PMG

5/2011  Due to the extreme rise in rare earth prices, and a number of other large problems  beyond my control… I will not be selling PMGs in the future. This page and links are left here for reference only.

UTTERPOWER Mission Critical Alternator

American Quality Control

>>>SOLD OUT, units on back order!<<<<<

This 3kw continuous duty unit is $xxx.xx with the drive pulley, bushing, bolts, Quality Marine Grade. Five Years in the Field providing the only source of power at one full time family residence test site. See below for actual screen shots of this unit under load. (order info)

Utterpower 3KW PMG

Utterpower 3KW PMG

120/240 AC 60HZ 3KW Continuous Duty

Note the anodized cases, quality plated marine grade pulley and fittings, the connection box is heavy, has a seal, and the fasteners are stainless. This is NOT designed to compete in price alone! If you’re looking for cheap, keep looking..

Mission Critical, Highly Reliable AC Generator, unit can start large inductive loads, scroll down for technical info.

Solar Storms? http://eclipptv.com/viewVideo.php?video_id=9745 The PMG will survive! Small diesels have no electronics, they will survive as well.

This would be Mad Max’s choice for an off Gird Generator. See the results of our 10,000 hour ‘destructive test’ below. This alternator can handle everything the Lister CS can deliver and more. It’s done so for 10 straight 24 hour days in one test. Note the advanced patented cooling system, simply a must in a high power rare earth PMG.

It’s EMP proof! (see foot note) If the unthinkable happens the diesel powered PMG will have total immunity. Yes we have experienced an unthinkable event recently. Some of our Government Officials readily admit, “they don’t know what to do”. Some think they have allowed the barn to burn down and now they are all working on putting the Cow back in! What will they totally mismanage next? Maybe there is something to be said about the Boy Scout Motto? Many are awakening to the fact that you can’t count on the Government, those that demand to be taken care of may be very disappointed in the months, years to come.

The development of the PMG has everything to do with why conventional generators FAIL. I have spent years studying these failures, and I’m sure that some people would be dumbfounded to learn that some of the ‘so called’ advanced features found on their generators actually caused them to fail. Furthermore, the repair is often more expensive than buying the generator over again! I found this out with a Honda Construction Generator I once owned, and so have a lot of other people with a range of brands.

The Utterpower PMG

  • No Brushes.
  • No rectifiers.
  • No electronics.
  • Totally sealed to run in harsh environments, dust and grit, BUT with a (must have) patented cooling system.
  • Meets important ANSI standard C84.1 from no load to full load, and runs cool while doing it.
  • Potentially higher efficiency to assure that your ever higher fuel costs are lowest possible for a kilowatt hour of energy produced.
  • 3kw Continuous 120, 120/240, or 240 VAC (all selectable by you) 60hz AC model, this unit has started and ran two 17,000 BTU air conditioners at the same time!
  • Broad International Patents, and a team with the means and motivation to protect these patents.
  • North American Repair Facility

Overview:

I consider myself very fortunate to be in communication with people around the world who live off the grid, some are in the jungles of South America, some in harsh environments in Africa, and still others are living in climates where -20F is not considered all that cold. My friend Mamad in Iran has probably been to some of the harshest environments anyone could imagine where he made repairs to equipment he specializes in. Mamad for one knows what it takes for machines to survive in these hostile places, it’s often all about “SSR” Simple_Rugged_Reliable design (KISS engineering).

It just doesn’t seem to matter where the generator is or how it’s used, 99% of all reported failures of Generators (Alternators) occur in certain components. If the Generator has a voltage regulator, this is the device that often fails, and it is also reported as the most expensive item to replace. Fact is; some people report that buying another generator was cheaper than the estimated replacement or repair of their voltage regulator. Some are shocked to learn that it was the voltage regulator they paid extra for that damaged the field or other components by boosting the current as their generator ran out of fuel. Other items responsible for failures are rectifiers that supply the DC current to the field winding, brushes or brush holders, worn out slip rings, broken or damaged wiring associated with the brush rigging, and defects in the field winding on the rotor.

In the case of the Brushless Alternator designs, there are still components on the rotor that fail, diodes and capacitors are often used, and they fail. Some Brushless Alternators have an access door that will allow you to replace these components without taking the generator apart, in other generators; you’re in for some work, or you’ll pay a high labor charge to have someone else disassemble the machine and fix it. If you know Murphy as well as I do , these components ALWAYS fail when you need the generator most.

Prior to developing this unit, the only acceptable high power PMGs I could find were either Military pieces, or expensive aircraft alternators.

About 4 years ago, I placed an utterpower built 6/1_PMG listgen in an off gird location in the North Western Cascade Mountains in Washington State. This unit usually runs eight hours a day, seven days a week. The test site is rather perfect, fewer mechanical skills in the house hold and until last month the family had no idea they were running one of the more powerful 60HZ 120VAC PMGs I’ve ever seen. This family will readily admit that this 60hz generator set has not received the best of care, the family has learned what not to do, and all troubles have been related to the prime mover, zero troubles in PMG or drive.

Just to note, total harmonic distortion on this machine was measured at 3.6% or less and this 3KW (conservatively rated) unit has carried 4000 watts plus for some hours without over heating in the LAB and again in the field. That’s well beyond what most off grid families ever need, and there’s more surge capability left. One of the strong points of this design is it’s ability to start larger induction motors like those found in 1.5HP 240Volt well pumps. In a lot of locations, if you can’t start the pump, you haven’t found the right solution. In my opinion, there is a reason to utilize the AC generator for charging batteries, in many cases, it’s just too easy to select an Inverter with a built in battery charger and AC transfer switch, AND take advantage of the convenience. If you have a 48 volt battery bank, the PMG works great as a battery charger, simply run the prime mover at lower RPM, and feed the output into a quality high power rectifier and onto your batteries, this offers a great ‘back up’ should the built in charger in your inverter ever fail.

In 2007, the PMG was further refined, with units in the jungles and harsh saltwater marine environments.

So you ask… if they’re so good, why doesn’t Sears and Roebuck have them?

I think part of the answer is the EXTREME effort it involves to properly engineer a PMG for a specific use, unlike the Synchronous Generator; you can’t tweak the field current to make it right, you need design it exactly right and you find that the PMG is not exactly scalable. There are certainly more challenges beyond that, you don’t go to “HappyMagnets”, and stick any old thing to the rotor , each magnet is custom machined, then charged and >certified< to have the proper flux density; this is a time consuming process, but it is the only way you can get what we are after from no load to full load, and again, we can’t cheat by increasing the current in the field. We also need to note that the PMG rotor is currently far more expensive than a few turns of wire, and the other components used in the more common designs. Both the rotor and the cooling system are patented, this work came about after studying another effort that failed miserably as per voltage droop and other criteria, but that doesn’t stop people from marketing it!

Other problems with the PMG design involve air flow and properly cooling the Generator while keeping dust and dirt out that erode the protective coatings of the magnets and stator windings. The Utterpower design cools the rotor directly, but it’s a sealed unit, so no dust or dirt is blown thru the stator windings or past the magnets to contaminate the inside of the unit. Open framed PMGs can prematurely fail as we soon learn that there is a lot of ferrous materials in soils and in and around the typical operating environment of a generator set. We must remember just how strong these magnets are. The Utterpower PMG makes use of patented technology to keep the unit cool and to provide a superior voltage droop. Do not buy a PMG without knowing and understanding it’s voltage droop, research the ANSI standard and learn why it’s important to have a generator that can meet ANSI voltage droop specs like this one does!

There are several test sites where the Lister 6/1 and PMG are the source of power feeding (AC IN) to inverters that are known to be a little particular as to the Frequency and voltage of the generators, since this PMG makes a nice clean sine wave and the expected peak voltage, these finicky Inverters connect to the PMG when they reject other Generators, some of them have respected names.

The model 1003 120/240 60hz unit is a perfect match for the mighty 6/1, and it can make all the current that the massive flywheels can help deliver for starting heavy loads like well pumps.

One of the major advantages of the PMG is it can be sent via UPS, or FEDEX. This is a major savings over other generators all by itself, and as we know, the cost of fuel continues to increase the cost of truck shipping.

The voltage droop in the utterpower PMG will allow you to operate at 60hz and meet ANSI C84.1 from no load to full rated load, and if we look at the ANSI utilization chart, if your distribution system is short or heavy gauge; you can place a 48% overload on the PMG and still meet the standard in many cases.

Uganda PMG

Uganda PMG at Pilgrim Research

A veggie burning test site in Africa. 50HZ 220VAC Utterpower PMG. Note the exhaust system, there’s a condensate trap, and the exhaust exits away from the work site. That looks like a grain grinder to the right? Also notice the pre heater for the SVO fuel. Notice how clean they keep the platform. See other test sites below.

6/2010 Note Added…BEFORE YOU BUY AN ALTERNATOR, find out what you are buying!

We all know there’s stuff out there that is rated at what the alternator can do in the first few minutes, our 3KW can run all day in moderate ambient temperatures at much higher output. In our research, we found one alternator that literally started smoking and failed when it was ran at it’s advertised rating for two hours! Following is actual screen shots of a 3KW PMG on the Variable Frequency Drive Test Bench. We are plenty happy with the power analyzer we own, and I guess FLUKE liked it to, because they now own the company who made it…

Power Analyzer 4KW load

Power Analyzer 4KW load

4000 Watt (4KW) load, Utterpower PMG provides an excellent voltage even when it is operating well above it’s continuous rating. I would have put more load on the unit, but it wasn’t handy at the moment.

118.4 volts AC at 4000 watts, we can run all day here at lower ambient temperatures.

Power Analyzer 4KW load 118.4 Volts

Power Analyzer 4KW load 118.4 Volts

Power Analyzer Display 2.9 THD

Power Analyzer Display 2.9 THD

Notice how low the total harmonic distortion is with this 4000 watt load, 2.9 THD is not something you’ll likely see in an ST generator or many other generators.

Before you compare the Utterpower PMG with another alternator, find out what the other one promises, what kind of voltage does it put out at rated capacity? How long have their units been in service?

One of the first Utterpower PMGs was placed in an off grid year around house hold in our Northern Cascade Mountains. Due to the location in densely wooded terrain with a steep mountain slope to the south, there is little chance of using solar. Average run time is 8 hours a day, and now that we have suffered far cooler temperatures in this area, average run times are around 10 hours a day. This is year 5 for the PMG with no maintenance! during one customer visit, we did put the PMG on the test bench to measure voltages and THD under load, we could find no changes since new.  This unit is still running on the original drive belt!

There’s other things to think about when you buy an alternator for mission critical applications like storm or Hurricane duty. What kind of “hands on” knowledge and experience does the Dealer or Seller have? One I hear all the time is “The salesmen was a really nice guy”.

Here’s a Video sent in by DIYer Greg W. in Hawaii, unit is set up for 127 volts at 60hz  (no load), the little 3kw unit will do some serious work as shown..

Utterpower PMG  ‘Perpetual Motion Gizmo‘ read all about it here! (added 8/1/10)

Generator Reality

PMG Applications

DIYer’s PMG Generators

Combined Heat and Power Generation PMGs offer long term reliability

PMG specs

PMG wiring

PMG testing (it’s this simple to trouble shoot) NEW

PMG Q&A

New 186_PMG_GEN Prototype

Building your own frame for a PMG based generator <<< NEW

Assembly Line final (GO-NO GO Test) <<< Verify your wiring the easy way!

Field testing

Bench Testing <<<<< youtube video <<<<<<<<<<

PMG Repair

PMG Mounting Tips

Emails Generated by this page

Kiss Transfer Switch An Interlock is a smart option.

Economy PMG Generator

Automatic Voltage Regulation AVRs (What a DIYer need consider)

Marketing Hype an example of Mainstream Deception, we attempt to give you the facts here.

Understanding the technology Competition

HOME

Why bushed pulleys?  “I learned never to use anything else!”

Solar Storms? http://eclipptv.com/viewVideo.php?video_id=9745 The PMG will survive! Small diesels have no electronics, they will survive too!

EMP foot note: As of 4/2009, we now have Iran and North Korea who are nearing the capability of launching an EMP weapon. Do some Google searches, and you will realize that this Bomb has the potential to Kill Western Civilization as a first strike, and it doesn’t take all that much capability to build the weapon.  We also might note that no one in the world Community (at present) seems too interested in taking the EMP threat seriously.

All the best

George

Posted in PMG | Tagged , , , , | 2 Comments

A DIYers September Nightmare? Crossing the Canadian Border

Do you remember a day when you felt comfortable exercising your rights of free speech and freedom of religion? The following might be proof positive that those rights are slipping away here in the great ole  USA. While the FEDs refuse to control the southern border, here’s a story of how the border patrol treated two old white guys that spent their lives farming or ranching in the mid west. Maybe I tell this story so my Hispanic and Middle Eastern  friends might know that they are not the only ones detained at the border?  Mac is 73 this year, the other DIYer in this nightmare story  is 63.

Some of us know Mac from the bio-fuels forums, I had the honor of visiting Mac at his Western Montana home  eight or more years ago..  he lives on 10 beautiful cultivated acres fed by an artisan well.  The row crops are all fed from the well with no need to pump a drop of water.  Mac has solar PV, passive solar, the house is designed from the ground up to be efficient.  His hands on experience with SVO, and transesterified bio fuels puts him at the top of the heap in operating hours and experience. 

Mac’s word is as good as gold, a man you can trust with your wallet any day.  But Mac has a dark side maybe.. At least half the country might think so.. you see Mac believes in God, and he does like Ron Paul.

So without further delay, here’s a story of two old duffers who refuse to lay down their tools, they enjoy learning, and decided to meet with some of our like minded Canadian Cousins to discuss the construction details of a wood gasifier design that runs near white hot with low emissions.  I can assure you, Mac is no drug runner, he’s way too busy turning wrenches and learning how to squeeze that last BTU out of veggie oil, or  a piece of wood to cause anyone trouble, but it’s obvious he’s on someones shit list. The question is who’s list? Here’s his story…

 

American Citizens Forcibly Detained At US-Canada Border Crossing: No Reason Given  (September 2010) 

To Whom It May Concern:

This report is given relating the experiences of two American citizens being detained at a US-Canada border crossing, both on the way into Canada on 09/03/10 and in returning to the US on 09/06/10.  In any previous border crossing, neither American had ever been subjected to any delay or detention whatsoever, the latest being in 2007 by one of the two Americans.  The following report will be given in first person narrative.

09/02/10:

Never having been to Canada as far east as the Manitoba Province, we computer mapped the “best” route from SW Montana to Brandon, Manitoba.  The route took us east on I-90 to Steele, ND, then north on Hwy. 3.  We arrived at the border crossing near Dunseith, ND  about 9:30 AM.  All cars were being passed through with a cursory inspection conversation with the drivers by the Canadian Border Agents.  We pulled up and were starting the same process. 

One agent took our passports in to run through their computer reader.  We were asked if we had any fruits or vegetables, any guns, alcohol or tobacco, to which we replied “no”.  We wondered what could possibly be taking so long as with other travelers it was in and out.  After nearly 20 minutes and agent returned without our passports and told us we would have to pull over to the side for further search, obviously being triggered by some list when our passports were scanned.  The agent would not confirm this nor say if it was triggered from the US or Canadian side.  Later when we asked the purpose of this extra search, they said it was “strictly random”.  

They asked where we were going and what we would be doing when we got there, how long we planed to stay.  We explained to the agent that we were heading to Brandon, Manitoba for a training seminar on wood gasifiers, giving the name of the person we were going to see.  They asked where he lived to which we replied all we knew was Brandon, we were supposed to call upon arrival in the town.  We even showed two agents our wood gasifier book.

We were told to wait over to the side at a bench.  We were asked if we had any “valuables” in the car before they began their search. What we should have done was retrieve our computers, cameras and any other thing that contained personal information from the vehicle prior to their search, claiming these items were “valuables”.  By not protesting and claiming our rights at this point we might have by default given them permission.  Two agents completed a thorough search taking most bagged items out of the car, then returned inside.  After another 20 minutes of waiting outside, with being quite chilly in a blowing wind, we asked if we could come inside to wait.  The first time we were told we needed to wait outside.  This time we were allowed to come into the reception area where others were coming inside in a regular stream, primarily truck drivers for their load approvals.  It was obvious that there was a reception area inside with chairs that were for the public.  Once again, it was weird that they did not want us to come into the reception area initially.

The agents again went to search our vehicle, coming back with our computers, saying they needed to search the contents.  This was getting more bizarre by the moment.  They said they were in the process of making phone calls with “higher-ups” (obviously instructing them to invade our computers).   We questioned this, being told by one agent they had to make sure we did not have child pornography on our computers…weird!  When the next agent came through alone, we again asked him this question, to which he responded in case we were drug or gun runners, they had to look for customer lists on our computers.  By this time it was beginning to feel like we were in the twilight zone, about an hour and a half into this ordeal.  We asked if we were being “singled out” for some reason, to which they undoubtedly withheld the truth in saying, “No, this is just a random check”.  There was nothing random about our inspection.  Many more vehicles traveled through without a single one of them being subjected to our detainment and searches.  Maybe they have a special definition for the term random, but we know better.  It was an ordered detainment and search.

We asked the agents why we were being detained since we obviously had no contraband, were not child porn perverts and not running guns or drugs.  They absolutely would not answer our question, only saying they could not let us go through until they received a return call from higher up.  Finally, after 3 hours one agent came out and said they still had not received an authorization call to release us to continue into Canada, but they were going to go ahead and let us go on our way.  We could not even have tired of waiting and turned around to return to the US as they kept our computers until they finally released us.  That is a pretty effective method to “unofficially” detain a person by holding valuable personal property in a locked, obvious observation mirrored wall room.  

Knowing the customs agents were fishing for information with their questions, we returned the favor by asking them questions.  We told them we had seen on Internet news services that the US and Canadian govts. had secret watch lists on people in various groups like the Constitution Party, Ron Paul supporters, etc., we wondered what they had heard about these?  The agents were mystified.  The lady agent returned to the one-way mirror room for more phone calls.  A short time later she returned with pad and pen asking what were the names of those organizations and writing them down.  She then questioned us about the “Constitution Party” and Ron Paul, if either of us were members of those organizations.  She then asked if we knew anyone who did belong to them.  She then returned to her back room for more phone calls.  

As strange and evasive a behavior as this was by the Canadian Border Agents, it was nothing compared to what we would experience a few days later upon returning to the US in the treatment we received by US CBP agents, which is the reason for compiling  this report.  The above info has been given simply to set the stage for the far more egregious invasion of privacy and suspension of US Constitutional Rights we would receive at the hands of US CBP.

09/06/10:

When at our wood gasifier training class, we asked about the shortest route home since the computer map had shown the trip to be about 1060 miles, but we went nearly 1200 miles in getting there.  Our trainer, Greg said it would be much shorter to take a different route back, which he mapped out and printed for us. This would prove to be yet another cause of us coming under suspicion at the border crossing into the US, because we would be told by CBP it is not normal to come back a different route than we went in, so they had to check us out.  Our route took us through the border checkpoint nearest to Melita, Manitoba and Westhope, ND, which would take us across the NW corner of ND back into Montana, which did cut off 100 + miles from the trip.

We arrived at the US CBP (Customs & Border Patrol) checkpoint about 10:15 AM local time and would not be released from detainment until 2:45 PM, four and one half hours later without being given any explanation whatsoever as to why we were detained.  Following will be the detailed summary of the events of that four and one half hour detainment.

We pulled up to the checkpoint where we handed over our passports and advised the CBP inspection officer of our travel details and what we had purchased.  We were asked if we had any fruits or vegetables, guns, tobacco or liquor in the car.  We had only purchased a small quantity of food at a grocery store.  The officer told us what was illegal to bring back which reminded us of one onion in our cooler which we told him about and turned over to him.  While he was doing the overview inspection of our car, we could see the other agent was running our passports through the computer scanner machine.  The inspecting agent was through with his car inspection when the other agent called him inside after scanning our passports.  The inspecting agent returned, directing us to pull over to the side and come into the reception area as they needed to do a complete inspection of our vehicle.  We were asked if we had any “valuables” in the car before they began their search. Again, as at the crossing into Canada, we should have retrieved our computers, cameras and any other thing that contained personal information from the vehicle prior to their search. Though probably a mute point which would have been unquestionably ignored by the inspectors, we should have adamantly clamed these items were “valuables” to which they referred.

Once inside the building, we were immediately instructed to empty all our pockets contents onto the counter.  The officers said they could not take any chances that we might go berserk and pull weapons.  Being country folks, we each carried Leatherman type multi-tools, which of course have a pocket knife blade and were confiscated for the duration of the detainment.  They called both of these “weapons” along with a 2” Leatherman one of us carried in his pocket.   Every single item  in our pockets was inspected, including contents of pocket notebooks and billfolds.  All credit cards, business cards, membership cards, etc. were looked at.  The officer picked up the pocket US Constitution and asked what is this?  We advised it was to assure our Constitutional rights were observed if a situation arose.  He asked, “So do you have a lot of problems with that?”  No doubt, this was a fishing question on his part.  We responded, “No, never before now.”  It was readily apparent in this “no-man’s land” between the border checkstations that Constitutional rights were set aside and we were considered guilty until proven innocent.   

Amazingly, he commented that those rights do not apply between the Canadian and US checkpoint stations, that the US CBP can detain and search American citizens to any degree with no explanation as to why.  This description of authority of CBP was later restated by the supervising officer, Stuart Coleman, when we repeatedly asked why we were detained.  He would only say he did not have to tell us why and was under orders from above not to reveal the cause of our detainment.   Those higher-ups above Officer Coleman evidently went way above his next two levels of supervisors. Only after we specifically requesting and reminding the CBP officers, did Coleman later give us the names just prior to releasing us.  Ok, back to chronological order of events.

When emptying our pocket contents on the counter when we first went inside, we noted another car had pulled into the checkpoint inspection.  The driver came in to be told by one of the two CBP officers he would have to wait outside until they finished with us, evidently because they did not want anyone else in the reception room where we were being detained, “unofficially” at that point in the early going of the detainment.  One officer continuously monitored us while the other went into the back room to make phone calls.  The officer “guarding” us accompanied either when we needed to go outside to the restroom or 25 feet away from the building for a smoke by one of us.  We noticed the people in the car awaiting inspection were looking pretty fatigued and disgruntled after about an hour when going out for a restroom or smoke break.

While outside, we happened to look back up the road toward Canada seeing a line of cars and trucks.  Curious, we asked the “guard” officer why none of these vehicles were being allowed through to which he said they only had the two of them on duty and could not handle any other people coming through while dealing with us.  He then went and told the waiting drivers the checkpoint was closed.  We then really wondered, wow, what in the world kind of threat were we being viewed as, that they would close the border crossing checkpoint and keep it closed for four and one half hours because of us?  We watched incredulously as a considerable stream of vehicles turned around, being forced to go to border crossings 60 miles either to the east or west.  

After about an hour, supervisor Stuart Coleman showed up to manage the detainment investigation initiated by CBP Inspection Officers Ross Reimche and Todd Adducci.  To their credit, the duty officers had made every effort to be somewhat cordial and treat us like American citizens.  When Supervisor Coleman arrived it was somewhat different, being quite apparent he was very formal and all business in coming there to supervise our investigation.  He went in the back room and hardly came out during the course of the detainment.  He had Officer Reimche search our vehicle a third time.

Officer Reimche advised us they had a policy to allow detainees to make a phone call if held over two hours.  After that time had elapsed we questioned him about the call.  He went to the back room to ask Supervisor Coleman who refused to allow us to make a call, only replying that the investigation was ongoing.  We were told that we would be questioned by investigators, to which we said fine, we would be happy to answer direct questions.  During the entire duration of the detainment, we were never questioned on anything for which we were being held.  We asked Supervisor Coleman we were under arrest and if this was a criminal or civil matter, to which he replied neither, that it was just an investigation. 

This further confused our understanding of why we were being held.  Evidently, pending interrogation, they were going to keep us in separate rooms to prevent corroboration of stories between us and said we would already be in handcuffs if we were under arrest.  We commented there was no need to separate us because we are telling the truth with nothing to hide.  They decided to keep Officer Reimche continuously guarding us to monitor any conversation.  He was very friendly in attempting to be the “good cop” in engaging us in conversation that would encourage us to volunteer information.  Having nothing to hide, we were very forthright with him.  Later on, we heard his comment to someone that we had been very straightforward in talking with him.

After the first couple of hours, we saw a black Suburban type vehicle pull in.  Turns out it was two CBP enforcement officers who had been called in from a station 60 miles away.  They came in with a stern mannerism, not speaking one word to us, only speaking to the three inspection officers on site.  We figured these were the guys called in to interrogate us, considering we had been told we would be questioned, but that never happened.  They started a stream of additional car searches, each time bringing in another item to the backroom, from computers to cameras to notebooks  We were told that would not be allowed..  We could see out the window each time they returned to the car, which seemed to be about six times.

The CBP enforcement officers brought in my fellow American’s camera to take to the back room.  He saw them taking his digital camera into the back room and asked “where are you going with my camera and why?” We were told that they were going to be looking at the contents. He said “I want to be present when you look at my private stuff”.  He immediately told the guarding officer that he would like to be in the room with the officers when they looked at his camera.  The guard officer went and asked Supervisor Coleman, who told him no.  I, being a tad incensed, asked the officer to have Coleman come out and answer my companion’s question to his face.  My companion told Coleman that as a free born, Sovereign American under common law jurisdiction and he had a right to be present when his private property was being invaded, especially when no reason was given as to why.  Coleman simply said they could do what they want, refusing to answer what the reason was.

Not long after the two enforcement CBP officers arrived, an evidently plain clothes officer arrived in a white Suburban type vehicle that may have been a Cadillac Escalade, from the gold tailgate emblem, but this was not confirmed.  We asked who he was and were told he was an “off duty” border patrol officer.  This seemed strange that with 5 CBP officers already holding and investigating us, they would need a sixth regular duty officer to come in while off duty to assist those five officers.

 He went into the back with the other four officers sequestered in that room.  Officer Adducci came out and asked for my driver’s license.  I asked why and he said it had different information than the passport, but would not answer what different information, only replying they also needed to make sure the license matched up with the passport, which both had my identical homely photos.  No doubt, this was another non-answer in trying to think of something to justify asking for the driver’s license in addition to the passport. 

At one point we were getting pretty fed up with our treatment and wanted to talk to whoever is “in charge”. Coleman came out, admitted that he was in charge of this facility and, again, would not answer any of our questions as to why we were being detained … indicating that it was out of his hands … up to the unknown person on the other end of the phone calls.

We could see the eventual five CBP officers through the window into the back room, reviewing a stack of what apparently were fax pages they received from somewhere on us.  After about an hour, the plain clothes officer, Officer Dan Dahlstrom, departed without any comment whatsoever to us.

During the last half hour or so, the two enforcement officers, Officer Lakefield and Officer Gangey, stayed out front in the reception area with us and the one officer who had been guarding us the entire time.  They were pretty mum, so we engaged them in conversation.  Apparently after seeing we were just a couple of plain old country-boy Americans, they started talking with us about hunting and generally shooting the bull.  They did not bother asking us a single question pertinent to the investigation.  We were getting pretty frustrated and asked if they were going to “question” us so we could finally get down the road. We were informed that no one at this facility was going to question us but the person on the other end of the phone conversation “had questions”. One of us said “put him on the phone … I will answer his questions”.  The response was “we cannot do that”.

Finally, after well over four hours, Supervisor Coleman and Officer Adducci came out of the back room.  Coleman said we were now free to go, to which we responded, “not quite yet, we need some answers as to why we have been detained.” Coleman smugly said he was not allowed to tell us why we had been detained and did not have to tell us why.  We understood that someone high up had forbade him from revealing any facts to us.  Early on, we asked about the obvious fax sheets being read behind the window and were advised that no, we could not see them and that they would be shredded for our “privacy protection” at the end of the investigation.  We advised Supervisor Coleman that we were going to do everything possible to get to the bottom of this, including a Freedom of Information Act request.  My fellow American advised Coleman that we wanted those records maintained in a file there to be available as we now conduct our investigation of them through FOIA and members of Congress.  It was apparent that none of these agents had any fear of consequences of their actions.  It was as if, in their minds, they were “untouchably above Constitutional law”.

My fellow American laid his pocket recorder on the counter while Coleman was refusing to tell us why we were detained and the remainder of the above conversation.  This way they would have no doubt the conversation was being recorded as Coleman asked if it was a recorder and my fellow American said it sure is!  On more than one occasion the agents were informed that we were “Free Born Soverign Americans under common law jurisdiction”. When one of us told Coleman this and asked if he understood what we were saying, with an expressionless, unphased persona, he acknowledged that he did understand what we were saying (and obviously did not care by his expression). 

We could not count the number of phone calls during our detainment.  Of course, we have no idea of how high up the phone calls were going.  After we asked, supervisor Coleman only gave us a sheet of paper with his next two level bosses:                          1) Brent Beeter, Port Director – Portal  phone: 701-926-4221                                                                                                         2) Thomas Jorgensen, Area Port Director – Dunseith  phone: 701-263-4460                                                                                and Coleman’s info:                                                                                                                                                                                  3) Stuart Coleman, Port Director – Westhope  phone: 701-245-6194

On 09/09/10, we queried a thirty year law enforcement veteran and were told that the probability of two extensive border searches we encountered on the same trip, out and back, being completely random is beyond reason.

We do not know if the detainment was intended as intimidation or it really takes four and one half hours in the modern computer age of instant communication to determine that they had no need to hold us, finally sending us on our way.  We really have no personal dispute with all the officers involved.  They conducted themselves in a professional manner in our personal treatment, with no personal abuse inflicted beyond insulting our intelligence with never telling us the truth in their egregious trampling of our Constitutional rights in their handling of our investigation.  Their evasiveness in avoiding our oft repeated question of why we were being held was obvious proof that they were not the source of our detainment and only following orders from somewhere above them.  It is pretty conclusive that the source also went on up above Coleman’s superiors, Beeter and Jorgensen. 

We can only hope that through the FOIA and help of Congressmen, we can discover who issued the order to detain us and why? Maybe our efforts to expose the source of such tyranny toward free born, Sovereign Constitutional Americans, will help other Americans to avoid such unconstitutional disregard of rights.  We will keep asking the question until we get an answer, “How can we be detained under investigation and never be told why or by whom?”

Evidently, this was a taste of “friendly” martial law.  I call it friendly as the officers involved remained friendly and never threatening, while denying our rights, even disregarding their self-professed rule of allowing a phone call after two hours detainment, which they failed to do.  As despicable as racial profiling is, that was not even involved with two old, 63 and 73 year old Caucasian males.  Therefore, the rumors about govt. patriot “hit” lists of people to watch certainly gained a high degree of credibility.  As much as we were engaged by the officers in “fishing-for-info” conversation, we were likewise engaged in the same process with them. 

Neither of us have ever experienced being so violated as all our personal property was  ransacked, even after proving we had no illegal contraband, not to mention the helpless feeling of being held against your will without being told why.  It is a stretch to compare the mental trauma, but our experience equated in our minds, to a small percentage of the feeling of a lady being raped, with what we experienced at the Canadian customs checkpoint on 09/02/10 and gang-raped at the US customs checkpoint of 09/06/10.

Enough actions and words were expressed to remove any doubt from our minds that we must be on some kind of irritant list much higher up from these officers who chose to errantly honor their duty to their bosses far beyond and forgetting their oath of office to defend the US Constitution and rights guaranteed thereunder to American citizens.  These six officers repeatedly exhibited a blatant disregard for the Constitutional Oath of Office in their fear of maintaining their jobs if they did not follow orders.   It is a sad day in realizing that this is probably the case with the majority of law enforcement officers in disregarding their Constitutional Oath of Office if it puts them in fear of losing their jobs.

We do not look to these eight officers involved, six on site and two via phone at a distance as being accountable for our unconstitutional detainment.  That blame obviously lies above them.  We do not even have any ill feelings against any of the eight.  We are highly disappointed in how they sorely dishonored their names in the sight of God, us and their own consciousness in their wanton disregard for their Constitutional Oath of Office in our detainment, even breaking their own stated rules in the process.  We bless them that they and us may all receive the full measure of God’s law of consequences in the final resolution of this matter.  Being old enough to be the dad or granddad of these CBP officers in some cases, we can only imagine the embarrassment their actions would cause to their parents and grandparents who are good, Constitutional Americans being from North Dakota, were those good folks aware of this.

09/09/10:

This is the day this narrative report of events is being written.  After finally leaving Westhope CBP checkpoint the afternoon of 09/06/10, we drove all night arriving home about 7:00 AM on 09/07/10.  We recuperated that night, meeting with a computer expert the next day, 09/08/10.  He holds a PhD in electronics and is pretty much a computer genius.  He took my computer, saying he had analytical programs and equipment to determine everything that had been done on my computer by the US CBP agents.

Interestingly, he found that the downloads file on the computer had been wiped clean.  Obviously, nobody’s computer download  file would be empty, unless brand new, unused.  He has done considerable investigative work of this nature, saying there would be only one reason to wipe the downloads file clean.  That would be to cover their tracks for something they would have downloaded.  If they did, he said they were good because he was not able to locate what it was in his first three hours of investigation.  Coleman was specifically asked if anything from our computers had been downloaded or copied. He stated “no”. “We are only authorized to look … not copy”.  The truthfulness of his statement could come under some serious scrutiny from our follow-up investigation of him in regard to the computers.

Our computer investigative expert did find this: C:\Documents and Settings\JPF\Recent\Removable Disk (E).lnk 179 bytes.  He said this is where they inserted a disc to copy all the over two dozen files of personal information they copied from the computer.  If we, as “formerly free” Americans, think we have any legal privacy rights, this ought to be an eye opener as to how those rights are long gone, evidently under guise of the patriot act.

I do thank God for this experience to now know where we Americans stand in our “former” Constitutional rights.  I have never even been accused of a crime, much less tried nor convicted, beyond a traffic ticket, yet some unknown watch list has me and who knows how many other loyal Americans targeted.  We abhor any type of hate and “anti” type groups.  In fact, since we feel the American way of life is now in danger of economic and or political collapse, we are concerned enough to try to help people learn to be more self-reliant to be ready to help in the event of catastrophe.  The CBP agents surely learned this upon review of my computer files.  We will have no part in any demise of any system, but will be there to give service to help in recovery. 

We honorably adhere to our personal oath to defend alland aggress none!  Our hope is that someday all will have the ideal of the Golden Rule finally sink into our noggins’ and simply live it.  This is why we have no ill will toward the eight CBP officers involved in our unconstitutional detainment.  There is no doubt that some day in their future God will manifest these many event details in such a manner that they will be far more disappointed in themselves than we are in their choice of allegiance to their jobs rather than their Constitutional Oath.  Though they dishonored their Oath, they are not the perpetrators of this unconstitutional tyranny.  The latter are the ones that should be ferreted out and called to justice if we are to have any hope in preserving the principles this nation was founded upon.

We had two choices after this experience.  We could cower in intimidation or be courageous in publicly telling our story as far and wide as possible in service to our fellow Americans.  There was no doubt, our choice is courage due to our personal oath of “defend all and aggress none”!

During this sequence of events the thought occurred to us that this is a small glimpse of what it must have been like in Nazi Germany when you were stopped at a “check point” and asked, “your papers please”.  Wake up America … you might be next!

Our request in behalf of the civil rights of all Americans is that any Congressional member or media personality who truly honors their Pledge of Allegiance and or Oath of Office will assist us in discovering why we were targeted in this unconstitutional denial of rights and unexplained detainment. 

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If Mac says this is what happened, I’d bet my last nickel it did.

George B.  


Posted in Your Wasted Tax Dollars | Tagged , , | 11 Comments

Direct Drive VS Serpentine Belt Drive in Small Power Applications

pmg-hingeplate-mount

Here’s a question I was recently asked:  “George if a engine is directly coupled to a generator head is it easier on the motor power wise?
Darryl”

I do scratch my head when I see the use of the term ‘motor’ VS engine, but when I see the use of engine and motor in the same sentence, I almost want to ask for clarity.  There is reason to frame the question further, but let’s march on.

Direct drive forces you to operate the >engine< at synchronous speed. (generator speed). This means you are forced to do the work with a fixed number of power strokes per minute regardless of your average loads IF you are interested in running near target frequency, which might be 60hz for an example.

With direct drive you have no opportunity to tune your machine for the best Fuel/Kwh conversion. We also know that some of these prime movers will live twice as long if we move the RPMs from 3600 to 3000 for instance.  I remember a study of one popular British Leyland Auto engine years ago.  Lowering the shift points to 300 RPM below the factory red-line doubled the miles driven between rebuilds VS using red-line as the shift point on the race course.

People look at any drive system outside of direct drive as a loss, but seldom do you see them investigate how little loss there is in some drive systems.  You will  see a lot of interest in 900 rpm generators that might be direct driven off a slow speed prime mover, and you wonder how much effort has been put into evaluating the advantage?  At the end of the day… the Engineer realizes he is now either buying or building a very specialized generator head that will be very costly to produce an/or repair because of the limited market in both supply and demand.

Using a low loss drive and making RPM adjustments to the prime mover can make all the difference in fuel economy, and it allows you to operate with more common and less expensive equipment, this is at the heart of KISS design.

At the end of the day; the longer term cost of making a KWH of electrical energy is the measure and the comparison you should make.  A lightly loaded diesel generator does not produce the better fuel/KWH figures, if you change the ratio and load each power stroke a little more, there is an oppurtunity to produce a better Fuel/KWH figure while running your average daily loads.  In addition, a low loss drive gives you options in the field, you can quickly remove the drive and look for the source of noise, replace the engine or generator head with a spare and be back working in short order. You can also perform much more of the work operation with gloves on, which can be nice if you are in cold country.

It’s not so easy with quill shaft (single bearing generators) which are the majority in small generator power.  As for other direct drive units, we need be careful to note how alignment was attained and note any shims unless we will perform a new alignment.  These things get overlooked in the bush when getting back on line quickly is the focus.  An example is a small hospital in Africa, or a family living off gird anywhere with temperatures well below zero F.  Another thing to note, when we drive generator heads like the ST 4 pole at our North American speeds, we are at the rotational limits for this design. Since the rotor has a lot of mass and diameter, we need be careful how we couple it.

I have noted a few backyard engineers post that they designed a direct drive coupling that wouldn’t break. With such a coupler, if you were to parallel grid power and your generator power (in error) close to 180 degrees out of phase, it would look like a train wreck.  IT >could< literally strip the bobbins off your generator’s rotor or break the crankshaft in the engine.  A lot of the better direct drive couplers have a rubber  spider or similiar to absorb some of this hammer like blow from the power stroke, and others have a roll pin or link that will fail when that ‘train wreck’ happens.  A properly designed coupler should act as the fusible link, it is far easier to replace the coupler than a rotor or crank shaft.

There may be another thing to consider, diesels are more efficient than most other prime movers, BUT they produce a lot of torque during their power stroke and it looks less friendly to some loads than gasoline engines produce. The Serp drive can mitigate the train wreck, and may help somewhat with the peak power stroke.  Let me give you an example.. there are some really nice diesel powered aircraft, picture a V8 four valve turbo charged diesel stuffed in a Cessna. Ron Pointer (a pilot serving mission work) has flown such an aircraft and was really impressed with performance, especially the ability to take a good load off a short jungle run way in the Congo for instance.  Of course the higher your climb rate, the less likely you are to be shot at.  Ron tells me of all the problems they have keeping quality petrol fuel in stock. The diesel power in Africa would be wonderful asset BUT it requires the use of a composite prop.  The metal props are best suited for Africa and it’s many primitive dirt and sand run ways eat composites quickly!  Since metal props are not certified to be compatible with these violent diesel power strokes,  there were no diesel powered air craft in African mission use at the time of this writing.  The fear is that the metal prop will work harden prematurely and cause a violent failure in the air, (According to Ron’s research).

Some people are able to quantify the pros and cons of direct drive VS a low loss belt drive while out for a walk.  I might take a stab at it after a long walk… maybe all the way around Australia? At this time, I see advantages to the low loss belt drives for the third world and serious “off grid >SMALL< power plants”.  One of the first lessons to learn is the serious error we make in buying or building a power plant too big,  you lock yourself into a poor fuel/KWH figure IF you can’t load the generator to 80% or better. A drive system that can be tuned to match your average load and find that sweet spot in RPM and number of power pulses required could be key in gettign far superior fuel economy over the direct drive configuration.

Other studies worth your time is the continued use of motorcycle chains over shaft driven bikes in performance motorcycles. The chain is a far more efficient drive, an no one wants the extra losses of  shaft and ring a pinion in a all out performance bike.  It’s more expensive and heavier.  The Serp drive is right in there with the chain as per efficiency without all the problems.  Of course those big ole power strokes might help stretch a chain, and there are plenty of maintenance issues with chains.

Opinions vary, but at the end of my walk, I think the Serpentine drive has a lot to offer us off griders and serious back up power folks. Direct drive does not offer the flexibility or ease of replacement or repair.  Opinions will vary…  some will want to deploy a more expensive, hard to find,  less flexible drive, we who believe in KISS would ask why?

Here’s an email I received 11/18/2010

George-

Question:

Do you know if anybody ever used a cog drive (ie, Gilmer belt) to couple a Lister to a ST head?  Just trying to think outside the box.  Seem to recall that cog drive is more efficient than plain old belt like serpentine? Thanks, Al

Answer:

“Plain old belt like serpentine?”

Wait a minute! “Plain and old?” Is that a bad thing?

Al, Part of KISS is designing around most available, inexpensive and proven  components that do the Job well.

I remember a hard drinking union laborer who bought an Industrial Serpentine Drive Pulley and belt at twice the price of our stuff BECAUSE he thought it would be better 🙂 All he did in our opinion is make it far harder to source parts when he needed them and pay double.

But in your case, seems you want to buy two cogs and two bushings instead of one pulley and one bushing?

There’s also the issue of carrying a higher radial load further out on the Lister shaft. In the case of the incredibly inexpensive and available  automotive serpentine belt which makes use of the outer diameter of the flywheel to drive off of, we place such a small radial load on the crankshaft bearing that it is likely difficult to calculate a lower MTBF (of the bearing) than the no load running. Part of the advantage is placing the load right next to the bearing on the inside of the flywheel rim. With the cog, we need fit out on the shaft past the Gib key head, and we create a need to transfer torque VS higher feet per second of belt travel WHICH the Serpentine design does well.

To try and answer your question more completely, yes…the cogged belt had been used, it will work, but I doubt anyone will beat the performance VS cost of the serpentine drive in the application you describe. One customer finally changed his $28 Serp belt after 16,000 hours plus of documented running. He didn’t change it for any reason other than scheduled maintenance and wanting to be ready of a predicted cold winter at his off grid residence.

As for efficiency…. I doubt you’ll measure that.

George B.

All the best,

George B.

Posted in Generator Realities | Tagged , , , , | 4 Comments

New Videos on the way, Here’s the Pumphouse in HD

Finally, I figgured out how to make a higher resoultion video with my camera and editing software.. expect better videos from us.

This is in 720 HD, and it’s a short video of the Easton Pump house, the generator’s principle job is to charge the water tank or run the deep well pump in irrigation mode, the water line to the cabin is nearly 600 feet long, there are also buried power runs that allow this generator to feed the Power House, Cabin, combination storage, and shower house. There’s a second Lister/PMG set that can power these sites as well through interlocks.

OH.. the whistling…I will learn not to do that!

Look forward to daily additions, and think about using that RSS link.

George B.

Posted in Off Grid Power | Tagged , , , | 5 Comments

Total Power: Why You Need to Consider Your Independence Today

Is it time to sell that property down South and move to a more temperate climate BEFORE it’s too late?

Many of us live in areas and in dwellings that take a lot of energy to live with any comfort, and in some cases the home itself depends on energy to stay healthy. Without energy, some structures will literally decay and soon become inhabitable.  Some of us use $70 or more a month to power active septic systems where soils left us no choice but an expensive and ‘active septic  system’.  Who will be able to afford to run such a home if CAP and Trade passes? If less people can afford your real estate property, then the value will fall.  If we study human nature, we might anticipate that renters and homeowners alike might ‘power down’ these active septic systems in order to make their house payments.  This could cause the ground water to be contaminated and cause a SERIOUS health epidemic.  If you live in such an area, and your home value has dropped in the last few years, imagine what might happen when there’s articles in the  paper that the aquifer you rely on for drinking water has been contaminated, and the sources too numerous to trace.  Sell now while you still can, and move to a more temperate climate with better soils? Move to a place where  you need less energy to live with reasonable comfort?  Maybe you should read on and revisit the energy plan for America?  What a minute…. what plan ???

We live in a time when people no longer read more than a paragraph, even the Senate has no time to read the bills they pass, and you know this is no joke!  If you’ve read this far, you are the minority,  but what you are about to read is true and frightening.  It’s about people who have no clue as per cause and effect, but yet they think they have the answers to all of man’s problems. How niave they are…    

Ten years from now, we’ll all understand that this conversation was all about the fork in the road.  We need to allow proven economic benifit to guide us in green investments.  Many of these investments I have studied don’t hold up under the scrutiny of basic physics yet alone an economic benefit to the country.  Too inept to do the basic math, but still they endorse insane ideas.  Some even give them awards!  See my article on the Indian air powered car, and the hydrovolt.  I believe these articles that promote irrational and unworkable ideas  blur the line between reality and the impossible and makes it more likely that an 18 year old, or totally inept, lazy person….. (like many of our Congressmen) who won’t or can’t do the simple math would vote for funding the impossible.  

Following is wisdom from one man who has risen to the top of his game in the field of energy.  His company has wisely navigated through a mine field of false promises, a field of uncertainty  a nightmare of regulatory insanity.  

The motives behind the legislation?  CEO Gary Smith of Powersouth shares his wisdom on the Cap and Trade issue, his words follow.

Those of you that follow my columns know that I have offered my opinions on global warming, climate change and green jobs a number of times on these pages. This month, I offer statements and opinions of others on the subject.

Most of you would expect me to quote Dr. John Christie, Dr. Richard Lindzen or other deniers to the warming of the earth or the harm of any climate change brought on by the anthropogenic emission of carbon dioxide.

This month, I offer you something different — the statements, opinions and predictions of those who strongly support of the concept of reducing carbon dioxide emissions.

“I believe we must pass Cap and Trade because we see it as a source of revenue.” U.S. Speaker of the U.S. House of Representatives, Nancy Pelosi (San Francisco Chronicle, January 22, 2009)

“Cap and Trade is the significant revenue generating proposal of our time.” Maryland Democratic U.S. Senator Benjamin Cardin (Washington Post, April 3, 2009) “Nobody in this country realizes that Cap and Trade is a tax, and it is a great big one.”

Michigan Democratic U.S. Congressman John Dingel (Politico Magazine, April 27, 2009) “Whether you call it a tax or not, everyone agrees that Cap and Trade is going to increase the cost to the consumer.”

New York Democratic U.S. Congressman Charles Rangel (Roll Call, May 2009) “The greatest political task of our time is not raising the living standards of the poorest, but rather narrowing the rich-poor gap.”

Rupert Read, Head of United Kingdom’s Green Party (Rupert Read’s Thoughts of the Day, October 15, 2009) “The prosperous lifestyles of the people in the West simply must be curtailed. Radical taxes must be imposed and automobile use must be curbed by the state or some other authority.”

Rajendra Pachauri, President of U.N. Intergovernmental Panel on Climate Change (The Observer, November 29, 2009). “We must get to a system where an electric company will be able to hold back some of the power so that maybe your air conditioner won’t operate at its peak. You’ll still be able to cool your house, but it will be a savings to the consumer.”

U.S. Energy and Climate Czar, Carol Browner (US News & World Report, March 9, 2009) “We have to figure out how to boost the cost of gasoline to the levels in Europe.”

U.S. Secretary of Energy, Steven Chu (Wall Street Journal, December 12, 2008) (At the time of this quote, the price of gasoline in Europe was an average equivalent of $8 per gallon and in places an equivalent of $11 per gallon.) “We can’t drive our SUVs and eat as much as we want and keep our homes at 72 degrees at all times…and then just expect that other countries are going to say OK. That’s not leadership. That’s not going to happen.”

President Barack Obama (AFP, May 16, 2008) “Under my plan for a Cap and Trade System, electricity rates would necessarily skyrocket, so if somebody wants to build a coal plant they can — it is just that it will bankrupt them because they are going to be charged a huge sum for all that greenhouse gas that’s being emitted. Regardless of what I say about whether coal is good or bad, because I am capping greenhouse gases, coal power plants, you know, natural gas plants, you name it, whatever the plant is, whatever the industry is, they would have to retrofit their operations. This will raise billions of dollars.” President Barack Obama (San Francisco Chronicle, January 8, 2008)

Of course, the predictions of a collapse of the U. S. economy by some economists are sobering, as are the predictions by climate scientists that reduction in anthropogenic carbon dioxide emissions will have no effect on global temperatures or the climate. However, the plans and predictions of those that I have quoted above — and others I have not — on what the world will look like after they get through with their climate change Cap and Trade programs is more sobering.

These leaders don’t predict a good future for you if you like to drive SUVs or trucks, keep your house comfortable, use electricity when you like, afford gasoline, eat as much as you want or just enjoy your present lifestyle. I told Gus Mayer — my dog who appeared in an earlier article about climate change — about these predictions and he was still worried about eating all the red meat he can get. He is still concerned red meat will be outlawed and he will go hungry. Maybe we should all be as concerned about our next meal and our future as Gus Mayer.

Beginning January 1, 2011, as part of the health care reform bill, over-the counter (OTC) medicine will no longer be an eligible item for reimbursement as part of a Health care Flexible Spending Account, Health Reimbursement Arrangement and Health Savings Account unless otherwise prescribed by a provider. Therefore, any OTC drug expenses incurred on or after January 1, 2011, will require a doctor’s prescription in order to be reimbursed. Items such as cough, cold and flu medicines, pain relievers and acid relief medication will now require a doctor’s prescription to be submitted along with the reimbursement request. The debit card will reject these types of items at the time of purchase. Other OTC items, such as diabetic supplies, elastic bandages and wraps, band-aids and reading glasses will continue to be eligible without a prescription and can be purchased with validation through an inventory point of sale approval system (IIAS) using the debit card. This change is effective for all groups on January 1, 2011, regardless of the plan year. Expenses incurred prior to that date are still eligible for reimbursement without a prescription. OTC medicine

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Heres’ what I suggest you do…. Bank on the fact that your living standard will plunge like a anvil tossed off a bridge IF Cap and Trade passes in >any< form.  The plan will be to pass it without detail and fill in the plan as they need to silence the opposition. .  Pelosi and her friends will do whatever necessary to stay in power, legalize the sale of dope in California? Pass a law allowing the 14 year old vote?  No problem, they know all they need do is promise a shorter school day and a free ipod to our voting children, and unfortunately a lot of adults too.

There’s two classes growing numbers, those who will sell any plan in order to stay in power, and those who would buy any plan if there’s a promise of a free lunch in it for them.  We were told this day would come…. well it’s here. Be prepared, you might want to move to higher ground.  The extreme left will not rest until energy is so expensive you can’t afford it.  They have no clue as to how it will impact all of us as they have no time to study the details, our elected officials focus  on being re-elected, not on building a better and stronger America. Term limits might help if we (collectively)  were wise enough to put them in place and put an end to the career politician.     

George B.

Posted in The New Green Movement | Tagged , | 2 Comments

Your New Small Diesel Won't Start?

There are few things more simple that a diesel engine, but if you start out buy cialis daily online on the wrong foot you may quickly grow intimidated by diesel power.

Nothing is simpler, and few things are more efficient, reliable, or live longer.  You need clean dry fuel, decent compression, and the engine should run.  There are a few simple things people trip over all the time and it shakes their confidence.  The following is not a complete guide by any means, but these are typical things people new to diesels trip over.

What generally happens is they lose focus of the simplicity and they widen their search for the cause and become even more frustrated, this is exactly the wrong approach. Stay focused on the basics, that’s all there is on a diesel.

First things first. I have seen a lot of engines come right out of the box with a frozen fuel rack. On some engines, this is easy to spot because the linkage is external, and you can disconnect the linkage and then grab hold of the rack itself and prove it is free or frozen.  An example of this type engine would be the Lister 6/1 and clones.  A typical example of other engines where it is not so obvious there’s a problem is the Yanmar air cooled clones, most Chinese horizontals, in fact the majority of small diesels often have the connections between the governor and fuel rack inside the engine case out of the elements. If you look carefully, there’s often a little door you can remove and watch the linkage. In other cases, you might need to remove the injection pump, but you will know there is often a slot and a ball that need be aligned when the pump is reassembled. In a number of the Chinese horizontals, there’s a bolt in the side cover that can be removed and you can push on the linkage to prove it’s free.

Removing all the tension from the governor adjustment is typically the thing to do before you remove the pump.

Once you decide the rack is frozen, understand that applying a lot of pressure to the rack itself could break something. It is best that you understand how the basic helix plunger works, and how a frozen plunger will prevent the fuel rack from moving. It is not wise to try and free the rack, it is your goal to free the plunger which is keeping the rack from moving.

I don’t know all the reasons plungers stick in brand new engines, but I do know that the fuel can not be left in the engine when it is shipped, and fuel displaces air which might allow minute amounts of oxidation and cause the plunger to stick.  This is a high percision part…. simple yes, but highly precision and close tolerances just the same.  The trick is to understand which way the plunger travels, try and get some of your favorite penetrate like WD40 into the plunger and barrel. then with the delivery valve removed, and loose parts off.. look for a piece of hard wood to lay on top of an anvil or other dead surface. bring down the pump body hard on this surface and let the kinetic energy free the plunger.  In the most stubborn cases, drop the pump in a small can of diesel fuel overnight. Heating the pump up to about 150F might help too, but usually two or three serious smacks onto the hardwood will free the plunger. once you get the rack to move even .001″, you work it back and forth and keep applying  penetrate.  Once free, you’ll likely never see this problem again as long as you keep clean and dry fuel in the pump.

Again.. frozen pumps are over looked by people new to small diesels and it can cause a LOT of frustration. I know one person who literally burned out a starter trying to start a small diesel that had a frozen plunger in the injection pump.   Once you understand just how basic the system is and what to look for first, and how similar all small diesels are, your confidence will grow.  Spend your time understanding how something  works instead of trying different things to make it work.

If you have a manual start engine you can hear the very distinct ‘clink’ as the injector pops off and sprays fuel into the combustion chamber. If you don’t hear this, there is room to suspect a fuel problem.

Fuel problems in brand new engines with brand new owners are often traced to the improper bleeding of air from the fuel system.  This is a frustration for the beginner , but easily understood if you put a little effort into studying the system. you start by assuring that the air vent to your fuel tank is open, next you go to the outlet side of the fuel filter, or on the top of same you’ll finds a vent, open it and let the air escape from the lines and filter, next, move onto the injection pump and remove the high pressure line that goes to the injector. Under this fitting is another nut that holds the fuel delivery valve, remove it and watch for a spring on top. make sure the decompressor is on, turn the engine flywheel slowly until fuel gushes from the top, put the fuel delivery valve back in place. Yes rags are nice to place and making sure all parts are clean before you disassemble anything it important.

Now it’s onto the high pressure side, replace the high pressure line on the injection pump, making sure you understand that you need not use two hands! Many HP lines are ruined by over tightening, it need be tight enough not to leak, too tight cracks the metal, and the line leaks until replaced.

With the injector end loose, and the throttle open, check that that the decompressor is still on, and turn the engine over until you see fuel  coming out the injector end of the high pressure line. Now keep turning over the engine, and slowly tighten the HP line at the injector. You should hear a very distinct ‘clink’ sound.

Another problem for the new owner and some not so new owner is to try and fire the engine and not get any ignition at all. After studying the problem, you determine it’s cranking a little too easy. Take off the air intake and the exhaust of you can, put an ear to either side and listen for the “hiss” as the piston comes up. A common problem is a piece of carbon lodged between the valve and valve seat. This is a common problem see in the Lister 6/1, and of course it can be seen more often in engines running a percentage of waste or poorer quality fuels. Simply put the engine on top dead center and tapp on top of the rocker arm directly over the valve stem. Every time I’ve been faced with is problem, I’ve had the engine running with a few taps.  I try and find a piece of clean wood, but on one occasion it was a clean field rock that fit in my hand nicely.

I have a CD that has a PDF file on it that shows the typical pumps and how to take them apart and put them back together again. there are small parts in here, and a wise person will lay out an old sheet or similiar to work on. Remember, when you take a pump apart, you need work as if you were in a clean room.

All the best,

George B.

Posted in Small Diesels | Tagged , , , , | 2 Comments

PMG Frame Building Secrets

Building frames is something that evolves, it’s a combination of looking at other people’s designs and making changes to suit your needs. For the DIYer with limited tools, it’s always wise to look at early equipment as they spent a lot of time to KISS it.  A lot of this stuff was developed to be made simple, with fewest parts and common tools and materials.

I was talking to friend SW Lee in Malaysia, he’s a Businessman for a multinational company, but he worked at his Father’s side first to learn a lot about stationary power plants big and small. He also worked in a store that sold stationary engines and engine parts when he was attending College.  One day we were discussing a trick his Father had taught him about setting up a direct drive generator.  His Father constructed the frame where the generator mount was wedged in and could be knocked around with a large hammer until all was perfectly in alignment.  The shoulder bolts that held the generator to the mount were designed to fit snugly in the mounting holes.

Once all was in perfect alignment Lee’s Father would weld in the mount.  What he created was a generator where the gen head or engine side could be removed and then replaced without the worry of losing shims or the need to do a realignment.  All that one needed to do is use a shoulder bolt and a proper sized hole for both the engine mount and the generator mount to keep all in alignment.  This is an example of what you learn by doing, and you learn quickly to consult the man who has touched the work versus those who have never got closer than a CAD drawing. If you look back at my earliest pages, you will see my efforts to shim in aligments on direct drives.  I had to pay special attention to the shims, and put a straight edge across the coupler to verify all was ready to run if I took things apart.

SW Lee and his Father

SW Lee left, A Master of KISS right, "Lee's Father"

In our case, we are designing for the Do it Yourself-er who may not have an abundance of tools or building materials, in this example, we make use of a welder as they are everywhere, and most people have a friend who owns one.  If that’s not the case, it’s fairly easy to bolt a frame together, so just change your design a little.

I can’t tell you how many times I’ve been asked for all the measurements of generators and engines because some one wants to build the frame in advance of receiving the major pieces. This is usually a big mistake as it is so easy to miss something.  To ‘fab up’ the frame when you have all the parts is easy and quick, It’s a lot more fun too, because you are sure it all fits. Prebuilding the frame almost always leads to disappointment, something is taller or sticks out further than expected, or the measurements you were given was for an earlier model.  

Following is another KISS fabrication trick Lee’s Father uses.  Simply add the detail to the cross members so they nest between the rails ‘unwelded’.

a keep it simple fabrication trick

"Keep It Simple" applies to fabrication methods as well.

 Install the engine and use a bar and hammer to position the cross members and engine where you want it before you weld it in.  You will be able to date my frames as either pre or post knowledge of KISS assembly. Pictured here is a loved and reliable Yanmar with a single flywheel about the same diameter of a Lister type. It runs at 1000 RPM and is known for it’s long life and reliability.   

basic-pmg-frame

We start with a very basic frame.

Basic PMG frame

The three cross members are made of heavy Angle, I used a $59 harbor freight cut off saw with composite blade to cut the square tube on each side, and the angle iron. The angle iron cross pieces are 17 inches long, a notch was cut to allow one side of the angle to drop down between the side rails, while the top of the angle lays all the way across the square tube. I used the harbor freight saw to do this as well. In my case, I used a wire feed welder, and fully welded the pieces in place. The two angles to the left are spaced to assure that my engine mounting holes will fall in the middle of the angle iron tops, about 10.5 inches for the CF186 horizontal shaft diesel I will use here. We will be mounting our generator head to the right on this frame.  A mistake the beginner makes is placing a hole too close to the angle iron corner, and then finding it’s too tight to get the nut on the bolt on the underside. You’ll see nuts ground down on one side for clearance on some DIYer frames, it’s easy to avoid this problem when you do your layout and measure properly. 

angle-iron-gen-mounts

Angle iron generator mounts, note they form slots for tension adjustment.

Angle Iron Gen Mounts, easily and quickly fabbed up with basic tools.

Simple to fabricate generator mounts made from two pieces of angle.

Making slotted holes is a problem if you don’t have a mill, in this step we make generator mounts the easy way by adding a wrap of masking tape around the bolts and then placing them in between as spacers. We clamp it together and add a small scrap of metal to each end and weld it to keep the proper width in the slot.

add-gen-mounts

Adding the Generator mounts to the frame.

Here’s why you wait until you have the components BEFORE you fab. We place the generator in position and make sure it slides smoothly back and forth before we weld. There’s no guess work with this method. If the generator manufacturer changed the hole location on the mountingtabs and didn’t update the online drawings, you won’t be inconvenienced.  

After you have mocked up you engine and PMG, you will bolt the engine into the frame, then place your PMG on the frame and move it one way or another till it is perfectly in line with the engine pulley. Of course small adjustments can be made by moving the pulley in or out on the shaft, but running fairly close to the inside is always preferable. Only after you get your alignment sorted will you weld in these mounts. As you can see, you have a lot of latitude to move the PMG one way or the other, and since this angle is a lot smaller than the larger angles in the frame, you have room for the bolt head and washer on the bottom.

welding-in-gen-mount

With alignment proven, we weld in the mounts top and bottom.

Generator Head test fit done, we weld in the brackets on top and bottom.

 

PMG generator mount, note, the cement floor does not give good contrast here, but the pairs of angles that will support the generator head are evenly spaced and were checked by temporarily fitting the generator head and assuring that the pulley on the engine and on the PMG were aligned. Once done, I tack welded in the angles, and now that we have verified all, we fully weld in the mounts.

basic-frame-complete

Basic frame completed, engine and generator mounted.

Basic frame complete, careful attention paid to pulley alignment. A steel straight edge comes in handy.

It’s hard to see just how much movement is allowed in PMG adjustment, but close to three inches! Using some sheet metal channel, we can quickly build a a shield around our belt drive.

This is the heart of a frame, there’s all kinds of things you can add, but remember, it is best to mount gauges and all the items you can reasonably mount elsewhere off the frame, or if it is a portable generator set, then use rubber isolators for panel that gauges will be mounted on. Remember, if you are going to use this as a portable unit, and you have electric start, make room for a battery box.

If you look at a completed generator, it can look like an overwhelming job to make it, fact is, it’s fun and a great hobby. Now if you look closely, you’ll note that the following video clip shows the above generator with some easily constructed square tube frame added. Note on one side there’s a removable horizontal piece of the frame. This allows use to remove the engine and replace it. Note that we need NOT use the same engine, we can readily use a variety of horizontal shaft engines to power our DIYer PMG, all we need is the PMG and Utterpower pulleys, used or new engine and we’re ready to build.

Don’t want to go to all the trouble? Go to your local shop that handles chain saws, lawn mowers and small generator repair. Out back there’s generally a pile of Generators that can not be economically repaired, simply offer the operator a few dollars for the whole thing or part. This is how I found the power panel for this build, but it’s easy to make your own, and that’s another story. Sometimes you can remove the Generator and reuse the engine and frame to power the PMG.  Construction generators are often wonderful sources of donor parts. 

Here’s the YouTube video of the above generator with a few pieces added.  I cut the square tube with a $59 composite cut off saw, but it’s quick enough with a new blade in a hand hack saw. My wire feed welder is a favorite toy, and once you own one and play with it, you’ll realize there’s little you can’t make or repair.  With a wire feed you can even join sheet metal by backing it with with a big piece of steel, you owe it to yourself to have a wire feed welder.

But what about that hinge plate setup you may have heard about? Well, it sure did work well here on our test engine.  One of the advantages is you can set it up where you just pull the rod out of the hinge and you can quickly remove the mount and the generator head for access to the engine, or to move it to another prime mover very quickly.  Following is an example of the hinge plate, some will design using the weight of the PMG for the tension, if you study the direction of rotation, adding load can actually help apply a little more tension.  If you engineer it right, you should be very happy with the results.  There are now several PMG owners who have used the hinge plate design and they are totally happy, you can add a spring for tension if it suits your needs.

pmg-hingeplate-mount

Pull the rod out of the hinge and remove mount and generator in 30 sec.

Shown here fitted to a Lister type, generator and mount can be removed in seconds. Engine flywheel is CCW rotation from this view.

This ought to get you started thinking about how you will build yours, it’s the beginning of ideas, not the end.  KISS is a philosophy, it really does take time to evolve simplicity.  Anyone can make the process or the machine more complex. Many thanks to Lee and His Father for the valuable DIYer tips.

Look here for small engines, you might be surprised what you can buy for the money..

https://www.surpluscenter.com/Item.asp?catname=engines&item=28-1768

Visit the utterpower PMG pages.

All the best,

George B.

Posted in PMG | Tagged , , , , , , | 3 Comments

We are in Transition to a new and more useful format

Thanks for your patience. Web searches prefixed with utterpower should bring up all the articles and pages at the old utterpower.com

Using the search bar here should bring up the same pages.

Expect to see new posts here daily once we get things tweaked in, ‘we have a lot to cover’. 

All the best,

George B.

Posted in Announcements | 2 Comments

The Amazing “Kill A Watt Meter”

It’s a tool designed around one of the principle philosophies of utterpower, do your own math!

The Amazing Killawatt Meter

>>> Buy a Kill A Watt Here

I’ve mentioned this handy and inexpensive device many times, it gives the DIYer a very inexpensive method to monitor Voltage, Current, Frequency, Kilowatt hours, and Power Factor, Few of us need much more, and at a cost of twenty five dollars or less, it is very difficult to pass up as your power monitoring display(s). Sure thing; a beginner starts off wanting those cool looking analog meters for each display, but at some point you learn the downsides whether it be cost, breakage, ease of replacement, lack of features, flexibility or more.

A Current Transformer is easy to find, some at surplus prices

Your hands on experience will build an appreciation for the killawatt, inexpensive enough to have spares on hand. Plug one in where ever you want to monitor your power, the kitchen, the shop, add ONE external component, and get total load information at your generator head, or at the first distribution box.

Thanks to DIYer and PE ‘Bill Rogers’, the killawatt has been tested with a Current Transformer than can extend it’s range in reading current and tracking total kilowatt hours. There will be very few serious off grid power producers that will find a need for more monitoring information, accuracy, or data collection than what the kill a watt provides.

If you watch the forums, you’ll soon see things like a person posting that he’s carrying 10KW of load with his modified DIYer 12 horsepower engine and gen head. All he did was change the compression ratio and add some of those new trick racing valves, and he’s now offering to sell you the modification and knowledge. The odds are high that he has deceived himself, he hasn’t yet learned to measure AC power with any accuracy. KVAs and KWHs are very different things. The formula for figuring AC power is not E times I as the poster likely calculated. Lucky for you, the killawatt is smarter, and it will produce running totals and even show you that all important power factor. Reality is an important thing for the true DIY Power Producer.

Let me give you a real world example of the value of the killawatt. Consider a Xantrex Inverter with a built in Charger. You read the manual and become impressed with the efficiency rating of these chargers (as you should). But you may walk away with the thought that this high efficiency is across the board. If we look at that big transformer core in the older and reliable Xantex, just what do we expect for efficiency if we are using the grid or another source of AC power to keep our batteries in float? Let’s get some hands on experience with the killawatt right now and give it the task of answering our question. With the batteries in float, we’ll ‘lockout’ all AC loads or turn the inverter section off. This will assure we don’t pull more current through our unmodified killawatt than it was designed for, and since we are studying what it takes to float the battery, we’ll be looking at power well within the range.

First we find the AC input to the charger, this may go over to a wall style plug where we see commercial power when it’s available. for off girders, it’s likely your generator output. if you are already wired this way, the study is easy, just pull the plug out, plug the killawatt in, and then plug the charger back into the front of the killawatt. With the batteries in float, push the button on the front of the killiwatt for power factor. Do you see a dot six or similar, not all that pretty huh? Now let us look at the power and compare it to the current into our batteries and then calculate the power in and the power out to the batteries. What you may find is that you are using about five times the energy to float your battery bank as a purpose built charger might use. We might see this set up in on grid installs where the inverter system is back up, if you are paying 8 cents a KWH, you may not care, if you are paying 40 cents, you may be motivated to make changes. If we look at the cost over a year, it all adds up. Locating that purpose built charger on sale or at surplus prices might be an easy thing to do. Of course, this is only an example and you will find lots of studies and experiments to conduct, especially inductive loads of all sorts. A refrigerator is full of surprises, and the mods you can make for greater efficiency and to reduce the burden on your power plant are numerous and fun. This might be an excellent topic to cover in the near future.

>>buy Kill A Watt here

All the best,

George B, Utterpower.com

Posted in Recommended Gadgets & Tools | Tagged , , , , , , , , , | 3 Comments

Is Every Green Idea A Good Idea?

Did you follow Dilbert in the early days? I used to look at that cartoon strip every day and wondered how Scott Adams had gained access to our work-group? Did he have an informant, was it Mel, maybe Stan? What I found out later is he worked in a technical environment in the Phone Company just like I was doing at the time.  He witnessed the same irrational stuff my work group experienced. Why make it up when you are surrounded by real life examples of insanity?

government dilbert

A joke?

The following may be another example of Dilbert ideas;  you can’t make up stuff like this.  Unlike the Author of Dilbert, you may be able to use the Freedom of Information Act  and actually name the real characters in the story.  Scott Adams had to do his best to keep his job or he’d have no new material to write about I’m sure his Boss enjoyed the comic strip less than we did. 

Looking for an Idea that might generate a lot of traffic to your WEBsite? How about a  collection of ideas like the following with a hand picked example added everyday?  You would inform the public about what our Tax dollars are being used for and as far as I know this idea could qualify you for   an educational grant too!

So sit back watch this video and then read on, there’s two ways for YOU to make some serious money.

Have you ever studied the efforts and research done to develop a paint that would stay on the road for any length of time? They spend millions to study and develop a better paint and then place test strips to see if it is both visible after dark and durable enough to last a few years, just keeping the centerline painted (where people seldom drive) is a huge expense.  Ever study the damage studded tires do to a road in one season? Ever see the windshield damage people get every year driving over mountain passes and on snow covered roads where salt and sand are applied? They are lucky to go two seasons on the same windshield. Now imagine a glass roadway and its ability to hold up to the elements, cleats, chains, aggressive treads that trap all kinds of material that are considered hard on the Rockwell scale… they act as a serious and aggressive grinding compound to any roadway, and would turn glass into wind blown sand overnight.

But that’s just the beginning of concerns many transportation engineers would raise.  I think the key to limiting grants to the more rational studies is to make the public aware  of who approved the funding.  This information needs to be available via the web and citizens should know exactly who was involved in approving their tax dollars be spent in such a way.

Of course I am a little envious; I could have created Dilbert, (or at least I had the same material to work with). I could have applied for this grant and turned out the same work, but many of us could and that’s what makes the story.  Think how much fun it would be to have spent all that money playing around. Think of the expenses you might charge, maybe even a trip to Spain with your friends to study an acient Roman built roadway.  You know that Dogbert would have done exactly that. 

In exchange for lifting one of Scott Adam’s gems, perhaps I should suggest you visit his blog? Do remember to hit the back arrow and return.  

http://www.dilbert.com/blog/

All the best,

George B.

Posted in Your Wasted Tax Dollars | Tagged , , | Leave a comment