Blichmann BoilerMaker Surface Installation instructions

BoilerMaker Surface™ V1 © Blichmann Engineering, LLC 2023
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts 1
BoilerMaker Surface™
Assembly, Operation, & Maintenance
Congratulations on your purchase, and thank you for selecting the BoilerMaker Surface™
brew kettle from Blichmann Engineering. We are condent that it, and our suite of
accessories, will provide you years of service.
Sections labeled “Warning” can lead to serious injury or death if not followed. Please thoroughly read these sections
and understand them completely before use. If you any questions, contact your
retailer or Blichmann Engineering (www.BlichmannEngineering.com) before use.
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.
Sections labeled “Important” should specically be followed to ensure satisfactory results
WARNING:
CAUTION:
IMPORTANT:
IMPORTANT INFORMATION
PLEASE READ THIS MANUAL THOROUGHLY PRIOR TO USE
FOR IMPORTANT SAFETY INFORMATION!
What’s In the Box?
Thermometer (Optional)
Power Cable
Level Gauge (Optional)
Valve (Optional)
Kettle
Lid

BoilerMaker Surface™ V1 © Blichmann Engineering, LLC 2023
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TABLE OF CONTENTS
First Time Cleaning..........................................................................................................
Dimensions And Weight..................................................................................................
Power And Connections..................................................................................................
Boil Kettle........................................................................................................................
-Assembly
-Operation
Hot Liquor Tank..............................................................................................................
-Assembly
-Operation
Mash Tun.........................................................................................................................
-Assembly
-Operation
Valve Assembly................................................................................................................
-NPT Linear Flow Valve
-Cleaning The Linear Flow Valve
-Installation Of The Dip Tube
-Optional Rotating Dip Tube
-Tri-Clamp Valve Assembly
Use Of The Level Gauge....................................................................................................
Maintenance....................................................................................................................
Dry-Run Thermal Breaker Reset Instructions..................................................................
NPT To Tri-Clamp Adapter For Accessories......................................................................
Kettle Accessories............................................................................................................
3
4
4
6
7
8
9
13
14
14
14
15

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After you have received your new equipment and removed it from the box it is very important that you properly clean the equipment thoroughly
with a general detergent such as Dawn dish soap. This will remove any debris and oils that may have been left behind from shipping and the
manufacturing processes.
Cleaning and sanitizing all your home brew equipment before every use is an important aspect of brewing. Using good cleaners and sanitizers
can make the difference between having a great beer and a spoiled one. Good preparation for your upcoming brew day is key. Make a checklist
of the equipment you will be using and note whether it needs to be sanitized or only cleaned. In prepping for your brew day, always make sure
your equipment is ready to go when you are.
IMPORTANT INFORMATION
Caution: DO NOT SUBMERSE KETTLE IN LIQUID
FIRST TIME CLEANING
ALWAYS START WITH A CLEANING AGENT
Before you do any sanitizing, you need to thoroughly clean your equipment. Sanitizers do not work on equipment with soils on the surface, and
bacteria and wild yeasts will remain. It is always best to immediately wash your equipment after use while the soils are soft and easier to
remove.
There are a number of good cleaning agents on the market. One Step™, Straight-A™, and Powdered Brewery Wash™ (PBW) are three of the
most popular. These products may be used on bottles, fermenters, and other equipment. Cleansers should be rinsed after use. Don’t soak your
equipment in a cleansing solutions for longer than the time recommended on the packaging, or you can damage your equipment.
As with ALL chemicals. ALWAYS thoroughly read the instructions, material compatibility, and safety warnings. Never use more than the
recommended concentrations or soaking times or you may damage your equipment.
Cleaning Stainless Steel and Aluminum
For general cleaning of stainless steel and aluminum, mild unscented detergents, PBW, or percarbonate-based cleaners are
excellent choices. Bleach should not be used to clean or sanitize stainless steel or aluminum as it will corrode and pit them.
SANITIZING
Only when your equipment is clean, can you sanitize it.
All items that contact the wort or beer below 140F need to be sanitized. This includes the fermenter (including the lid), airlock,
rubber stopper, yeast rehydration or starter container, thermometer, funnel, spoon, and siphon etc. On bottling day, bottles,
caps, hoses etc. also need to be sanitized. Chemical sanitizers can be prepared in a bucket and used throughout the brew day.
Chemical sanitizers are by far the most common. Most can be used on metal, plastics and glass. Most do not require rinsing; a
good feature since your tap water, particularly well water, may contain small amounts of bacteria. Again, always follow the
manufacturer’s recommendations for concentration, contact time, and the need to rinse before use.
Five Star Chemicals™ StarSan™, and Iodophor are the most popular sanitizers on the market. Always use according to the
manufacturer’s directions.
If you have a particularly tough stain, liked burned malt extract, stains, or other buildup, Barkeepers Friend (oxaylic acid) works
very well to remove them from metallic surfaces. This product is available at your local grocery store.
AFTER USE CLEANING
For keeping your equipment clean and looking new, we strongly recommend cleaning immediately after brewing as soils and
residue will be much easier to remove before it dries. Never toss components in a bucket of cleaning agents “to clean tomorrow”
as these chemicals may damage the product if you exceed the recommended contact time.
Once you’ve thoroughly cleaned your stainless products, wipe them dry with a towel and let them air dry thoroughly. A clean
surface will instantly passivate once it is dry, leaving a durable corrosion resistant surface.
John Palmer also has a more in depth discussion about removing rust and how to passivate stainless steel at this link -
https://bit.ly/2VrZ1u8.

BoilerMaker Surface™ V1 © Blichmann Engineering, LLC 2023
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DIMENSIONS AND WEIGHTS
POWER AND CONNECTIONS
BoilerMaker
Surface Kettle
Size
Power Amp Receptacle
(NEMA)
Voltage GFCI Breaker Size
10 Gallon 3500 14.6 L6-30 240 30
20 Gallon 5500 23 L6-30 240 30
BoilerMaker™ Brew Kettle Models (gal.) 10 20
Recommended Boil Capacity (nished batch size) 5 10
HLT Capacity (approximate) 8 17
1.00 qt/lb (Mash Capacity of grain at 75% full) 24 49
1.25 qt/lb (Mash Capacity of grain at 75% full) 20 41
1.50 qt/lb (Mash Capacity of grain at 75% full) 17 35
1.75 qt/lb (Mash Capacity of grain at 75% full) 15 30
2.00 qt/lb (Mash Capacity of grain at 75% full) 13 27
Approximate lauter rate (gpm) 0.19 0.33
Min Recirculation rate (gpm) for RIMS or HERMS 0.75 1.25
Kettle dead space (gal.) 0.13 0.22
Volume to thermometer stem (gal.) 4 8.25
Weight 18.1 lbs 28.8 lbs
Height 22” 26.5”
External Diameter 14.13 17.75
Lip Diameter 14.38 18.38
Warning: The Surface™ electric kettle is only to be used in conjunction with a Ground Fault Circuit Interrupter
(GFCI) protected power source. If you are uncertain about the status of your power source contact a licensed and
qualified electrician familiar with National Electric Code standards before proceeding. Operating the BoilerMaker
Surface™ heater in any fashion other than described in this manual can result in personal property damage, injury,
electrocution or death.
Warning: NEVER plug the Surface™ electric immersion heater directly into a power source. ALWAYS use a power
control device capable of de-energizing the heater coil.
Warning: NEVER plug in or unplug the heater cord when energized. Doing so will result in arc damage to electrical
connections.
Caution: Before connecting and energizing the Surface Kettle, verify that it has at least 1in of water or wort covering
the bottom of the kettle.
Warning: Never energize the Surface Kettle without the bottom fully submerged. “Dry firing”the Surface™ will cause
the heating element to reach excessive temperatures which can create a dangerous situation which can result in
product damage or personal injury.

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*** Safety should be the highest priority of any brewer. Use common sense! ***
Do not IN ANY SITUATION lift or move any kettle when full with water. A kettle full of hot water may
easily be spilled causing burns. Use a pump or siphon/gravity drain to move liquids from one kettle to
another! Pots of this size are extremely heavy when full and lifting can cause back injury and severe
burns. The handles are provided solely for moving the EMPTY kettle. Do not risk injury to yourself or
others to save a few minutes of inconvenience.
ALWAYS brew on a stable surface to prevent accidental tipping.
NEVER brew where children are, or may be present, and never leave your brew kettle unattended.
WARNING:
CAUTION:
DOS AND DON’TS
NEVER:
• NEVER leave this equipment unattended
• NEVER allow children near this equipment
• NEVER heat cooking oil with this equipment
• NEVER operate on soft, uneven surfaces like dirt, gravel, or asphalt
• NEVER use near or with combustible chemicals, gasoline or other flammable vapors or liquids
• NEVER bypass the GFCI circuit protection
• NEVER operate any equipment with frayed or damaged power cables
• NEVER expose electrical connections to moisture
• NEVER connect heater cable assembly directly to power source
• NEVER modify or alter the supplied electrical cables or connectors
• NEVER operate kettle with higher than rated voltage
• NEVER unplug kettle when energized
• NEVER energize the kettle without a minimum of one inch of liquid in the bottom.
ALWAYS:
• ALWAYS use kettle with rated voltage
• ALWAYS unplug kettle when de-energized
• ALWAYS use on level and stable hard surfaces
• ALWAYS connect to a GFCI circuit
• ALWAYS check power cables and connectors for signs of damage or wear prior to each use
• ALWAYS use approved control device between heater and GFCI power source
• ALWAYS use genuine Blichmann Engineering replacement parts
• ALWAYS unplug before moving
• ALWAYS allow the brew kettle to fully cool before handling
• ALWAYS wear appropriate personal protective equipment, such as gloves, clothing and footwear to prevent
burns and scalds

BoilerMaker Surface™ V1 © Blichmann Engineering, LLC 2023
For replacement parts, visit: blichmannengineering.com/genuine-replacement-parts 6
ASSEMBLY
Connect the power cable to the receptacle of the Surface™ and to a power or temperature controller, such as the
BrewCommander™(sold separately).
Install the optional Brewmometer™, per its product specific assembly manual, to observe temperature. Alternatively,
install your controller’s optional temperature probe into the kettle to maintain temperature.
Install optional accessories as needed, referring to the later section of this manual for assembling valves, and any
manual specific to the optional accessories for their assembly.
OPERATION
Whirlpool Kit (optional) - Recirculate through the whirlpool arm, at the end of the boil, to collect hop matter
and other solids in the center of the kettle as well as decrease chilling time with an immersion chiller. This kettle is
compatible with immersion style heat exchangers as well as external heat exchangers like the Therminator™.
If using a temperature probe, be sure that it is always submerged in liquid during use. Read the temperature on the
displace screen of the controller or read from an optional analog thermometer directly installed on the kettle. The Boil
Kettle is best operated using power control, adjust your power up or down to achieve a rolling boil that is not foaming
over.
Rotating Dip Tube (optional) - Use of a rotating dip tube allows you to pull clear wort from above hops and trub
that have settled on the bottom of the kettle. While transferring out of the kettle at the end of the boil, start with the
dip tube oriented horizontally and rotate downward until desired liquid level is achieved.
Tips: To prevent boil overs, add fermcap or other foam suppressant at the start of the boil. It is standard practice to
boil with the lid off to allow the escape of volatile compounds that may poorly affect the flavor of your beer.
BOIL KETTLE

BoilerMaker Surface™ V1 © Blichmann Engineering, LLC 2023
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ASSEMBLY
Connect the power cable to the receptacle of the Surface™ and to a power or temperature controller, such as the
BrewCommander™(sold separately).
Install the optional Brewmometer™, per its product specific assembly manual, to observe temperature. Alternatively,
install your controller’s optional temperature probe into the kettle to maintain temperature.
Install optional accessories as needed, referring to the later section of this manual for assembling valves, and any
manual specific to the optional accessories for their assembly.
OPERATION
Fill the kettle to no more than 80-85% full to allow for expansion of the water as it heats. The Hot Liquor Tank is best
operated using temperature control, setting your controller to Auto with a specified set temperature. Be sure that the
temperature probe for the controller is always submerged in liquid during use. While draining the Hot Liquor Tank,
de-energize the Surface when liquid level reaches the temperature probe to avoid over-heating the liquid or a dry-fire
condition. Damage to the kettle may occur.
Herms Coil (optional) – The herms coil is used to maintain mash temperatures
by recirculation the wort, from the Mash Tun, through the heated Hot Liquor Tank.
Set the temperature of your Hot Liquor Tank to be 5 degrees above your desired
mash temperature (3 degrees if using a Whirlpool Kit). Recirculate your mash water
through the Herms Kettle. See the HERMS Coil manual for more information.
Whirlpool Kit (optional) - Use the Whirlpool Kit and a pump to re-circulate water through the Hot Liquor Tank to
increase heating efficiency. This reduces time to strike by 30%, and reduces the HLT-MP temperature differential by a
couple degrees.
HOT LIQUOR TANK

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ASSEMBLY
Connect the power cable to the receptacle of the Surface™ and to a power or
temperature controller, such as the BrewCommander ™ (sold separately).
False Bottom - To install the false bottom, first remove the dip tube. Place the false
bottom on the stepped bottom of the kettle with the “buttons” facing upward and
the support feet down (shown in Fig. 1). Note that the 10-gallon false bottom does
not have support feet. Install the large washer onto the dip tube, and then insert the
dip tube into the false bottom hole.
(NPT KETTLES ONLY) - Inserting the diptube through the false bottom hole on NPT kettles is more difficult than Tri-
Clamp kettles. Place the dip tube in the bulkhead fitting (shown in Fig 2). Position the hole in the false bottom close
to the dip tube and rotate the dip tube until it engages the hole. Rotate the false bottom into place (shown in Fig. 3).
Push the dip tube into place and slide the washer down to cover the hole (shown in Fig. 4).
Only newer false bottoms can be used with the Surface™.
AutoSparge™ (optional) – Install the Autosparge in the top port of the kettle. Refer to the Autosparge™ for more
detailed setup and operation instructions.
Brewmometer™ (optional) - Install the Brewmometer™ in the wall of the Mash Tun, to observe the mash
temperature.
Temperature probe (sold separately) - Install the controllers temperature probe in the path of the flowing
wort, NOT in the wall of the Mash Tun. For NPT kettles, we recommend to use the Blichmann “In-Line Temperature
Fitting”. For Tri-Clamp kettles, we recommend using a tee and a Blichmann“1.5inch Tri-Clamp Adapter for attaching
Thermometer” (BE-001139-00).
Fig. 1 Fig. 2 Fig. 3 Fig. 4
MASH TUN
NPT RIMS
TRI-CLAMP RIMS

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Note: You can use the optional level gauge as an indicator that the mash is beginning to stick. If the wort level in the
level gauge drops below half the height of the liquid level in the inside of the kettle, you are drawing too hard and
should reduce the flow rate.
Recirculating Infusion Mash System (RIMS) – The Boilermaker Surface can be used for maintaining heat inside the
kettle, but heating the wort can only be done during recirculation. Set the BrewCommander to 50% power to reduce
the chance of over-heating the element and tripping the built-in thermal protection. Step mashing is acceptable.
Verify that wort is recirculating during the mash. Take note of the liquid level on the level gauge before starting re-
circulation, and reduce flow rate if the level on the gauge begins to fall more than 50% of the initial level.
If you have stuck the mash, immediately turn off power to the kettle, close the valve and gently scrape the compacted
grains from the bottom of the mash. Allow ten minutes for the air to dissipate from the mash then vorlauf (recirculate)
until the wort clears. Then you may begin lautering again at a reduced rate.
CAUTION: Installing the controller probe into the wall of the kettle, rather than in the recirculation loop, will cause
over-shooting and unstable mash temperatures, because the mash will react slowly to heating. Refer to the RIMS
setup images on page 8.
CAUTION: When doing step mashes (heating the wort with the false bottom in place) it is imperative to circulate the
wort while you are heating. The false bottom impedes the natural convection of heat to the mash above the false
bottom and traps the majority of it below the false bottom. Failure to recirculate may result in scorching of the wort/
grain and possible permanent heat damage to the kettle. This is NOT a warrantable failure. Use a pump to recirculate
during mash. Be sure not to exceed the recommended flow rates for your kettle volume. You will find that the mash
temperature indicated on the BrewCommander may overshoot or undershoot a bit during the heat cycle, but the
kettle’s temperature will remain steady. See the BrewCommander manual for more information.
Tip: Use the RIMS Setup and Operation Tips section of the BrewCommander manual to achieve the most precise
control of the Surface in the mash configuration.
OPERATION
False Bottom – We recommend filling your mash vessel to no more than 75% of gross capacity. This will allow
sufficient space for dough-in and sparge arm. The chart at the begining of the manual includes water to grist ratios
for reference. The chart also recommends lauter rates to reduce sticking the mash and provide consistency. A typical
mash lauter should take 45-60 minutes. Also included in the chart is the max recommended flow rates for RIMS or
HERMS systems in the chart. Of course, each RIMS and HERMS system and grist crush will affect flow rate, so you will
likely need to experiment with your system.
The button louver false bottom is extremely resistant to plugging, however, most stuck mashes are usually the result
of drawing too hard on the mash, causing it to compact and reduce permeability. Too finely crushed malt and air
in the mash from raking too vigorously are the most common causes of a stuck mash. Additionally, wheat, flaked
barley, and oats are particularly problematic due to lack of husks, higher protein and/or gluten content. Rice hulls are
recommended for beers with these ingredients.

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Fig. 7 Fig. 8 Fig. 6
Installation of the Dip Tube
The unique design of the dip tube assembly allows removal/installation without tools. Simply pull the dip tube
directly out of the drain fitting for removal. To reinstall, wet the dip tube with water, insert it into the fitting, and rotate
it until the pin engages the small hole in the fitting. When properly seated, the tube will “snap”into the O-ring groove
and provide an excellent seal. Since the boil kettle is on the hot side of the process, it is not necessary to have these
components sanitized before use. Simply having them clean and free of soil is adequate. It is not necessary to remove
the fittings or O-rings for cleaning after each use.
If you do want to remove them for periodic cleaning or replacement, O-ring replacement kits are available at
blichmannengineering.com. To reinstall the dip tube fitting, use the following sequence to ensure a tight leak free
joint:
Reinstall the O-ring in the inside of the bulkhead fitting after inspecting for tears or cuts. If any are found, replace the
seal. Insert the bulkhead fitting into the kettle as shown in Fig. 6. Then place the large O-ring in the groove on the
face of the valve. Turn the bulkhead fitting to thread it into the valve. Take care that the O-ring does not fall out of the
groove when tightening. Do not use Teflon tape on this joint. When hand tight, use a wrench on the flats of the valve
and a socket and torque wrench on the bulkhead fitting to tighten to 40 ft-lb (54 N-m)(roughly 1/4 turn)(shown in
Fig. 8).
Two Teon Washers
CLEANING THE LINEAR FLOW VALVE
Ensure that the kettle has been fully drained and turn the
valve counterclockwise until the threads disengage. A careful
pull on the knob will “snap” the shaft into a“detente” position,
letting you know that the stem has reached the end of travel
in the valve body (Shown in Fig. 5). Confirm again that
the kettle is empty and pull firmly to remove the stem. To
reassemble press stem firmly back into valve body and turn
knob clockwise to engage threads and close valve.
WARNING: Do not disassemble the valve with liquid in the kettle or severe burns can result!
Fig. 5
Use of the Linear Flow Control Valve-The linear flow control valve comes with a Teflon washer for added
rotation functionality. The valve can be rotated by loosening the internal bulkhead fitting while securing the valve
with a wrench. Once loosened, rotate the valve to the desired position, and re-tighten. Always ensure linear flow
control valve is tightened prior to use. To open the linear flow control valve turn valve knob counterclockwise slowly
until desired flow is achieved.
WARNING: STOP turning when you begin to see the threads when draining kettle. Continuing to open the valve will
not increase the flow and can result in an unintended release of hot liquid, causing severe burns!
NPT LINEAR FLOW VALVE
VALVE ASSEMBLY AND USE