Electric Brewing Controls - getting there, but...

[ecbrewer]

So, I've spent the past few months researching other all-electric breweries and talking to a few all-electric brewers - special thanks to Jay (aka BaltoBrewer) for taking the time to discuss his awesome system (http://www.wortomatic.com/articles/Baltobrewer%27s-Electric-Stand), which I used as the model for mine!!)... I have the stand and plumbing finished... I've purchased 2 PIDs (2352), 2 SSRs (40A), and 3 RTDs (1 in each HLT, MLT, and BK, but 2 will be switched to PID from HLT or MLT depending on point in process), and 2 5500W 240V ultra low density heating elements. I've also gotten the 10/3 cable for connecting the 240v elements and the 14/3 cable for the pumps and PID power. I've also picked up the connectors and outlets to ensure all electrical connections are waterproof. I've yet to buy the project box and other small electrical components because I want to see what kind of influence I'm hoping to get from this post will have on the design. I will be posting some pics of the non-electrical portions of the rig in the very near future.

So, with that all said (and I'm guessing I'll get requests for more info - just don't want to write a book for the first post), a link to my seemingly millionth draft of the wiring diagram for the controls and the diagram of the brewing process are below.

http://www.rehmert.com/ControlPanelWiring.jpg (746 KB)
http://www.rehmert.com/BrewingProcess.jpg (1,134 KB)

I greatly appreciate any discussion, questions, or offers to help that result!! I would REALLY appreciate constructive feedback or nudges in the right direction on the wiring and components in the controls as I'm not a process/electrical engineer by trade, but I'm certainly learning...
Thanks all!!
- John

Edit: Please note, I know I didn't use UL wiring colors in my diagrams - but only because white wouldn't really show up and I wanted to make it easier to quickly discern 120v and 240v...

[BadRock]

Looks to me like you are on the right track, I'm not sure what kind of input you are looking for but I'd be glad to lend an opinion if you have any specifics you have questions about.

[foomench]

So if I'm reading your diagram correctly, the HLT is PID controlled as is the BK. Why a PID controller on the BK? How effective can that be? A gentle simmer and rolling boil are both the same temperature.

I don't see any control of mash temperature, so not an automated HERMS system I guess.

How much wort can you boil with one of those 240V heating elements? This really has me rethinking gas vs. electric. Luckily I'm still putting my stand together, so I haven't committed either way on that yet.

-Eric

[ecbrewer]

I've gotten quite of bit of constructive and EXTREMELY helpful feedback - much of which I've incorporated in version 1,000,319 of my brewing sculpture/process plans from my post on the Brew Board (http://www.brewboard.com/index.php?showtopic=105819)... I'll be posting the diagrams of my new electrical control panel and brewing process shortly... Hopefully that will help clear up some of the unknowns and spur some more discussion...