect the female
end of the power cord(s) to the male terminal of the Power Controller. Lastly, connect the male end of the power cord(s) to a GFCI
power source. Connection may be different if you have wired the units yourself.
To increase power from 0% (off) to 100% (full power) turn the knob clockwise to the desired % power setting. For example, a setting
of “6” will represent 60% of full power of the installed heating element.
Maintenance
The Power Controller requires little maintenance. Inspect fasteners and wires regularly and replace as needed ONLY with genuine
Blichmann Engineering™ parts. Parts can be ordered through your retailer or directly from Blichmann Engineering. After brewing,
wipe any drips off with ordinary soap and a soft sponge.
Optional Accessories
Adapter Plug
The 240V model of the Power Controller is equipped with L6-30 connections (30A). The 120V model of the Power Controller is
equipped with L5-20 connections (20A). Blichmann Engineering™ offers six optional power cord adapters to adapt common 240V
outlets to an L6- 30R connection.
Adaptors available for purchase from Blichmann Engineering™ for receptacles as shown below.
Power Controller V1© Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
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Adapter Plug
10/3 AWG Cable
(1.5 ft)
6-30
Receptacle
BE-000482-00
6-50
Receptacle
BE-000485-00
10-30
Receptacle
BE-000483-00
10-50
Receptacle
BE-000486-00
14-30
Receptacle
BE-000484-00
14-50
Receptacle
BE-000487-00
Extension Cord
120v 11.5ft
Extension Cord
BE-000365-01
240v 11.5ft
Extension Cord
BE-000364-01
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. This product is for home use only. 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. Damage by over-tightening the fasteners;
f. Failure to follow cleaning and / or maintenance procedures; or
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 notied 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 warrantee 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 tness, 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 tness 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 specically 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 specic 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 modied, only to the extent necessary to be consistent with such local law.
This product uses FDA and/or NSF approved 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.
Power Controller V1© Blichmann Engineering, LLC 2018
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts
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