Rewiring Brewzilla

[Mash]

While your are there, get a crimp tool and some terminals.

[DorsetScott]

Thanks both.

I'll get it ordered, then it will get here when it gets here.
Bottom is currently still off so will have a think about placement.
There arent too many place I can drill to mount so should be easy enough to work out.

I'll wait to hear on the wire, thanks again

[Windoe]

DorsetScott, I have not forgotten about the wire. I have some knocking around here. You will need three lengths. One to run from the 1900w switch to the phase angle controller. The second to run from the phase angle controller to the element. And finally an earth from the metalwork on the phase angle controller to the earthing point. You will need to remove the existing wire from the 1900w switch to the element.
If you can advise the diameters of the holes required for the holes in the tags for the element and the earthing point I will crimp ends on for you. (Width of the tag on the switch would be also helpful.) A rough idea of the lengths of the cable also would help. If you PM me with a postal address I will try to get it all out this week to you. It should still arrive before the Chinese shipment!

[DorsetScott]

Windoe, you are truely going above and beyond to help me with this, you have my sincerest thanks.
Currently the unit is full of water as I got lazy and couldn't be bothered to clean it after a beer run Sunday, but I am draining and cleaning today so i'll whip the bottom back off and take the measurements today/tomorrow and send you the details. Thank you so much

I am fairly certain from your explanations I know what we're doing and you're basically making it plug and play for me, couldn't be happier

[DorsetScott]

Hey windoe

Diameter of the hole is 4mm for both element and earthing point. I'm struggling to remove the wire from the tag on the switch atm ,dont know if there's a knack but it looks to be 6mm. Distance from the place I'll install the controller to earthing point is approx 30cm. Switch to controller around 20cm.

And colour me surprised, the controller arrived today. Wish everything else I ordered 2/3 weeks ago was here already!

[Windoe]

Hey windoe

Diameter of the hole is 4mm for both element and earthing point. I'm struggling to remove the wire from the tag on the switch atm ,dont know if there's a knack but it looks to be 6mm. Distance from the place I'll install the controller to earthing point is approx 30cm. Switch to controller around 20cm.

And colour me surprised, the controller arrived today. Wish everything else I ordered 2/3 weeks ago was here already!

There probably is a knack, have a very good look at the spade connector, some of them have a very tiny ‘lever’ in the middle which has to be depressed to allow them to be released.

I have your wires ready to send, the brown one will need cutting somewhere in the middle to connect to the controller. I think I have made it long enough, it should be. The earth wire will need a 3mm hole drilling in the metalwork of the controller for a separate earth back to your main earthing point. I’ve put in a nut and bolt to make the connection to the controller. PM me your address and I will post them in the morning.

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Let me know if you need any more help. Take some photos and if you can put up a final post of how to do this for posterity!

[DorsetScott]

Package received Windoe, thank you so much.
I'll have a read through the thread again to work out what I'm attaching where and post any questions

[DorsetScott]

Just an update to let you know there's currently no update. I took the phase angle controller out of the package and one of the wires fell off the control knob.
Having searched high and low for a soldering iron I may no longer have, one of my colleagues who used to be an engineer has offered to re-solder it for me so it's currently with him. I'll update further once I've actually made the mods

[DorsetScott]

Right, controller has been returned after colleague went on holiday, so I'm ready to rock. Possibly a stupid question, but how do I know which side is in and which is out, or does it not matter?

Also, the earth wire, is that from the heat sink, or the controller body itself?

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[Windoe]

It won’t matter which is in or out, the circuit is designed to work either way. Earth the heatsink thru one of the existing holes. I cant tell if the triac (black thing bolted to the heatsink) is isolated or not so try not to connect any metal to the tab on that to avoid shorts.

[DorsetScott]

Cheers bud, looks like I'm just about to mod the brewzilla (or make a really expensive mistake )

[DorsetScott]

It is done. I tested it before I drilled any holes, just heating up a few litres of water, and when throttled all the way down the temp barely rose.
Haven't been able to test it again now everything is connected as its the wedding anniversary and I should probably spend some time with the wife

Mash, thank you so much for the input on the project.
Windoe, thank you for the input, and the over and above of sending me crimped, cut to length wires, you made the whole thing a breeze for me.

I am absolutely overjoyed now, my beer machine will also function as a t500 style boiler with inbuilt control. I am truly indebted

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[Windoe]

Looks fantastic and I am glad you got to save some space and cash

[Mash]

Guide work indeed. Nice seeing the forum work together.

Is there a kit available now Windoe