I'm tossing around the idea of building a self-contained control panel (16" x 24" enclosure) that incorporates my BCS-462 with a Gigabyte Z77N-WiFi motherboard (M/B) (http://www.gigabyte.com/products/produc ... id=4337#ov), with the M/B's onboard I/O used to drive a free-standing (VESA-mounted) 23" Viewsonic (TD2220) touchscreen (USB, DVI-I, 120V power). OK, I guess maybe I'm really building a customized computer case that will also house a BCS-462 and all the various I/O that it needs or controls (e.g., seven temperature & one pH probe inputs, two 24VAC outputs to control the Honeywell VR8200 gas valve-controlled Blichmann floor standing burners sitting under the HLT & BK, 120VAC electrical outputs to control the three March 809-HS pumps (HLT, MT, BK) and a 2000W/120V RIMS, and 12VDC outputs to control seven 3-way electric water valves). Anyway, everything but the monitor would be housed in one box - call it a computer, call it a control box.
I'm planning on mounting the M/B to the backplane using standoffs, along with two 8-channel 5V relay boards (for the 7 water valves, 2 gas valves for the burners, 3 pumps). Also on the backplane will be the BCS and DIN rail(s) for the terminal blocks and the SSR (RIMS today, but I may go all-electric when I get back to the states next year, so room for four more SSRs). While I could control the BCS without a LAN, since the computer is already onboard and directly connected to the BCS, this Gigabyte M/B also functions as a Wireless Access Point (WAP), so I'd still have wireless access to the BCS from any other computer on my LAN (and beyond).
I'm going for 3 modes of redundant control; 1) Mostly Manual, 2) Semi-Automated, and 3) Almost-Fully-Automated (but not yet 1-touch).
In the Manual Mode (no BCS), the control panel will have several 2- and 3-way contactor switches on the front that will allow me to run the system manually. In this mode, I would still need electricity, but the switches would only be used to turn on/off the pumps and the gas valves, but the water valves would have to operated manually. I would not be able to run the RIMS in this mode, but I can always throw my immersion chiller into the HLT and suffice with a make-do HERMS).
In the Semi-Automated Mode (no BCS), I could turn the system over to three Omega CN9000A (CN9221A) PID temperature controllers (http://www.omega.com/pptst/CN9000A.html) that I already have sitting in a box (from my Pre-BCS control panel following Kal's design). These would respectively drive the two gas valves (via 3-wire RTDs in the HLT and BK) and the RIMS (also 3-wire RTD monitored). In this mode, there is no logic driving the process - still somewhat hands on, telling the Omegas what to do and when to do it.
In the Almost-Fully-Automated Mode, I would turn over full control to the BCS-462, and just run (watch?) the system with the touchscreen, letting the BCS run through all of it's logic and just tickle me when it gets lonely, or needs a little brawn (adding grain, adding hops).
Yeah, maybe this is all a little overkill... but it starts to satisfy my need for full redundancy - a weakness that I attest to my deep-seated paranoia of something electrical going wrong on brew day... which of course NEVER happens, right?!!!
Anyway, I wonder, I've searched for other integrated BCS/motherboard combinations here and on homebrewtalk.com, but I couldn't find any. I'm often told that I'm not the sharpest tool in the shed, so I'm wondering... am I overlooking a major disadvantage to automating my brewery in this way??
Go ahead... throw stones! I can take it!!
Mini-ITX MB incorporated into BCS Control Panel
Mini-ITX MB incorporated into BCS Control Panel
Indecision may or may not be my problem...
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Re: Mini-ITX MB incorporated into BCS Control Panel
I use a large touchscreen to contol my brew day and love it. I had thought about a mini-itx system, but couldn't justify the cost. Plus, using my laptop, I have dual screens. One is touchscreen for control and the built-in laptop screen for Beersmith and other things. Is doing a dedicated Mini-ITX overkill, sure, but it'd bee cool!
I had always planned on adding manual switches for overriding things, but never got around to it since I really rarely find the need to do something outside of my processes. If I do need to do something to intervene, I pause the process and manually control the output I need. If you want to add manual switches, I highly suggest wiring them to do simple 5V switching. You can use On/Off/Auto switches to feed either the BCS power or 5V power to trigger your relays & SSR's. This way, you keep your high voltage wiring in one place and don't need to wire it to multiple switches on the panel.
My personal opinion - you should drop the Omega PID's. Once you start using the BCS, you'll quickly see that you'd never use the PID's. Maybe do a bench setup and brew with it a few times before setting up the new control panel.
I had always planned on adding manual switches for overriding things, but never got around to it since I really rarely find the need to do something outside of my processes. If I do need to do something to intervene, I pause the process and manually control the output I need. If you want to add manual switches, I highly suggest wiring them to do simple 5V switching. You can use On/Off/Auto switches to feed either the BCS power or 5V power to trigger your relays & SSR's. This way, you keep your high voltage wiring in one place and don't need to wire it to multiple switches on the panel.
My personal opinion - you should drop the Omega PID's. Once you start using the BCS, you'll quickly see that you'd never use the PID's. Maybe do a bench setup and brew with it a few times before setting up the new control panel.
Re: Mini-ITX MB incorporated into BCS Control Panel
I guess my desire to use the Omegas stems from 1) I have a dozen of them in a box, 2) they were part of my original design and I hate admitting defeat, and 3 I'm comfortable in using them. Combine that with my lack of experience with the BCS, and you might see my attachment. I haven't developed the trust with my BCS yet, but I can tell from everyone else's comments, I need to just trust the force!
I have about made the decision to drop the PIDs... They're proving to be a pain to design the schematic around
I have about made the decision to drop the PIDs... They're proving to be a pain to design the schematic around
Indecision may or may not be my problem...
Re: Mini-ITX MB incorporated into BCS Control Panel
Just to add to my last post... I'm likely going to pull the plug on keeping the Omegas integrated into the system because I started having difficulties in getting the temperature probes wired in. The BCS-462 uses 10K thermistors, while the Omegas use 3-wire RTDs. The original intent was to have the Omegas as a backup should I ever lose connectivity with the BCS, but I couldn't figure a way to have the probes hot-swappable. In others words, how do I quickly switch to the Omegas - and RTD control - in the middle of a session if the kettles are full? I'd have to have both probes inserted into each kettle (and the RIMS exit), and so I was looking a lot of wires.
So, while I was going for redundancy, others more experienced than I with the BCS aren't even bothering with switches as a backup, and are happy with their decision... Clearly the paranoia is mine, and mine alone
Now, the question is, can I take away my other safety net - the switches??? Oh, the dilemma
So, while I was going for redundancy, others more experienced than I with the BCS aren't even bothering with switches as a backup, and are happy with their decision... Clearly the paranoia is mine, and mine alone
Now, the question is, can I take away my other safety net - the switches??? Oh, the dilemma
Indecision may or may not be my problem...
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Re: Mini-ITX MB incorporated into BCS Control Panel
Like I said before, maybe do a test setup with no control panel and brew with just the BCS a few times.
Re: Mini-ITX MB incorporated into BCS Control Panel
Good idea... However I'm rebuilding my breast and based on what I learned from the first one, and space for a control panel is a consideration, vice space for a monitor only. But I am leaning towards dispensing with many of the switches as well.
I would still like to be able to run the pumps and the water valves without a monitor - cleaning would be easier without having to worry about splashing the monitor.
I would still like to be able to run the pumps and the water valves without a monitor - cleaning would be easier without having to worry about splashing the monitor.
Indecision may or may not be my problem...
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Re: Mini-ITX MB incorporated into BCS Control Panel
not exactly 100% on-topic, however I am happy with iPad after using it for 10 or so brew sessions...
here is yesterday's brew... had the office PC running the graph while we were outside brewing