Phase Angle Power Controller With Integrate Flow SW Shutoff

[Cardinalbags]

I've posted in the past regarding use of flow switches to kill boiler power in the event of cooling water loss. I wanted to post my wiring diagram for this.

First I must give a tip of the hat and a thank you out to Mulekicker. It was from his posts on phase angle controllers that I took as my original design starting point.

Anyhow, here it is:

Here is a downloadable version:

Still Heat Controller Wiring Diagram-Model.pdf

(51.66 KiB) Downloaded 726 times

And finally here is a picture of the controller enclosure in operation.

The keen observers will notice the amp meter is not reading properly. It went Wango Tango on the first run. Although the meter face reads 0-50, it is not uncommon for manufacturers to make only 0-5 amp models and then it is required to use a coil transformer to scale up to the maximum faceplate value, in my case I would need a 5-50 CT. When I first installed it, it was inline and receiving the full amperage, hence the Ted Nugent reference.

Cardinalbags

[heartcut]

Nice and simple.

[RonH3154]

Nice job. That looks like a heavy duty flowswitch and using a contactor to remove the power independent of the SSR is the way to go.

[patriotal]

nice set up! I also noticed the Tekmar thermostat on the wall. Real nice controls! Radiant heated home?

[Cardinalbags]

You a Tekmar rep?? haha....

Yeah, in floor radiant hot water system using a 100 amp boiler.... now that I am distilling, I can only imagine how big a rig I could make witch a 100 amp heater.....

I was so concerned about amp draw of 100 amps on a 200 amp entrance that. i decided to double the service and go with a 400 amp dual panel arrangement.

If they ever legalize home distilling in my neck of the woods, the i am opening a still fabrication shop in my garage... I should be able to supply a couple tig welders with that...

[Groddi]

Nicely done, that's one killer power cable that you got running through that thing, how many amp's the controller using?

[Cardinalbags]

Its just 4500w on 220v for now so 18 amps, however everything is sized for a maximum 30 amp on the wiring. My current bottleneck limitation is the relays. They are 25 amp max rating.

I wanted to get a 5500w element, but they are just not available where I live. i would have to order one online, but i much rather buy local if I can.

[Groddi]

Its just 4500w on 220v for now so 18 amps, however everything is sized for a maximum 30 amp on the wiring. My current bottleneck limitation is the relays. They are 25 amp max rating.

I wanted to get a 5500w element, but they are just not available where I live. i would have to order one online, but i much rather buy local if I can.

Ok, that's a lot of power... You should be able to get one custom made from an electronic engineering shop with your exact size and length request. I know of one that did the same, it was 4500w element was circular al in al maybe a 1.5 meters of tubing, it was used in a keg.

[Cardinalbags]

The flow switch made a save today..... my circulation pump was plugged into a outside GFI plug and it ended up getting tripped. Everything shutdown per design and no vapours escaped the still.