Blichmann Engineering TOWER of POWER Quick guide

TOWER of POWER
tm
Modular Brewing Control System
Operation, Assembly & Maintenance Manual
Congratulations on your purchase, and thank you for selecting the TOWER of POWER
tm
Modular Brewing
Control system from Blichmann Engineering
tm
. We are confident that it will provide you years of service and
many gallons of outstanding beer. This manual will familiarize you with the assembly, installation
procedures, and use of the TopTier
tm
brew stand and accessories.
**** PLEASE READ THOROUGHLY PRIOR TO USE FOR IMPORTANT SAFETY INFORMATION ****
IMPORTANT !!
Warning: Sections labeled “Warning” can lead to serious injury or death if not followed. Please read
these thoroughly and understand them completely before use. If you do not understand them
or have any questions, contact your retailer or Blichmann Engineering
tm
(www.BlichmannEngineering.com) before use. Do NOT at ANY time operate the product until
you have thoroughly read and understood these instructions!
Caution: Sections labeled “Caution” can lead to equipment damage or unsatisfactory performance of the
equipment. Please read these sections thoroughly. If you have any questions, contact your
retailer or Blichmann Engineering (www.BlichmannEngineering.com) before use.
Important: Sections labeled “Important” are critical to the proper performance and life of the product.
Service & Support: Please thoroughly read this manual and view our online videos before contacting
your retailer with questions. If after reading this manual and viewing the videos you still have questions
please contact your RETAILER for support. Note that the pump is warranted and supported through March
Manufacturing directly, not through your retailer or Blichmann Engineering
tm
.
Advanced features (automatic ramping) are accessible through software only and requires the purchase of an
optional communication cable. Due to the advanced nature we do not provide direct factory support. Please
work through your RETAILER if you have any questions after reading the manuals or viewing the online
tutorial.

2
Overview of Tower and Control Modules:
The TOWER of POWERtm Modular Brewing Control is, by name, modular in nature. The user can purchase a
single or dual control module separately and mount and integrate into their brewing system plumbing. Or if
the user does not have the necessary valving, pumps etc., they can purchase the Tower module that provides
all the needed plumbing and provides a convenient stand for the control module(s). If you already own a
March 809/815 pump you can purchase the Tower without the pump.
Note: the hoses that connect from the Tower to the pots are not included. If you are a TopTiertm owner, an
optional mounting kit is available to mount it permanently to the stand.
Controller Module
Mash and HLT
labels provided
Sample port
Pump
Flow meter
3-way valve
Tower with dual controllers

3
Requirements Of Your System:
IMPORTANT! Read before unpacking or using this product!
For the TOWER of POWERtm control system to function properly, your brewing system must meet
some basic requirements. If your system is unable to meet these requirements please contact your
RETAILER for guidance. We cannot guarantee the performance of the product if these basic
minimums are not met.
Hot liquor tanks perform well on nearly any system that can maintain a moderate flame. Mash Tuns require
a couple basic performance parameters to be met for proper performance.
Important! Do not use or install the TOWER of POWERtm equipment until you verify that your equipment is
capable of the requirements below. If you are using Blichmann Engineering BoilerMakertm mash tun with our
false bottom, and a TopTiertm burner you will not have equipment limitations. However, it is still important
that you verify that your crush will allow adequate wort flow! Most stuck mashes are caused by too fine of a
crush. It is also expected that
Your mashing system must have the capability to continuously recirculate your wort using a pump for the
duration of the mash without sticking. The flow rates in the chart below are minimum values.
Finished Batch Size gal (L) Min Flow GPM (LPM)
5 (19) 0.5 (2.8)
10 (38) 0.75 (3.8)
15 (57) 1.25 (4.75)
20 (76) 1.5 (5.7)
32 (121) 2.25 (8.5)
Important: Grain bed flow rates are highly dependent on crush quality. Move to a coarser crush if you are
not able to flow at the above rates. It is also recommended that you allow a 10 min dough-in prior to turning
on the pump to allow the air to purge from the grain and for the grain to fully absorb the water.
Burner Requirement: Your burner must be capable of operating well at low power settings. If you cannot
maintain a flame at about half power your system stability will suffer. Specifically, you should be able to
reduce your heat to achieve an average heating rate of 1.5 F/min or less. To do this, recirculate your wort at
the above rates or faster (use a stop watch and known volume to measure flow rate). Then apply heat on your
burner at the lowest stable level. If over a 20-30 min period the increase in wort temperature divided by the
time is at or below 1.5 F/min you have met this requirement.
Fuel Supply: The solenoid valve supplied is suitable for up to 25 PSI propane regulators and residential
natural gas. Fuel flow rate through this valve is adequate to power Blichmann Engineering TopTiertm burners
on both fuels, however, other burners may need a larger solenoid valve (not included). Do NOT install a
solenoid valve that draws over 2A at 120V including inrush or you may damage the ignition start relay which
is NOT a warrantable failure.

4
What to Expect From the TOWER of POWERtm:
The TOWER of POWER
tm
control system is a very precise instrument that has been developed to provide
exceptional control over a very broad range of batch sizes, flow rates, and input heat values without the need
to re-tune as each individual condition changes. However, it DOES require a reasonable set of parameters to
be met to achieve these results. When operated within the parameters listed in the previous section, your
system should be able to maintain your mash and HLT temperature to within 0.5 F (0.25C) of your set point.
Please note that in the case of mash control, we are controlling the temperature of the wort into the top of the
mash bed, not the temperature of the mash itself. The large mass of the mash will dampen out the
fluctuations of the recirculation temperature and provide incredible stability. If you are not able to achieve
the conditions above with your system that is OK, but it must be expected that stability and control will be
compromised.
Note: A slight overshoot of the recirculation temperature is normal and will NOT harm your enzymes.
Enzymes are denatured over a period of time, not instantaneously. We have tuned this system to offer the
best match of ramp speed and stability.
The chart below shows a typical response curve from an actual brew session. Note that the mash temp
will lag behind the recirculation temp by a few degrees as you ramp, but will settle in quickly as you reach the
set point. Also note that the recirculation temperature (displayed on your controller) will overshoot by a few
degrees. This is NORMAL. Also note that the actual mash temp overshoots very little and settles in quickly to
set point, drifting slightly within the +/- 0.5F tolerance band. While we could eliminate the recirculation temp
overshoot it would severely slow down your ramp rate.
110
115
120
125
130
135
140
145
150
155
160
0.0 3.3 6.7 10.0 13.3 16.7 20.0 23.3 26.7 30.0 33.3 36.7 40.0 43.3
MashBed
Recirc
StabilityBand +/‐0.5F
Time(min)

5
It is expected that control stability will change slightly as you change your batch size, flow rate, or heat input.
In general:
Faster flow rates reduce oscillation and overshoot
Lower heat input reduces oscillation and overshoot, but increases heating time
Higher heat rates increase overshoot and oscillation – shoot for 1.5F/min
Larger batch sizes generally exhibit less oscillation and overshoot
That said, doing small batches on a system intended for large batch sizes will usually be difficult to control. If
this is unavoidable, use the largest water to grist ratio possible, and use the lowest heat setting on your
burner, and be ready to accept control outside the +/- 0.5F band.
It is also expected that you will need to do a few experimental batches to dial in your specific system and
become familiar with the operation and control of your system. You will quickly learn the flame height that
results in a 1.5 F/min average ramp rate in your mash bed. You will also discover what flow rates you can
achieve without sticking your mash. Note that rice hulls can aid in increasing recirculation rates.
Assembly:
The TOWER of POWERtm Modular Brewing Control ships partially assembled to allow it to be shipped more
economically via ground carriers, and to protect it from shipping damage.
Parts List:
The following items are shipped with the product. Please check to verify that you received all the parts.
Contact your RETAILER if any parts are missing. Blichmann part number is in parentheses.
Digital Control Module
1 Control Module
1 Gas solenoid valve (TOP-016-00)
1 Solenoid power cord (TOP-017-00)
1 Male ¼ NPT X 3/8” Male Flare brass adapter (BE-500008)
1 Male ¼ NPT X 3/8” Female Flare brass adapter (BE-500009)
1 Ignition electrode (TOP-020-00)
1 Screw - #8-32 with nut (installed on electrode)
1 Ignition wire (TOP-019-00)
1 Temperature sensor (TOP-001-05)
1 O-ring (sensor) (BE-00083) – installed on sensor
1 O-ring retainer (washer) (BE-00084) – installed on sensor
1 Nut – ½-20 UNF SS (BE-000026) – installed on sensor
1 Decal – HLT (BE-00062)
1 Decal – MASH (BE-00063)
1 1/2NPT X ½-20 UNF stainless bushing (TOP-007-01)
4 Rubber feet (installed) BE-500013-00
6 Reusable plastic Wire twist ties - small McMaster 70535K52
6 Reusable plastic Wire twist ties - large McMaster 70535K53

6
Optional Tower Stand
1 – Tower assembly (enclosure, plumbing manifold, valves, flow meter)
1 – Grommet – pump wire, installed McMaster 9600K33
1 – Grommet – flow switch wire, installed McMaster 9600K15
2 – Legs, LH (TOP-003-03-LEGSET, one RH and one LH per set)
2 – Legs, RH
4 – Leveling feet BE5000012-00
2 – Leg stiffening plates (3” X 2-1/4” plate with 2 holes)
1 – Pump mounting bracket (replacement order: aTopTier_Pump_Bkt Includes plate, drip shield, hardware)
1 – Pump drip shield
8 – ¼-20 X3/4” L hex bolts, nuts and washers
2 – 5/16 X 3/4” hex bolts
4 - #10-24 X 3/8” L pan head screws
1 – Hose assembly (silicone hose and 2 QuickConnector aQC_12_S)
1 – 3/8” 90 deg QuickConnector fitting (aQC_38_EL)
1 – 1/2” 90 deg QuickConnector fitting (aQC_12_EL)
1 – Pump – March 815 (if ordered with Tower)
Optional Dual Controller Mounting Plate (reqd for mounting two controllers onto the tower)
1 - Plate (model aCon_plate_TOP)
4 - #10-24 X 3/8” long pan head screws
Assembling the Tower
Prepare a work area with a soft pad to protect the tower enclosure from getting scratched during assembly.
WARNING! –Make sure that the tower is NOT plugged in until you have fully completed the assembly!
Electric shock is possible while wiring the pump!
Begin by unpacking and spreading out the parts. Install the legs to the bottom of the tower using the ¼-20
bolts, nuts and washers as shown in Fig 1a and 1b. Please note that there are two LH legs, and two RH legs.
One of each leg is installed on each side of the enclosure. Make sure to install the rectangular leg stiffening
plate on the INSIDE of the enclosure. Next thread a leveling foot into the end of each leg as shown in Fig 3.
Fig 1bFig 1a

7
Install the pump bracket using the 5/16” bolts as shown in Fig. 4. Then using the ¼-20 X ½” bolts, nuts and
washers, install the drip shield and pump as shown in Fig. 5.
Important: Referencing Fig. 7, it may be necessary to re-orient the pump head to so that the inlet faces down
and the outlet faces up (flow arrow faces up). Simply remove the 4 mounting screws, rotate the head, and
reinstall the pump head. Consult the March manual if needed.
To wire the pump, insert the pump lead wire through the rubber grommet in the back of the enclosure and
feed it out the bottom of the enclosure (Fig. 6).
Fig 3 Fig 4
Fig 5
Fig 6
Drip Shield
Fig 7 Fig 8
Place pump wire
through grommet

8
TIP! It may be helpful to use needle nose pliers or use the end of a coat hanger to pull the wire out if you
cannot reach it with your fingers. Spray the pump wire with a little Windex so that is slides easily through the
grommet.
Remove the wire nuts from the green, black and white wires that are labeled “pump power” and connect them
to the matching color leads on the pump lead using the wire nuts as shown in Fig 8. Then push the
remaining wire up into the bottom of the tower.
Install the pump hose between the pump and the bottom of the flow meter as shown in Fig. 9.
Install the ½” 90 degree QuickConnector onto the bottom of the pump. Fig. 10
Install the 3/8” 90 degree QuickConnector onto the sampling port valve. Fig. 11
Assembly of the Tower is now complete!
Fig 9 Fig 10
Fig 11

9
Installing Single Control Module On The Tower
Using 4 #10 X 3/8” screws install the control module as shown in Fig 12
installing the screws through the through the mating holes in the angle
brackets on the top of the Tower.
TIP! Using a long Phillips screwdriver or a ratcheting or 90 deg screwdriver
makes accessing the front two screws easier.
Plug the controller into the GFCI receptacle on the back of the tower.
Installing Dual Control Module Onto The Tower
Using 4 #10 X 3/8” screws install each control module onto the adapter
plate as shown in Fig 13 using the outer most 4 screw holes. Then use an
additional 4 screws to mount the assembly onto the tower as shown in Fig
12 using the inner 4 screw holes and placing the screws through the
mating holes in the angle brackets on the top of the Tower.
Plug each controller into the GFCI receptacle on the back of the tower.
WARNING! –Make sure that the tower is NOT plugged in until you have fully connected the ignition and
ground wires or electric shock could occur from the ignition wire!
NOTE: An optional mounting kit is available for installing the TOWER of POWERtm onto the TopTiertm
modular brewing stand as shown in Fig 14.
That completes the assembly of the tower and control modules!
Screws
Long
Screw
Drive
r
Fig 12
Fig 13
Fig 14

10
Connecting the Controllers to Your System:
WARNING! –Make sure that the tower is NOT plugged in until you have fully connected the ignition and
ground wires or electric shock could occur from the ignition wire!
CAUTION! –Heat damages electronics. Locate the control units, solenoid valves, tower and wiring as far
from heat sources (burners) as possible. You should never feel your control modules getting warm to the
touch. If they do, they are too close to heat sources! The maximum surface temperature should never exceed
125F (52C). While the solenoid valves will get somewhat warm during operation they should never be
uncomfortably hot to the touch. Locate them as far from the heat source as possible.
Caution! Always route wires away from heat sources and hot surfaces to prevent burning and short circuits.
Important Warranty Information! Electronics damaged from excessive heat are not covered under
warranty! We have installed a non-reversible heat detector inside the control enclosure to detect excessive
heat. There are no user-serviceable components inside of the enclosure. Tamper labels that have been
removed or damaged will void your warranty.
Never Do These Things!
NEVER LEAVE THIS EQUIPMENT UNATTENDED
NEVER ALLOW CHILDREN NEAR THIS EQUIPMENT
NEVER Expose to heat or moisture. If it is warm to the touch it is too close to heat source.
NEVER HEAT COOKING OIL WITH THIS EQUIPMENT
NEVER operate on soft, combustible or uneven surfaces like dirt, gravel, wood or asphalt
NEVER operate indoors, in a garage, under an overhang, porch, deck, carport or similar structure
NEVER use near and combustible chemicals, gasoline or other flammable vapors or liquids
NEVER Bypass the GFCI circuit protection
NEVER Exceed 125F (52C) surface temperature
NEVER use the gas solenoid valve as a normal shutoff
Always Do These Things!
ALWAYS OPERATE OUTSIDE ONLY, AT LEAST 30FT FROM OTHER STRUCTURES
ALWAYS USE ONLY ON LEVEL AND STABLE CONCRETE, BRICK OR SIMILAR HARD NON-FLAMMABLE
SURFACES.
ALWAYS Connect to a GFCI circuit
ALWAYS Check that all fasteners are properly tightened prior to each use
ALWAYS Ensure that the base of the tower is resting on a hard surface
ALWAYS Use the propane tank shutoff valve or a separate valve when not in use
ALWAYS Use genuine Blichmann Engineering replacement parts
Install the gas solenoid valve:
The gas solenoid valve is turned on and off by the controller as needed to maintain the temperature of the
tank. Locate it as close to the burner as possible but DO NOT locate it in an area that will expose it to
excessive heat. If you can’t comfortably rest your hand on the valve during operation it is too hot! We have
included a male and a female flare X ¼” NPT fitting to aid you in connecting the valve to your gas supply.