Today I learned a little bit about clothes dryers

The bad news came this morning as we were cleaning the house in preparation for Christmas: the dryer wouldn’t start. Andrea and I both assumed that the belt must have worn out, and I made another assumption that cost me an extra two hours on this project: I thought, “Surely maintenance must take place from the back of the appliance,” so I pulled it out from the wall, unplugged it, climbed behind it, and removed the back panel, in the process knocking loose the flexible metal conduit of the lint vent.

Puzzled that I didn’t see a way of checking the belt or the motor from the back, I asked the Internet for help, and found that most normal maintenance takes places from the FRONT of the dryer! So I unscrewed the top, flipped it back, disconnected the door cut-off switch, removed and set aside the front panel, and then removed the drum.

The belt was intact. The Internet told me to run it briefly with the drum and belt removed in order to determine whether the motor was bad, so I scratched my head a little bit because the thing won’t run without the front panel on and the door cut-off switch connected. I put the front panel back on, connected the door cut-off switch, plugged in the power, and turned it on — the motor was fine. The belt looked fine. The gaskets looked fine. I had cleaned up a little bit of lint but I have no idea why the drum wouldn’t spin earlier. I think it must have been bound up for some reason. I put the dryer back together and the drum was now spinning.

Unfortunately, I couldn’t get the vent conduit back on the outlets, so I spent the next two hours cursing over that and cutting my fingers on the sharp metal edges. Eventually, I got it to work, and shortened the conduit by nearly three feet. After the holidays, I think I might fit it for rigid conduit, because the flexible stuff seems to collect lint on the interior ridges.

I feel a minor sense of accomplishment from all this, but wish it had happened on some other day. Mainly I feel a sense of relief we have a means to dry Jamie’s cloth diapers that will only take half an hour or so.

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How a tweak becomes a full-blown upgrade

The pre-built DIY brewery I bought earlier this year is now sitting in pieces on our garage floor. I realized something about DIY projects after getting it home and wired up for use — when the works of a thing are readily accessible like this, it’s difficult to impossible to resist tinkering with it. Sometimes a tweak is all that’s needed, sometimes a partial redesign is in order. The original owners’ extensive use of NPT threaded fittings allowed the brew stand to be constructed mostly of off-the-shelf pipes and hose fittings, but made parts of the system so tightly coupled, it was difficult to work on a piece of it without dismantling the whole thing.

For example, Scott and I had decided we needed to fix the leak on the RIMS, so we ordered a stainless steel tri-clamp RIMS tube, a 3-way valve, and various bits and pieces to hook it all up. I got it home and was all set to swap it in to the system, but was dismayed to realize in order remove the original RIMS, I’d first have to remove both the mash kettle and the boil kettle from the stand, because I needed to remove the platform to unbolt the RIMS. To remove the platform, I had to first remove almost all of the plumbing. The good news is that we only broke one thing, the threads on one of the pumps, when we were getting it all apart. It has two pumps mainly to avoid swapping hoses after the mash is complete. You don’t have too much else to do during the boil, so swapping a couple of hoses doesn’t bother me.

The threaded fittings are turning out to be a bigger weakness than I had originally realized – I already mentioned it’s very difficult to take apart, but it’s also touchy to put back together. You basically have to re-tape the threads on every connection each time you take it apart, otherwise it leaks. I also didn’t realize that sanitary food handling would have you disassemble and clean threaded fittings that contact the wort between every use! Oof! I’m going to look in to moving on with the tri-clover conversion; at least it’s easy to take apart and clean.

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Nest costs WHAT?

The Nest Learning Thermostat sounds neat, which is what I accidentally keep calling it when I forget its forgettable name. Even the nicer thermostats I use have room for improvement, but $250, excluding installation, smelled more than a little bit rich for a thermostat, even one that can “program itself around your life.”

I thought about building a thermostat that has many of the interesting features of the Nest, but I realize this would be an expensive and involved project. For example, the WiFly Shield to tie an Arduino in to my WiFi network costs $90 from Sparkfun. For the downstairs thermostat, I could use the $46 Ethernet Shield instead, but that’s approaching $50 just for network connectivity! I’m not the only one to try this. The easiest approaches I’ve seen don’t replace the existing thermostat, they just bypass it. Since I already have a digital thermostat instead of a simple mercury switch model, that approach wouldn’t work for me, and I’d have to interface with the 4-wire controls coming from my HVAC.

A lot more searching and reading leaves me with the same question as the folks over at tested.com: How is the Nest different? There are other smart, networked, programmable thermostats on the market at price points from around $100 for the Radio Thermostat, $300 for the Ecobee, and even more for solutions from traditional HVAC vendors, such as the Honeywell Prestige line that starts around $400. It seems like Nest isn’t a unique or new energy management system — it’s a networked thermostat with nice industrial design and slick software.

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Steampunk Homebrewery

Thanks to a DIY home-brewing engineer known as Sizz building a pretty cool electric all-grain brewing system and then deciding he wanted to play golf instead, our garage is now stuffed with a recirculating infusion mash system (RIMS)-based all-grain brew stand, a temperature controlled fermentation chamber, a kegerator with two taps, a nice grain mill, several carboys, and a cabinet full of related goodies.

The system works pretty well as is, but of course you knew this was coming, a couple of tweaks and a major equipment upgrade are in the works. The heaters for the RIMS unit and the boil kettle run off a 240v, 60 amp circuit, controlled by a BCS-460, three thermocouples, and a couple of PIDs. Two March brewing pumps, several valves, and a lot of silicon tubing move liquid through the system.

The biggest drawback to the system when I picked it up were the installation, orientation, and power connections for the two heating elements. The power terminals for the boil kettle were completely exposed, and the RIMS tube was installed vertically, with the terminals on the bottom. The RIMS terminals were covered by a silicon cap, but the many pieces of pipe and connector used to make the RIMS tube, even though sealed with some sort of resin on the thread joints, seeps water, which then drips down the tube, right past the power terminals, and on to the floor.

We’re covering the terminals on the boil kettle with a sleeve made from a silicon cupcake holder, connected to some plumbing pipe we added to as a hot wire conduit. The RIMS seeping we’re fixing with a major upgrade – we’re replacing the entire RIMS assembly with a stainless steel housing joined by Tri-Clover sanitary fittings. The tri-clamps will let us easily disassemble the entire RIMS for cleaning and inspection.

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Skype, Cause, Effect, and Overkill

My loathing of Skype’s new UI and horrible group conferencing performance at work has led me to implement a PBX at home. When I stop to think about it, it must be overkill, but once I got started, it was as if the momentum of geeky obsession just carried me along for the ride. The gateway drug was downloading ISOs of FreePBX, Asterisk, and SipXecs, and getting them running as conference bridges using software VOIP phones within minutes. “Hmm, ” I said, “pretty nice, but I don’t have time to really deploy this at work.” Obviously the solution was to implement it at home. So I can have teleconferences and page the kids in the playroom. Right?

It started with a couple VOIP phones on my computer for testing, but then I stumbled upon michigantelephone‘s blog, which had a lot of related information, and linked the rest of what I needed to picture what by that time I knew I was going to do. Before long, I’d set up a PBX, bought a pair of Obihai OBi110’s to act as gateways for our analog telephone line and our Ooma, added a Snom M9 VOIP DECT phone, and dropped the voicemail service and long distance fees from our local telephone bill.

Hooking the Ooma to a PBX gets around its inherent inflexibility by treating it as just another SIP provider. With the OBi110 also set up with our Google Voice numbers, we now have four directly-dialable telephone numbers that ring our house phones, all of which we can use simultaneously. Six phone numbers, if you count our mobiles. Of course, I could also put VOIP applications on our mobile phones.

Overkill? Maybe!

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