Description
The semi-automatic control system with complete control via touch LCD for the brewhouses Breworx Classic, Lite-ME, Tritank 1200L-5000L (upgradeable to the fully automatic system)
The BHSA-2 is a semi-automatic control system for brewhouse with the computer support. All valves are controlleable via the touch LCD panel, several operations are controlled automatically – according to a specified program.
This control system cooperates with our brewhouses Breworx Classic, Breworx Lite-ME and Breworx Tritank with nominal volumes from 1200 to 5000 liters.
The semi-automation of the brewing machine is supplied as part of the brewhouse, but is not included in its basic price.
Manual mode / Semi-automatic mode
The semi-automation of the brewing machine may operate in two modes :
- Manual control mode – all functions a and steps are controlled manually on the touch LCD panel
- Semi-automatic control mode – all functions a and steps are controlled on the touch LCD panel but several steps are operated automatically according to choosed program and manually entered parameters.
The user right level can be set on the touch screen. This eliminates possible errors by unqualified operators.
Part of the system is the measurement of the conductivity of the solutions (pH value) using a built-in conductometer and saving the values in a log, so that it is possible to retrospectively check whether the quality of the incoming water corresponded to the required parameters. It is also possible to check the quality of the sanitizing solutions used.
In semi-automatic mode, the operator can set the exact amount of water and its temperature to pour into the mashing tank, and up to 6 different heating steps to the desired temperature (°C), simply and quickly on the touch LCD. The brewing set’s PLC system also controls the brewhouse pump, so the operator can easily set how many liters of liquid and at what speed they want to pump from one container to another. For example, when the operator is about to pump part of the mash from the mashing tank into the filtering tank during the wort mashing process.
The pump of the wort brewing machine is equipped with an induction flow meter connected to the PLC of the brewhouse. Proportional valves are installed at the inlet of water and steam to the wort brewing machine, thanks to which it is possible to regulate the heating temperature so precisely that there are no temperature fluctuations above the set temperature, and the heating speed can be selected by the operator in the parameter settings. All functions are controlled from the touch display. All remaining valves and dampers are pneumatic and manually operated by the brewery staff on the touch LCD panel.
Operations with the automatic control
In semi-automatic mode, the following automatic steps are possible (they are programmed, but they can also be performed manually):
1: Automatic filling the mashining tank with water : Filling the specified amount of water with the exact water temperature using a mixing battery that is controlled by a PID controller. The automatic controls the proportional valves of hot and cold water.
2: Automatic mashing : Automatic temperature steps and pauses when heating the mash in the mashing container. The mash in the mash tank is heated to the desired temperature and remains at this temperature for the programmed time. Then the machine moves to the next step, when the mash in the mash tank is heated to the required temperature and remains at this temperature for the programmed time. In this way, it is possible to step up to 5 steps for different temperatures and pauses.
3: Automatic wort filtering (the malt grist separation process) : It is possible to regulate the speed of wort filtering, including the dosing of spraying water at a set temperature, according to the set parameters, including the possibility of automatically lowering the height of the knife stirrer and cutting the upper part of the malt sediment when filtering the wort through the malt grist sediment. At the same time, the speed and height of the knife stirrer can be adjusted. The system is developed on the principle of PID controllers, where the control of the wort flow rate controls the speed of the wort feeding pump, and any vacuum is controlled by a vacuum sensor, which limits the increase in pump speed during wort filtration and at the same time helps by cutting the upper part of the malt grist sediment for higher extract yields.
4: Automatic swirling of the wort (the hops separation process): The system senses the outlet temperature of the wort behind the plate cooler and uses a PID controller to regulate the pump speed so that the set outlet temperature of the wort behind the cooler is maintained. At the same time, the outlet water temperature is sensed and the flow is regulated by a proportional valve so that a constant outlet water temperature is maintained and the amount of cooling water is saved at the same time.
5: Automatic condensation of steam vapors: The system is developed in such a way that, in any container, when a temperature higher than 95 °C is reached, the exhaust steam fan starts automatically. The fan extracts vapors and at the same time regulates the flow of cooling water with the help of a proportional valve so that the output water temperature is constant at 80 °C and at the same time the amount of cooling water is saved.
Control of operations and processes when the semi-automatic control system is choosed :
| Automatic processes | Manual processes |
| Filling the mashing tank and filtering tank with water (volume, temperature) | Grinding the malt |
| Heating cycles | Malt dosing |
| Pauses for saccharization | The operator has to make a chemical tests of sacharization |
| Mashing | The operator must confirm that the pumping was succesfully done |
| Filtering | The operator must confirm that the filtration was succesfully done |
| Wort boiling (time, temperature) | Hops dosing during the wort boiling process |
| Swirling the wort | The operator must confirm that the wort swirling was succesfully done |
| Wort cooling and aeration | The operator must confirm that the wort cooling was succesfully done |
| Throwing out of malt residues from the filtering tank | |
| Rinsing and sanitation of the brewhouse |
The semi-automatic control system for the Breworx Classic wort brewing machines :
The semi-automatic control system for the Breworx Tritank wort brewing machines :
Hardware
Electric switchboard
Fully equipped electrical switchboard 800×1000, AISI 304 stainless steel, main switch, control elements, safety elements.
Siemens S1200 control system, Weintek 10″ touch panel
1x frequency converter Siemens 2.2 kW
2x frequency converter Siemens 1.5kW
1x 300W contactor
Operator safety is solved by an emergency stop
Declaration of Conformity, Electrical Test and Measurement Document
Wort brewing machine
1x servo drive 24VDC
5x temperature measurement
2x pneumatical valve
5x proportional valve 24VDC – 0-10V
1x induction flow meter
1x water flow meter 1l/pulse
1x vacuum sensor 0/1
Dimensions
width 271 mm, height 212 mm, depth 50 mm
weight 1,4 kg
Operation limits
Working temperature: 0 – 45°C
Storage temperature: -20 – 60°C
Humidity: 10 – 90% st 40°C noncondensing
Vibration: 10 – 25 Hz, max. Overload 2 G
Standard PLC : Mitsubishi FX3U 
FX3U is the most powerful processor from the FX family. This series combines the advantages of a compact with the flexibility of a modular control system, and is also one of the fastest systems with a cycle time of only 0.065 microseconds / logical instructions.
Optional PLC : Siemens Simatic S7-1500
SIMATIC S7-1500 – maximum productivity and efficiency. We offer this PLC system as an optional solution for our demanding customers.
Advanced SIMATIC S7-1500 Advanced systems stand out with top performance. They are designed to control medium-sized machines and demanding applications that require maximum performance, reliable communication, flexibility and technological functions.
Armatures
Pnematical valves for distribution system of the boiling equipment
Valve ZA 24-EE55 / ZA 26-EE63 / ZA 23-EE55
Thread size ¾“ (DN20)
Sealing PTFE
Min. temperature – 30°C
Max. temperature 180°C
Min and Max pressure 0 – 16 bar
Min and Max operating pressure 6 – 8 bar
Weight: 2 ,355kg
Valve is made form stainless steel grade 1.4408
Pneumatical valves for a spinal system of the boiling equipment
The valves are equipped with pneumatical actuators.
The indisputable advantage of AWH valves are a bearing housing, which minize the wear of axles, so the valves are very durable.
The shipment contains also all the approval and test certificates of used material such as EHEDG, ATEX, APZ 3.1 according to DIN EN 10204, FDA and regulation ES 1935/2004
FESTO valve terminal VTUG plug-in
Flow-rate 120 – 630 l/min
Width 10, 14 mm
Connections M5, M7, G 1/8
Push-in connections 3, 4, 6 ,8 mm
Multi-pole connections, industrial networks, IO-Link, I-Port
Power 24 V DC
Pressure : 0,9 … 10 bar
Degree of protection IP40 / IP67
Metal connector plate
Variants:
– valves on connector plate with output on the valve body
– valves on connector plate
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