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tmcmaster007
Joined: 11 Jan 2011 Posts: 48 Location: South Lyon, MI
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Link Posted: Tue Nov 20, 2018 4:18 pm Post subject: Smoking Receptacle or wiring |
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I've been using the brewery I built using Kal's directions since 2011. So far, I've had almost no issues. Last Saturday I was brewing a batch when I smelled something like burning plastic. I immediately turned off the panel. When I opened up the panel door smoke billowed out. I was able to switch the boil element plug to the HLT receptacle and reprogram the PID to finish the brew. The HLT element, receptacle, and all parts associated with it are in perfect working condition. It appears as the receptacle (locking flange) for the boil element, or the wiring melted (or both). If I replace all wiring leading to the receptacle and receptacle itself will this likely solve the issue? Or is there a bigger issue that is just manifesting itself at that location? I LOVE this panel and have brewed hundreds of gallons on it. TIA.
_________________ Crabby T
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kal Forum Administrator
Joined: 12 Dec 2010 Posts: 11116 Location: Ottawa, Canada
Drinking: Pub Ale, Electric Creamsicle, Mild, Pliny the Younger, Belgian Dark Strong, Weizen, Russian Imperial Stout, Black Butte Porter
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Link Posted: Tue Nov 20, 2018 4:41 pm Post subject: |
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Hi!
Got any pictures?
There was likely a loose wire somewhere, something that wasn't fastened properly that became looser over time with heat expansion/contraction. Anything melted or charred should be replaced.
Receptacles are here: https://shop.theelectricbrewery.com/collections/plugs-connectors-receptacles
If this is a heating element receptacle, you want: https://shop.theelectricbrewery.com/collections/plugs-connectors-receptacles/products/nema-l6-30-250vac-30a-twist-lock-electrical-receptacle
Wiring is here: https://shop.theelectricbrewery.com/collections/wiring
For the heating element receptacles you want the 10 gauge T90/THWN/THHN wire.
Why does a loose wire cause this? Heat is created when current flows through an area that is too small to handle the amount of current. This can happen:
(a) with a loose connection where only a few strands are making contact because the wire is not properly tightened/fastened, and/or
(b) a wire that is too small to handle the current is used, and/or
(c) when a properly sized wire is used but some of the copper strands were cut/trimmed to get it to fit (this should never be done), or
(d) if an electrical socket or blade is dirty or charred or if the plug is not pushed and locked in properly with the receptacle.
All of these cases effectively reduce the contact area meaning that more current flows through a smaller area which in turns creates more heat which can melt the insulation on wires and damage nearby components.
It could also be that you’re actually pulling too much current by using oversized heating elements. This would only be possible if an incorrectly sized breaker was installed in the electrical panel (larger than 30 or 50 amps, depending on your control panel size) as otherwise the breaker would pop if more than 30A or 50A was pulled. A 30A or 50A breaker should be used (sized for your control panel) per our control panel instructions.
I would look first to where all the heat is created. If a wire is melting, it's likely the closest spot to the bad connection.
I may also be a bad part, but that's rarer.
Good luck!
Kal
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My basement/bar/brewery build 2.0
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tmcmaster007
Joined: 11 Jan 2011 Posts: 48 Location: South Lyon, MI
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Link Posted: Tue Nov 20, 2018 5:32 pm Post subject: |
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I'll post some pics later if I can. The wire run to the Boil vessel is the longest. Suppose a wire came loose somehow over the last nearly 8 years. Thanks for the help.
_________________ Crabby T
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kal Forum Administrator
Joined: 12 Dec 2010 Posts: 11116 Location: Ottawa, Canada
Drinking: Pub Ale, Electric Creamsicle, Mild, Pliny the Younger, Belgian Dark Strong, Weizen, Russian Imperial Stout, Black Butte Porter
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tmcmaster007
Joined: 11 Jan 2011 Posts: 48 Location: South Lyon, MI
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Link Posted: Tue Nov 20, 2018 5:50 pm Post subject: |
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So something like this could take 7 years to show up? I never move the boil kettle. I guess I could have moved it a bit while cleaning, but I generally clean in place. I'll be sure to follow your guidelines about tight connections and intact wires when I repair. Thanks again.
_________________ Crabby T
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kal Forum Administrator
Joined: 12 Dec 2010 Posts: 11116 Location: Ottawa, Canada
Drinking: Pub Ale, Electric Creamsicle, Mild, Pliny the Younger, Belgian Dark Strong, Weizen, Russian Imperial Stout, Black Butte Porter
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tmcmaster007
Joined: 11 Jan 2011 Posts: 48 Location: South Lyon, MI
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Link Posted: Tue Nov 20, 2018 5:59 pm Post subject: |
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Got it. Just trying to puzzle out what I may have done wrong as to not repeat a mistake. I'll be sure to attend to precision on the repair. Thanks again.
_________________ Crabby T
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kal Forum Administrator
Joined: 12 Dec 2010 Posts: 11116 Location: Ottawa, Canada
Drinking: Pub Ale, Electric Creamsicle, Mild, Pliny the Younger, Belgian Dark Strong, Weizen, Russian Imperial Stout, Black Butte Porter
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tmcmaster007
Joined: 11 Jan 2011 Posts: 48 Location: South Lyon, MI
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Link Posted: Wed Nov 21, 2018 12:25 am Post subject: |
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Snapped a pic. Red wire was the hot one. Gonna replace flange and wiring.
_________________ Crabby T
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kal Forum Administrator
Joined: 12 Dec 2010 Posts: 11116 Location: Ottawa, Canada
Drinking: Pub Ale, Electric Creamsicle, Mild, Pliny the Younger, Belgian Dark Strong, Weizen, Russian Imperial Stout, Black Butte Porter
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