The project that started this whole new home brewery was the modified "brewhouse".

When I started brewing I used a cajun burner with one pot. Since I am not a welder by any means I needed to have someone do the fabrication when I stepped to a single tier all grain system. Brad, is a friend of a friend who last year helped me construct this single tier brew scuplture.

Realtive to the new system is was very simple, quick disconnects, one pump and three 55k btu burners.

The new system about 1/3 of the way through the modications. Once it is done it will be entirely hard plumbed, have two pumps (one for sparging and the other for wort transfer), HLT heat exchanger for step mashes, inline temp readings, several polycarbonate sight glasses, an expandable / swinging control panel supprt, a tipping mash tun, integrated plate chiller and a way to reuse the hot water from the chiller. So I guess this brewery will be "green" in the way it conserves water.





These pics include one of Brad who has done a very good job of coming up with problems with constructing the brewery. More pictures will be included as Brad's part is done and as we hard plumb it.



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It wasn't pretty but... What did you expect from a beer that has been "conditioned" for 4+ years.

If you have tried this beer post your comments about your experience.... That is if your still alive to talk about it.

Checkout the video review.

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We made a blackberry lambic recipe in the summer of 2004. We followed the recipe to the letter and like some other things in life my gut did not feel right following the recipe exactly. However, I thought "we have never have made a recipe like this maybe I should just do it". So we did. We added a second yeast addition, just like the recipe said and that is where I believe we went wrong.

So fast forward to four years later, and how has it aged??

It has decent head retention, a light mouth feel and a light sweet flavor. HOWEVER, this overwhelming yeast taste beats down all the other flavors. It is kind of embarrassing to talk about but twice now when I follow a recipe that does not sound completlely in line with a style it has not turned out the way we like.

Ira has the video of us tasting the batch. I will ask him to post it.
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We (Adam, Ira, Tobias, and Matt) did a fair amount of work on the brewery components tonight. Pictures will follow here in a few days.

We have most of the cold box completed we only need to caulk a few seams, paint the outside of the box and put on casters and affix the heat exchanger to the inside of the box.

We also started the cart that the glycol chiller will sit on. This will be somewhat complex in order for the glycol reservoir not to leak.

However, the most interesting piece thus far is the "Brain" of the fermentation process which Ira is building and programming entirely from scratch. We are using a touch screen to control and monitor the process. At this point we will be able to program manually or use preset modes for the temperatures and times for fermentation.

This is a lot of information but I promise to include video and pictures to make the whole concept more intriguing.

Later....
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Rain is great for the growth of our hops but we cannot work on the brewery then...what a dilemma.
Sent from my Verizon Wireless BlackBerry
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Here are a few pics to update the Glycol Chilled Conical. We are improving the straps to hold the coil against the bottom of the cone. We were torn on where to put the coil for two reasons. One the Blichmann Conicals do not allow you to place coils around the top part because of how the legs are attached, and Two because we will not always be doing 21 gallon batches most of the test batches will be at most 5 gallons. I have to say that the construction of the Blichmann conicals is very high quality, exellent job John! I included the picture of the cold box again because that is where we are placing the conical within the brewery. I have to say it looks tiny on top of that box....
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This is the physcial construction part of the cold box. Ira is doing a great job of the automation and control side.






I included some basic pictures of the framing and will add more as we go along. The frame uses 1/2" plywood and 2x4's to create the backbone of the structure. Essentially it will be a box within a box. The inner box consists of 2" Dow Blue foam and the inner most liner is made up of FRP panels for durability and easy clean up.






To cool the box we are using between 2 and 4 120mm fans to circulate air over a Haydens 405 Transmission cooler that will be hanging from the ceiling of one end of the box.






Just a tip when constructing a cold box with Liquid Nails adhesive. When applying it above you be very careful how quickly you sit up. That stuff is a pain to get out of your hair.
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I wanted to include some pics of the first year hops. We purchased rhizomes back in March but they were not mailed to us until the 2nd week in April so we were rushed to get them in dirt. It is obvious which of the rhizomes was the largest. One of the roots is already creating a 12" bine.
The new hop rhizomes for 2009 include Nugget, Glacier, Golding, Mt. Hood (by far the largest) and Cascade. Can't wait to try some of that Nugget in one of our brews.
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Last Saturday, May 9th, I went to check on the hops we are growing. There is both first and second year plants that we are growing at a local nursery. The first year plants are still in the greenhouse and the second year plants are on a trellis that we put together outside. The seond year plants went from 12 inches to up to 7 feet in those 12 days of rain. The ironic part is that the hops outgrew the weeds around them, grew across the tops of the weeds and then grabbed on the to first vertical surface they could find to grow upwards. So what did I do for three hours? Seperated weeds from hop plants. I have included pics. I know it is really hard to tell weeds from hop plants but I have to mow around them and put down some kind of weed control.


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I feel as though an insane amount of planning has gone in to putting our ultra home brewery together. Each person that is contributing to the brewery has their own specialty. Today I met with Brad, who is fabricating and welding the core of the brewery. I plan on bringing him in as a part of this blog in the future. I wonder how many other homebrewers have felt this way as they plan an exciting project like this. You feel as though you have done a ton of planning and things are slowly coming together but there is a great amount of anticipation and excitement as we proceed. One of the items that is on my punch list is posting some of the pictures that I we have taken along the way.
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A few of the other guys have tackled the task of construction of the brewery and i have concentrated on the automation of the fermenation process. So far i have created the logic which will be used for both the cold box and the Conical Fermenter controlling the heating and cooling process.

The idea is to make the system as flexible and easy to use as possible. To do this 2 variables will be used at all times to define if the system will be cooling, heating, or nothing. The logic is is shown below:


Both the Cold Box and the Conical Fermenter will be controlled separately. By controlling these process separately we will be able to ferment different types of beer at the same time. Because a PLC will be used to control this process it should be easy to track where each beer is in the fermentation process. The Control logic which will control the heating and cooling pumps is as follows:


This is the basis of what is needed to brew different beers. This logic will always be used regardless of the stage of the brew process Primary, Diacetyl Rest, Crash, Secondary. I will followup with the diagram which will show each of the process steps in a later post for now we have temperature control... O, yea not to mention the data logging. The data logging will be essential so that we understand what a beer experienced during the fermenation process. In logging this information we will be able to re-create a beer over and over again.
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So it's been a few weeks sense the planes where posted and we have made some progress and i have just been slow to post it. The Cooling Coils have been placed on to the Conical or as i like to call it 27 Gallons of goodness. For this 50' of flexible copper tubing was used to form around the base of the conical.

We chose to coil the base of the conical rather then the top so we could make a smaller batch and still cool the system. The Fermentation process should agitate enough to circulate larger batches even with the coils placed on the lower part of the conical. If needed a second set of cooling coils could be added to the top of the conical and could be driven by a third pump allowing cooling process to happen faster (if needed). This will all be controlled by a PLC so it should not be difficult to control the third pump.

It was tricky warping these coils around the base of the conical as it is cone shaped and it took some time to make sure we had good contact between the coils and the conical. After it was warped tension bolts used to hold the coils in place and keep them firm to the conical.

Check out the process in the following video:
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My fist adventure in radio! I started off by building a Hartley oscillator with one transistor and then amplitude modulated a signal with a second transistor. I then built an AM receiver schematic I found and calculated the tank circuit for the 50 MHz band.

Understand that this transmitter is extremely simple and haphazardly thrown together, it does not transmit any further than across the room but it is useful for understanding the basic concept of a transmitter.


AM Transmitter Schematic
(Q1 makes the Hartley oscillator, Q2 amplitude modulates the signal. It's only broadcast across a room. To increase power you would need to add some amplification. You may find this helpful for calculating the resistance values needed)

AM Receiver Schematic
(I recommend replacing the 120k
regenerative feedback resistor with a variable resistor. I used 2N3904 transistors in my build)

The Tank Circuit

The operating frequency of the Hartley oscillator and the frequency tuned in by the receiver is determined by the inductor (L) and the capacitance (C) values in the tank circuit.

Explanation of a "tank circuit".

In my circuit the variable capacitor's max capacitance is at 265 pF (estimated 290 pF to account for some stray capacitance) and the coils are roughly 1.746 uH (Micro Henrys). Turning the variable capacitor lowers it's capacitance and thus increases the resonant frequency.

I made the air-core inductor out of a .25 inch diameter soda straw.

Specs:
Diameter: .25 inches
Length: .75 inches
Turns: 31


This equation can be used for calculating the dimensions of an air-core inductor,



Where,
  • L is inductance in uH
  • d is coil diameter in inches
  • l is coil length in inches
  • n is number of turns.

I found this air-core inductor calculator to be a very handy tool for designing coils.


Calculating Inductance Needed

To calculate the inductance L (in mico Henrys) needed you will need to know 2 things. What frequency you want to operate in (I chose 50 MHz because its in the amateur band) and your maximum variable capacitance (265 pF + 25 pF estimated stray capacitance = 290 pF)

The easy way to calculate this is,



So using my values as an example,



Which comes out to,

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A while back I put my email in for a chance to be a beta tester for Quake Live. Long since forgotten I got an email today asking me to try it...

Quake Live is a free (ad-supported) browser based first person shooter in development by id Software. It only supports Windows right now (IE and Firefox) but will eventually support Linux and Mac.
No word on the release date yet but it seems to be well on its way.

To get started I had to make an account and download a 3.78 MB plug-in. I was greeted by a friendly tutorial talking me through the game.. I promptly skipped it. Starting an online match was quick, all the matches and settings are selected through the web browser. The game is rendered in a little box which can be made full screen; I'm happy to say that it supports wide screen resolutions (that's better than Battlefield 2!).

Once I started playing I noticed that it was pretty much Quake 3 loaded off a server. The textures and models may be a little bit compressed but all of the guns, maps, and game types are very close to the same. The graphics are decent, nothing stunning but something that will play well on older computers. I can see this being very useful for getting my online FPS fix when I am away from home.
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You should always be careful when connecting to a public WiFi connection, you don't want to end up like these poor saps at the Defcon convention.

I'm sure you have found yourself in a situation where you had an overzealous network filter block websites on a public connection (like at a library, work, or school). Or perhaps you don't quite trust the connection you are on?

If you have a Linux box at home that you can SSH into, you can set up a socks proxy to tunnel firefox over an SSH connection. To anyone else it will appear as if you were surfing from your servers connection.

The command is:

ssh -D 8080 user@host -N

(This will work with putty on windows too)

Leave that terminal running in the background then in firefox go to...

Tools > Options (Edit > Prefrences in Linux) > Advanced > Network > Connection Settings

And set up a manual proxy configuration under the SOCKS Host to connect to localhost (IP: 127.0.0.1) and port 8080.

You can also set up Pidgin to use a SOCKS proxy in the same way for more secure IM conversations.

Cheers.
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Well, today is the day that the small brewery, in a small town, in an even smaller garage started... to get a bit bigger (yea we had a smaller brewery before). To make the brewery bigger plans had to be made. We needed a new brew process capable of brewing higher volumes of beer and a new fermentation process capable of creating more consistence results.

The new brew process design provides the ability to create a continues brew process by breaking the system into three parts the Hot Liqueur Tank (HLT), Mash Tun, and Boil Kettle. This new process also contains a CIP (Clean in place) system making cleanup easier (we all know this is the worst part of homebrew). Finally the heating of the Mash Tun is done by using the hot water from the HLT. This should create an easier system to deal with as there should be no worries about burning the mash killing the batch.




The new fermentation process will be controlled by a PLC. This will use two PID loops which will read the temperature of the Cold Box and the Fermentor. These PID loops will trigger heaters and coolant. pumps if needed to keep the brew at the correct temperature throughout the process.




So, plans have been made now all we have to do is build it.

Let the Homebrew Project begin!!!
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This tutorial assumes you are using Debian based linux, such as ubuntu, and you have a server set up with root privileges on a home connection.

Update: Your router might already have Dynamic DNS functionality built it, specifically for the DynDNS service. If you can use that instead it will save yourself a lot of trouble! If not, read on and good luck :-)

DNS stands for Domain Name System, it is the service that allows you to go to google.com instead of having to remember google's IP address. A Dynamic DNS service will accept a change in IP address for a domain name. So instead of remembering your latest IP address assigned from your ISP to connect to your home server we will only have to remember one name, for example myhomeserver.dyndns.org. The server will then report any IP changes to the Dynamic DNS service.

There are a number of free Dynamic DNS services out there, for this tutorial we will be using DynDNS.

Head over to http://www.dyndns.com/ and enter in a name for your server.



You will then need to make an account with Dynamic DNS. Once you are finished it should set an IP address from where you logged in from by default. Now we are going to get your Ubuntu server to check if there is a change in IP address and if so log into your DynDNS account and report the change.

To accomplish this we are going to use the ddclient program.

First lets get ddclient from synaptic; execute this command:
sudo apt-get install ddclient

It will then run through a command line based installer and ask you a few questions to set up a basic config file. Answer all the questions it asks you, the DynDNS hostname you set, your DynDNS username and password, etc.

The tricky part is when it asks, "Enter the interface which is used for using dynamic DNS service."

If you are not behind a router or a firewall you can simply enter: eth0

But in my case I am behind a router so I cannot see what my global IP is, so I am going to use another server that will check the IP for me.

So if you are behind a router just skip this question and we will fix it manually in the config file later.

After synaptic is done installing ddclient we are going to have to manually edit the config file and add a few things. For this tutorial I am going to use emacs to edit the files.

Run the command: sudo emacs /etc/ddclient.conf

Your config file should look something like this:


# Configuration file for ddclient generated by debconf
#
# /etc/ddclient.conf

pid=/var/run/ddclient.pid
protocol=dyndns2
use=if, if=
server=members.dyndns.org
login=[your dyndns username]
password=[your dyndns password]
yoursite.dyndns.org


If your server is not behind a router then the use line should be set to "use=if, if=eth0".

However if your server is behind a router change this line,

use=if, if=

to this,

use=web, web=checkip.dyndns.com/, web-skip='IP Address'

And lastly put a new line that says,

daemon=600

This will tell the script to check your IP address every 10 minutes (600 seconds) using checkip.dyndns.com as a reference. If the IP has changed it will send an update to DynDNS else it will wait another 10 min and check again. The smallest value you are allowed to set for the update interval is every 60 seconds.

If you are using the emacs editor hold down the CTRL key and hit "X", then "S" to save your file. Then hold down CTRL again and hit "Z" to get back to the command line.


So your final configuration file should look something like this,


# Configuration file for ddclient generated by debconf
#
# /etc/ddclient.conf

daemon=600 #reports IP every 600 seconds

pid=/var/run/ddclient.pid
protocol=dyndns2
use=web, web=checkip.dyndns.com/, web-skip='IP Address'
server=members.dyndns.org
login=[your dyndns username]
password=[your dyndns password]
yoursite.dyndns.org



Now that we are all configured it is time to restart the ddclient program.

Cross your fingers and execute this command,

sudo /etc/init.d/ddclient restart

Assuming everything is set up properly ddclient should report any IP address changes. Now there is still one problem, DynDNS expects an update at LEAST once a month or else it will set your account as inactive. This is an issue if you keep the same IP for more than a month.

To avoid this we are going to make a cron job that will force ddclient to update every month.

Execute the command "crontab -e". You will be greeted with a simple editor. Add this on a new line,


00 00 28 * * ddclient -host yoursite.dyndns.org -force


Then hold down CTRL and hit X, it will ask you if you want to save, type "y" to say yes and hit enter.

Everything should work beautifully now!

Cheers.
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"The nice thing about standards is that there are so many of them to choose from."
Andrew S. Tanenbaum, computer science professor
When Benjamin Franklin made his conjecture regarding the direction of charge flow (from the smooth wax to the rough wool), he set a precedent for electrical notation that exists to this day, despite the fact that we know electrons are the constituent units of charge, and that they are displaced from the wool to the wax -- not from the wax to the wool -- when those two substances are rubbed together. This is why electrons are said to have a negative charge: because Franklin assumed electric charge moved in the opposite direction that it actually does, and so objects he called "negative" (representing a deficiency of charge) actually have a surplus of electrons.
By the time the true direction of electron flow was discovered, the nomenclature of "positive" and "negative" had already been so well established in the scientific community that no effort was made to change it, although calling electrons "positive" would make more sense in referring to "excess" charge. You see, the terms "positive" and "negative" are human inventions, and as such have no absolute meaning beyond our own conventions of language and scientific description. Franklin could have just as easily referred to a surplus of charge as "black" and a deficiency as "white," in which case scientists would speak of electrons having a "white" charge (assuming the same incorrect conjecture of charge position between wax and wool).
However, because we tend to associate the word "positive" with "surplus" and "negative" with "deficiency," the standard label for electron charge does seem backward. Because of this, many engineers decided to retain the old concept of electricity with "positive" referring to a surplus of charge, and label charge flow (current) accordingly. This became known as conventional flow notation:

Others chose to designate charge flow according to the actual motion of electrons in a circuit. This form of symbology became known as electron flow notation:

In conventional flow notation, we show the motion of charge according to the (technically incorrect) labels of + and -. This way the labels make sense, but the direction of charge flow is incorrect. In electron flow notation, we follow the actual motion of electrons in the circuit, but the + and - labels seem backward. Does it matter, really, how we designate charge flow in a circuit? Not really, so long as we're consistent in the use of our symbols. You may follow an imagined direction of current (conventional flow) or the actual (electron flow) with equal success insofar as circuit analysis is concerned. Concepts of voltage, current, resistance, continuity, and even mathematical treatments such as Ohm's Law (chapter 2) and Kirchhoff's Laws (chapter 6) remain just as valid with either style of notation.
You will find conventional flow notation followed by most electrical engineers, and illustrated in most engineering textbooks. Electron flow is most often seen in introductory textbooks (this one included) and in the writings of professional scientists, especially solid-state physicists who are concerned with the actual motion of electrons in substances. These preferences are cultural, in the sense that certain groups of people have found it advantageous to envision electric current motion in certain ways. Being that most analyses of electric circuits do not depend on a technically accurate depiction of charge flow, the choice between conventional flow notation and electron flow notation is arbitrary . . . almost.
Many electrical devices tolerate real currents of either direction with no difference in operation. Incandescent lamps (the type utilizing a thin metal filament that glows white-hot with sufficient current), for example, produce light with equal efficiency regardless of current direction. They even function well on alternating current (AC), where the direction changes rapidly over time. Conductors and switches operate irrespective of current direction, as well. The technical term for this irrelevance of charge flow is nonpolarization. We could say then, that incandescent lamps, switches, and wires are nonpolarized components. Conversely, any device that functions differently on currents of different direction would be called a polarized device.
There are many such polarized devices used in electric circuits. Most of them are made of so-called semiconductor substances, and as such aren't examined in detail until the third volume of this book series. Like switches, lamps, and batteries, each of these devices is represented in a schematic diagram by a unique symbol. As one might guess, polarized device symbols typically contain an arrow within them, somewhere, to designate a preferred or exclusive direction of current. This is where the competing notations of conventional and electron flow really matter. Because engineers from long ago have settled on conventional flow as their "culture's" standard notation, and because engineers are the same people who invent electrical devices and the symbols representing them, the arrows used in these devices' symbols all point in the direction of conventional flow, not electron flow. That is to say, all of these devices' symbols have arrow marks that point against the actual flow of electrons through them.
Perhaps the best example of a polarized device is the diode. A diode is a one-way "valve" for electric current, analogous to a check valve for those familiar with plumbing and hydraulic systems. Ideally, a diode provides unimpeded flow for current in one direction (little or no resistance), but prevents flow in the other direction (infinite resistance). Its schematic symbol looks like this:

Placed within a battery/lamp circuit, its operation is as such:

When the diode is facing in the proper direction to permit current, the lamp glows. Otherwise, the diode blocks all electron flow just like a break in the circuit, and the lamp will not glow.
If we label the circuit current using conventional flow notation, the arrow symbol of the diode makes perfect sense: the triangular arrowhead points in the direction of charge flow, from positive to negative:

On the other hand, if we use electron flow notation to show the true direction of electron travel around the circuit, the diode's arrow symbology seems backward:

For this reason alone, many people choose to make conventional flow their notation of choice when drawing the direction of charge motion in a circuit. If for no other reason, the symbols associated with semiconductor components like diodes make more sense this way. However, others choose to show the true direction of electron travel so as to avoid having to tell themselves, "just remember the electrons are actually moving the other way" whenever the true direction of electron motion becomes an issue.
In this series of textbooks, I have committed to using electron flow notation. Ironically, this was not my first choice. I found it much easier when I was first learning electronics to use conventional flow notation, primarily because of the directions of semiconductor device symbol arrows. Later, when I began my first formal training in electronics, my instructor insisted on using electron flow notation in his lectures. In fact, he asked that we take our textbooks (which were illustrated using conventional flow notation) and use our pens to change the directions of all the current arrows so as to point the "correct" way! His preference was not arbitrary, though. In his 20-year career as a U.S. Navy electronics technician, he worked on a lot of vacuum-tube equipment. Before the advent of semiconductor components like transistors, devices known as vacuum tubes or electron tubes were used to amplify small electrical signals. These devices work on the phenomenon of electrons hurtling through a vacuum, their rate of flow controlled by voltages applied between metal plates and grids placed within their path, and are best understood when visualized using electron flow notation.
When I graduated from that training program, I went back to my old habit of conventional flow notation, primarily for the sake of minimizing confusion with component symbols, since vacuum tubes are all but obsolete except in special applications. Collecting notes for the writing of this book, I had full intention of illustrating it using conventional flow.
Years later, when I became a teacher of electronics, the curriculum for the program I was going to teach had already been established around the notation of electron flow. Oddly enough, this was due in part to the legacy of my first electronics instructor (the 20-year Navy veteran), but that's another story entirely! Not wanting to confuse students by teaching "differently" from the other instructors, I had to overcome my habit and get used to visualizing electron flow instead of conventional. Because I wanted my book to be a useful resource for my students, I begrudgingly changed plans and illustrated it with all the arrows pointing the "correct" way. Oh well, sometimes you just can't win!
On a positive note (no pun intended), I have subsequently discovered that some students prefer electron flow notation when first learning about the behavior of semiconductive substances. Also, the habit of visualizing electrons flowing against the arrows of polarized device symbols isn't that difficult to learn, and in the end I've found that I can follow the operation of a circuit equally well using either mode of notation. Still, I sometimes wonder if it would all be much easier if we went back to the source of the confusion -- Ben Franklin's errant conjecture -- and fixed the problem there, calling electrons "positive" and protons "negative."
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Because it takes energy to force electrons to flow against the opposition of a resistance, there will be voltage manifested (or "dropped") between any points in a circuit with resistance between them. It is important to note that although the amount of current (the quantity of electrons moving past a given point every second) is uniform in a simple circuit, the amount of voltage (potential energy per unit charge) between different sets of points in a single circuit may vary considerably:

Take this circuit as an example. If we label four points in this circuit with the numbers 1, 2, 3, and 4, we will find that the amount of current conducted through the wire between points 1 and 2 is exactly the same as the amount of current conducted through the lamp (between points 2 and 3). This same quantity of current passes through the wire between points 3 and 4, and through the battery (between points 1 and 4).
However, we will find the voltage appearing between any two of these points to be directly proportional to the resistance within the conductive path between those two points, given that the amount of current along any part of the circuit's path is the same (which, for this simple circuit, it is). In a normal lamp circuit, the resistance of a lamp will be much greater than the resistance of the connecting wires, so we should expect to see a substantial amount of voltage between points 2 and 3, with very little between points 1 and 2, or between 3 and 4. The voltage between points 1 and 4, of course, will be the full amount of "force" offered by the battery, which will be only slightly greater than the voltage across the lamp (between points 2 and 3).
This, again, is analogous to the water reservoir system:

Between points 2 and 3, where the falling water is releasing energy at the water-wheel, there is a difference of pressure between the two points, reflecting the opposition to the flow of water through the water-wheel. From point 1 to point 2, or from point 3 to point 4, where water is flowing freely through reservoirs with little opposition, there is little or no difference of pressure (no potential energy). However, the rate of water flow in this continuous system is the same everywhere (assuming the water levels in both pond and reservoir are unchanging): through the pump, through the water-wheel, and through all the pipes. So it is with simple electric circuits: the rate of electron flow is the same at every point in the circuit, although voltages may differ between different sets of points.
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The circuit in the previous section is not a very practical one. In fact, it can be quite dangerous to build (directly connecting the poles of a voltage source together with a single piece of wire). The reason it is dangerous is because the magnitude of electric current may be very large in such a short circuit, and the release of energy very dramatic (usually in the form of heat). Usually, electric circuits are constructed in such a way as to make practical use of that released energy, in as safe a manner as possible.
One practical and popular use of electric current is for the operation of electric lighting. The simplest form of electric lamp is a tiny metal "filament" inside of a clear glass bulb, which glows white-hot ("incandesces") with heat energy when sufficient electric current passes through it. Like the battery, it has two conductive connection points, one for electrons to enter and the other for electrons to exit.
Connected to a source of voltage, an electric lamp circuit looks something like this:

As the electrons work their way through the thin metal filament of the lamp, they encounter more opposition to motion than they typically would in a thick piece of wire. This opposition to electric current depends on the type of material, its cross-sectional area, and its temperature. It is technically known as resistance. (It can be said that conductors have low resistance and insulators have very high resistance.) This resistance serves to limit the amount of current through the circuit with a given amount of voltage supplied by the battery, as compared with the "short circuit" where we had nothing but a wire joining one end of the voltage source (battery) to the other.
When electrons move against the opposition of resistance, "friction" is generated. Just like mechanical friction, the friction produced by electrons flowing against a resistance manifests itself in the form of heat. The concentrated resistance of a lamp's filament results in a relatively large amount of heat energy dissipated at that filament. This heat energy is enough to cause the filament to glow white-hot, producing light, whereas the wires connecting the lamp to the battery (which have much lower resistance) hardly even get warm while conducting the same amount of current.
As in the case of the short circuit, if the continuity of the circuit is broken at any point, electron flow stops throughout the entire circuit. With a lamp in place, this means that it will stop glowing:

As before, with no flow of electrons, the entire potential (voltage) of the battery is available across the break, waiting for the opportunity of a connection to bridge across that break and permit electron flow again. This condition is known as an open circuit, where a break in the continuity of the circuit prevents current throughout. All it takes is a single break in continuity to "open" a circuit. Once any breaks have been connected once again and the continuity of the circuit re-established, it is known as a closed circuit.
What we see here is the basis for switching lamps on and off by remote switches. Because any break in a circuit's continuity results in current stopping throughout the entire circuit, we can use a device designed to intentionally break that continuity (called a switch), mounted at any convenient location that we can run wires to, to control the flow of electrons in the circuit:

This is how a switch mounted on the wall of a house can control a lamp that is mounted down a long hallway, or even in another room, far away from the switch. The switch itself is constructed of a pair of conductive contacts (usually made of some kind of metal) forced together by a mechanical lever actuator or pushbutton. When the contacts touch each other, electrons are able to flow from one to the other and the circuit's continuity is established; when the contacts are separated, electron flow from one to the other is prevented by the insulation of the air between, and the circuit's continuity is broken.
Perhaps the best kind of switch to show for illustration of the basic principle is the "knife" switch:

A knife switch is nothing more than a conductive lever, free to pivot on a hinge, coming into physical contact with one or more stationary contact points which are also conductive. The switch shown in the above illustration is constructed on a porcelain base (an excellent insulating material), using copper (an excellent conductor) for the "blade" and contact points. The handle is plastic to insulate the operator's hand from the conductive blade of the switch when opening or closing it.
Here is another type of knife switch, with two stationary contacts instead of one:

The particular knife switch shown here has one "blade" but two stationary contacts, meaning that it can make or break more than one circuit. For now this is not terribly important to be aware of, just the basic concept of what a switch is and how it works.
Knife switches are great for illustrating the basic principle of how a switch works, but they present distinct safety problems when used in high-power electric circuits. The exposed conductors in a knife switch make accidental contact with the circuit a distinct possibility, and any sparking that may occur between the moving blade and the stationary contact is free to ignite any nearby flammable materials. Most modern switch designs have their moving conductors and contact points sealed inside an insulating case in order to mitigate these hazards. A photograph of a few modern switch types show how the switching mechanisms are much more concealed than with the knife design:

In keeping with the "open" and "closed" terminology of circuits, a switch that is making contact from one connection terminal to the other (example: a knife switch with the blade fully touching the stationary contact point) provides continuity for electrons to flow through, and is called a closed switch. Conversely, a switch that is breaking continuity (example: a knife switch with the blade not touching the stationary contact point) won't allow electrons to pass through and is called an open switch. This terminology is often confusing to the new student of electronics, because the words "open" and "closed" are commonly understood in the context of a door, where "open" is equated with free passage and "closed" with blockage. With electrical switches, these terms have opposite meaning: "open" means no flow while "closed" means free passage of electrons.
  • REVIEW:
  • Resistance is the measure of opposition to electric current.
  • A short circuit is an electric circuit offering little or no resistance to the flow of electrons. Short circuits are dangerous with high voltage power sources because the high currents encountered can cause large amounts of heat energy to be released.
  • An open circuit is one where the continuity has been broken by an interruption in the path for electrons to flow.
  • A closed circuit is one that is complete, with good continuity throughout.
  • A device designed to open or close a circuit under controlled conditions is called a switch.
  • The terms "open" and "closed" refer to switches as well as entire circuits. An open switch is one without continuity: electrons cannot flow through it. A closed switch is one that provides a direct (low resistance) path for electrons to flow through.
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As was previously mentioned, we need more than just a continuous path (circuit) before a continuous flow of electrons will occur: we also need some means to push these electrons around the circuit. Just like marbles in a tube or water in a pipe, it takes some kind of influencing force to initiate flow. With electrons, this force is the same force at work in static electricity: the force produced by an imbalance of electric charge.
If we take the examples of wax and wool which have been rubbed together, we find that the surplus of electrons in the wax (negative charge) and the deficit of electrons in the wool (positive charge) creates an imbalance of charge between them. This imbalance manifests itself as an attractive force between the two objects:

If a conductive wire is placed between the charged wax and wool, electrons will flow through it, as some of the excess electrons in the wax rush through the wire to get back to the wool, filling the deficiency of electrons there:

The imbalance of electrons between the atoms in the wax and the atoms in the wool creates a force between the two materials. With no path for electrons to flow from the wax to the wool, all this force can do is attract the two objects together. Now that a conductor bridges the insulating gap, however, the force will provoke electrons to flow in a uniform direction through the wire, if only momentarily, until the charge in that area neutralizes and the force between the wax and wool diminishes.
The electric charge formed between these two materials by rubbing them together serves to store a certain amount of energy. This energy is not unlike the energy stored in a high reservoir of water that has been pumped from a lower-level pond:

The influence of gravity on the water in the reservoir creates a force that attempts to move the water down to the lower level again. If a suitable pipe is run from the reservoir back to the pond, water will flow under the influence of gravity down from the reservoir, through the pipe:

It takes energy to pump that water from the low-level pond to the high-level reservoir, and the movement of water through the piping back down to its original level constitutes a releasing of energy stored from previous pumping.
If the water is pumped to an even higher level, it will take even more energy to do so, thus more energy will be stored, and more energy released if the water is allowed to flow through a pipe back down again:

Electrons are not much different. If we rub wax and wool together, we "pump" electrons away from their normal "levels," creating a condition where a force exists between the wax and wool, as the electrons seek to re-establish their former positions (and balance within their respective atoms). The force attracting electrons back to their original positions around the positive nuclei of their atoms is analogous to the force gravity exerts on water in the reservoir, trying to draw it down to its former level.
Just as the pumping of water to a higher level results in energy being stored, "pumping" electrons to create an electric charge imbalance results in a certain amount of energy being stored in that imbalance. And, just as providing a way for water to flow back down from the heights of the reservoir results in a release of that stored energy, providing a way for electrons to flow back to their original "levels" results in a release of stored energy.
When the electrons are poised in that static condition (just like water sitting still, high in a reservoir), the energy stored there is called potential energy, because it has the possibility (potential) of release that has not been fully realized yet. When you scuff your rubber-soled shoes against a fabric carpet on a dry day, you create an imbalance of electric charge between yourself and the carpet. The action of scuffing your feet stores energy in the form of an imbalance of electrons forced from their original locations. This charge (static electricity) is stationary, and you won't realize that energy is being stored at all. However, once you place your hand against a metal doorknob (with lots of electron mobility to neutralize your electric charge), that stored energy will be released in the form of a sudden flow of electrons through your hand, and you will perceive it as an electric shock!
This potential energy, stored in the form of an electric charge imbalance and capable of provoking electrons to flow through a conductor, can be expressed as a term called voltage, which technically is a measure of potential energy per unit charge of electrons, or something a physicist would call specific potential energy. Defined in the context of static electricity, voltage is the measure of work required to move a unit charge from one location to another, against the force which tries to keep electric charges balanced. In the context of electrical power sources, voltage is the amount of potential energy available (work to be done) per unit charge, to move electrons through a conductor.
Because voltage is an expression of potential energy, representing the possibility or potential for energy release as the electrons move from one "level" to another, it is always referenced between two points. Consider the water reservoir analogy:

Because of the difference in the height of the drop, there's potential for much more energy to be released from the reservoir through the piping to location 2 than to location 1. The principle can be intuitively understood in dropping a rock: which results in a more violent impact, a rock dropped from a height of one foot, or the same rock dropped from a height of one mile? Obviously, the drop of greater height results in greater energy released (a more violent impact). We cannot assess the amount of stored energy in a water reservoir simply by measuring the volume of water any more than we can predict the severity of a falling rock's impact simply from knowing the weight of the rock: in both cases we must also consider how far these masses will drop from their initial height. The amount of energy released by allowing a mass to drop is relative to the distance between its starting and ending points. Likewise, the potential energy available for moving electrons from one point to another is relative to those two points. Therefore, voltage is always expressed as a quantity between two points. Interestingly enough, the analogy of a mass potentially "dropping" from one height to another is such an apt model that voltage between two points is sometimes called a voltage drop.
Voltage can be generated by means other than rubbing certain types of materials against each other. Chemical reactions, radiant energy, and the influence of magnetism on conductors are a few ways in which voltage may be produced. Respective examples of these three sources of voltage are batteries, solar cells, and generators (such as the "alternator" unit under the hood of your automobile). For now, we won't go into detail as to how each of these voltage sources works -- more important is that we understand how voltage sources can be applied to create electron flow in a circuit.
Let's take the symbol for a chemical battery and build a circuit step by step:

Any source of voltage, including batteries, have two points for electrical contact. In this case, we have point 1 and point 2 in the above diagram. The horizontal lines of varying length indicate that this is a battery, and they further indicate the direction which this battery's voltage will try to push electrons through a circuit. The fact that the horizontal lines in the battery symbol appear separated (and thus unable to serve as a path for electrons to move) is no cause for concern: in real life, those horizontal lines represent metallic plates immersed in a liquid or semi-solid material that not only conducts electrons, but also generates the voltage to push them along by interacting with the plates.
Notice the little "+" and "-" signs to the immediate left of the battery symbol. The negative (-) end of the battery is always the end with the shortest dash, and the positive (+) end of the battery is always the end with the longest dash. Since we have decided to call electrons "negatively" charged (thanks, Ben!), the negative end of a battery is that end which tries to push electrons out of it. Likewise, the positive end is that end which tries to attract electrons.
With the "+" and "-" ends of the battery not connected to anything, there will be voltage between those two points, but there will be no flow of electrons through the battery, because there is no continuous path for the electrons to move.

The same principle holds true for the water reservoir and pump analogy: without a return pipe back to the pond, stored energy in the reservoir cannot be released in the form of water flow. Once the reservoir is completely filled up, no flow can occur, no matter how much pressure the pump may generate. There needs to be a complete path (circuit) for water to flow from the pond, to the reservoir, and back to the pond in order for continuous flow to occur.
We can provide such a path for the battery by connecting a piece of wire from one end of the battery to the other. Forming a circuit with a loop of wire, we will initiate a continuous flow of electrons in a clockwise direction:

So long as the battery continues to produce voltage and the continuity of the electrical path isn't broken, electrons will continue to flow in the circuit. Following the metaphor of water moving through a pipe, this continuous, uniform flow of electrons through the circuit is called a current. So long as the voltage source keeps "pushing" in the same direction, the electron flow will continue to move in the same direction in the circuit. This single-direction flow of electrons is called a Direct Current, or DC. In the second volume of this book series, electric circuits are explored where the direction of current switches back and forth: Alternating Current, or AC. But for now, we'll just concern ourselves with DC circuits.
Because electric current is composed of individual electrons flowing in unison through a conductor by moving along and pushing on the electrons ahead, just like marbles through a tube or water through a pipe, the amount of flow throughout a single circuit will be the same at any point. If we were to monitor a cross-section of the wire in a single circuit, counting the electrons flowing by, we would notice the exact same quantity per unit of time as in any other part of the circuit, regardless of conductor length or conductor diameter.
If we break the circuit's continuity at any point, the electric current will cease in the entire loop, and the full voltage produced by the battery will be manifested across the break, between the wire ends that used to be connected:

Notice the "+" and "-" signs drawn at the ends of the break in the circuit, and how they correspond to the "+" and "-" signs next to the battery's terminals. These markers indicate the direction that the voltage attempts to push electron flow, that potential direction commonly referred to as polarity. Remember that voltage is always relative between two points. Because of this fact, the polarity of a voltage drop is also relative between two points: whether a point in a circuit gets labeled with a "+" or a "-" depends on the other point to which it is referenced. Take a look at the following circuit, where each corner of the loop is marked with a number for reference:

With the circuit's continuity broken between points 2 and 3, the polarity of the voltage dropped between points 2 and 3 is "-" for point 2 and "+" for point 3. The battery's polarity (1 "-" and 4 "+") is trying to push electrons through the loop clockwise from 1 to 2 to 3 to 4 and back to 1 again.
Now let's see what happens if we connect points 2 and 3 back together again, but place a break in the circuit between points 3 and 4:

With the break between 3 and 4, the polarity of the voltage drop between those two points is "+" for 4 and "-" for 3. Take special note of the fact that point 3's "sign" is opposite of that in the first example, where the break was between points 2 and 3 (where point 3 was labeled "+"). It is impossible for us to say that point 3 in this circuit will always be either "+" or "-", because polarity, like voltage itself, is not specific to a single point, but is always relative between two points!
  • REVIEW:
  • Electrons can be motivated to flow through a conductor by the same force manifested in static electricity.
  • Voltage is the measure of specific potential energy (potential energy per unit charge) between two locations. In layman's terms, it is the measure of "push" available to motivate electrons.
  • Voltage, as an expression of potential energy, is always relative between two locations, or points. Sometimes it is called a voltage "drop."
  • When a voltage source is connected to a circuit, the voltage will cause a uniform flow of electrons through that circuit called a current.
  • In a single (one loop) circuit, the amount of current at any point is the same as the amount of current at any other point.
  • If a circuit containing a voltage source is broken, the full voltage of that source will appear across the points of the break.
  • The +/- orientation of a voltage drop is called the polarity. It is also relative between two points.
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