Typical PMG Install on Lister Type

Typical Install

Here’s a typical install on a (Lister Type) LG6 (GM90) supplied by Lovson in India.

Note that the Utterpower 3KW PMG can make 4.2 KW ongoing in lower ambient temps, and it has great motor starting capability, this makes it an excellent match for the 6/1 and even larger engines. Notice the generator mount, it is designed on a hinge plate which does away with complexity and allows you to remove the gen head and mounting plate in 30 seconds by Pulling the pin out of the hinge. Also a snap to ‘fab-up’ if you have a wire feed welder.

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PMG Fans: Tom

Tom's PMG

Tom is a Contractor who wanted something other than the hardware store solutions.
Hi George,

Tom here and I want to update you a little on my PMG.  ?It has 21 hrs on it 1 oil change on the engine and just about 5 gal of fuel run through it. WOW ?it’s perfect. Everybody that sees it wants one. I put it to the test during some construction on my building ?and ran it from 0700 till 1800 without a glitch. No one could believe I only put fuel in it once. Two nail guns and compressors ?saws—- you can guess the rest. I guess I’m just crowing, so here are a few pics.

A very happy..

Tom

Please consider sending me pictures of your utterpower PMG plant.  We enjoy viewing them!

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PMG Fans: Phil Podkanowicz

PMG Fan Phil

Thanks to Phil Podkanowicz for sending in a picture of his new 6 KW PMG. Phil is a retired heavy equipment operator in Illinois with a double helping of  hands-on skills.

Please consider sending me pictures of your Utterpower PMG plant.  We enjoy viewing them!

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PMG Applications

It was just last night I was talking to Darren Hill in North Land, you might know he’s a Kiwi I enjoy communicating with and I learn from him. There’s a lot of places in New Zealand off the Mains, and a lot of solar installs there. Darren explains that they have about half the Solar Energy that Ozzies in Sidney have to work with, this gives the Kiwis about twice the reason to have a backup generator.

Darren said, “We AE installers here are recommending investments in PV, and installing the smallest diesel generator one can get by with”. I was quite happy to hear this, as this has been my direction for 5 or more years, the larger the Gen Set, the more likely the owner will see higher than expected  Fuel/Kwh figures. Whether we invest in Solar or not, too big of generator can be an expensive mistake for the Off Gridder.

I have one customer with a 6/1_PMG generator with a gasoline powered backup,  he’s on his fourth year of running the PMG set in Stevens Pass, Washington State. He runs 8 hours a Day, 7 days a week, and when the 6/1 is down, the family is motivated to get it running again because it is hugely more expensive to do it on gasoline. This Location does have batteries, and an inverter, but no panels, the lower West side of Stevens Pass is NOT exactly a prime place to invest in PV Panels 🙁

The PMG has proven highly reliable for them, all the problems have been related to the prime mover, no drive problems, no PMG problems.

If you are starting with a clean piece of paper, I highly recommend that you look at 48 volt inverters and battery banks. I think there are a lot of reasons to start here, and pass on 12 or 24 volt systems. You might ask, what if I do invest in 48 volts, and find the even newer systems are 72 volt? well there’s reasons we’ll likely stop at 48 volts, all the Telco’s did, and for legal reasons. I think the higher voltages would likely carry more liability, and legal requirements, and this is why we’ll likely stop at 48Volts. Telcos have been using 48 volts for 100 or more years.

If you are adopt 48 volts as I have, the PMG may be your single off grid solution for 120/240 VAC, and for charging batteries directly! I am currently charging 4325 pounds of 48 volt Battery with the PMG directly, I have the two stator windings in parallel and they feed into a full wave bridge rectifier across the battery.

Above: PMG as a 48 Volt battery Charger

When it’s time to charge the battery, you operate a simple interlocked transfer switch, bring up the RPM until you see the amperage your battery manufacturer recommends you charge the batteries at. In the example above, the 1786 watts was at 32 amps, and I think the PMG could carry this type of current continuous in lower ambient temperatures. I need to monitor the test PMG at this load for about 4 hours to prove this power level. but during this test, I could not find any wire, connector or surface on the PMG hotter than 106F. The large air cooled rectifier did run around 140F with a fan blowing on it, so this part needs some attention.

So, you say you have a built in battery charger? I wonder, how more efficient might it be if we charge directly off the PMG versus using a 120VAC generator feeding into the built in charger in your inverter? I think it wouldn’t take long to measure the fuel using both methods, and see what is more efficient, and I think it’s nice to know that you have a back up charger in the PMG just in case the other one fails.

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Lister Type Flywheel – A Matter of Balance

Understanding how Lister Type Engines are balanced becomes even more important when you are building from parts, I have now either seen or have had it reported to me by reliable sources that they have received totally assembled engines from India with mismatched Flywheels!

The fact is, the production numbers of engines like the 12/2s are now very low, and Indian Erectors (as they call themselves) often can’t find, or don’t employ people who know how to build these engines correctly.

In one case, there were two 12/2s sold by Vidhata that reached a very mechanically inclined customer in Canada. When he started the first 12/2, it started hopping around like a Jack Rabbit on steroids! Now you might ask, how did Vidhata test run this engine and pass it? The Flywheel counterweights were both following the Pistons! Yes, there were signs it had been run, soot in the exhaust port, etc. but obviously, the untrained, or the uncaring still shipped the engine to the customer.

Maybe we need to look at how people in this business get paid in India, as I think it is often the case; they get paid for assembling and passing an engine, NOT for doing a job right. Another norm for India, the people you often deal with are office workers, they have very little interest in knowing the mechanical side of the business and technical questions are often passed along, and when the answer comes back to you, you know the question never made it to anyone who understood the question!

For some Indian office workers, knowing how to run a shovel and dig a proper hole is likely just as high on their agenda as understanding some machine, it is possibly beneath their position to understand these things at least from my experience with several companies, so it seems.

So now that you have the example, let’s cover some fundamentals that might help you spot potential problems.

The Standard 6/1 CS engine used a cast iron piston and a crankshaft with no counter weights on it. Many refer to this as a ‘standard crank’. In this engine, we expect to see the counters cast into the Flywheel, and when the piston is at top dead center, we expect to see both counter weights in the flywheels at bottom dead center.

But what about STOVER flywheels, or those that are concentric?  These flywheels are normally mounted on counter weighted cranks, the Pistons are sometimes made of an alloy, and the whole configuration is different than what many of us refer to as a ‘Standard’ CS. If you fit these concentric flywheels “without counter balances” to a standard crankshaft engine, you may have a serious out of balance problem.

As for the twins, the typical 12/2 has a 180 degree crank, with no counters on the crank. When the piston is top dead center, the flywheel counterweight on that side should be at bottom dead center. A quick visual will show the counters opposite each other, (180 degrees) taking off the door, and looking at the crank will prove they are countering the piston and rod on their perspective side of the engine.

There are different thoughts as to running concentric flywheels on twins, most I have seen are smaller in diameter, and designed for higher RPM, sometimes 1000 RPMs, The Stover flywheels are normally used with the counter weighted cranks.

It is wise that you check your engine and VERIFY you received the right flywheels and that they were installed on your engine properly. Your safety, and others should be the number one concern.

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Co-Gen

Making Moon shine (motor fuel) with your Listeroid?

Do a WEB Search on ‘co-Gen’ or ‘cogen’ and you’ll get the theme. I spend time thinking what a person can do with waste heat. It’s pretty obvious if you have a living space or green house space to keep warm, but if it’s plenty warm already, what do you do with this energy other than waste it like most people do already?

There are some processes that convert this heat into cooling through absorption, web searches using ‘waste heat’ and other related key words can fetch additional info.. Checking out how one of those ammonia refrigerators work can spark additional ideas.

Back in my 20s, I used to make Moonshine just because it was fun and illegal.  I had a few friends that used to drop by and check out the latest batch, sometimes I’d trade a little ‘motor fuel’, for some good home made beer. If you think about the process of making alcohol from grains or starch (like potatoes), I think it may be a natural co-gen project, and it may be closely related to other processes you might think of.

Consider the  Lauder Tun, this is an insulated container where the grains, potatoes, or other starchy foods are held at a temperature around 140-160 degrees F. The enzymes produced from sprouted, then roasted Barley is introduced into this ‘mash’ to break down the starches and convert them to simple sugars. The resulting mash is now ready for the fermentation process.

If we think of all this waste heat given off by our diesel via the coolant, and exhaust, it may be the perfect source of heat to keep the Lauder tun at the proper temp for the conversion period. If one considers that you could design the lauder tun with a simple thermostat to control the temperature via thermo siphon, this could be an easy and cost effective means of powering the lauder Tun.

Fermentation itself can be aided by a temperature increase, and by maintaining a constant temperature.  Here’s where you might have another thermal loop off the power plant with a simple thermostat for it’s independent regulation.

Once we’ve fermented our motor fuel, it’s time for the distillation process, here we try and maintain a temperature higher than the vapor point of Alcohol, and lower than the vapor point of the water in the mixture. Alcohol boils off at 140F, Water at 212F, so here we might find a coolant temp to be perfect for the distilling process. There are many possibilities here, you could set it up as a pot still or more like a reflux still.

As for the final stage , we could use a water pump off the flywheel, or we can borrow some power from the generator end to push water through a condenser/radiator loop to condense this alcohol into our collection vessel.

Making Motor fuel would be legal, and most likely far less fun. Considering the effective Octane rating of Alcohol, it should be quite feasible to run a stock compression ratio in a Listeroid and run alcohol through it. One should be able to fit a spark plug right in the middle of that plug often fitted to the CS head, a bump on the flywheel could run the points, or maybe you remove the cam cover and fit the breaker points and a cam lobe there?

Imagine showing up at an old time engine show with a moon shine burner! , you could have an extra fitting coming off the tank to fill shot glasses when the boss isn’t looken.

If the end of the world comes, you could be ready to power your mo-ped into town on home made motor fuel.

Making use of Waste Heat

I’m always amazed at how efficiently a propane or natural gas water heater is. I have a forty gallon unit at one off grid location, I use a 5 gallon propane tank to fuel it, and it’s pretty impressive how many showers one can take on this amount of fuel. I pump collected rain water and hauled in water via a solar powered pump, but we’ll soon have the Lister working the well.

I was talking to a plumber who told me he has installed several heating systems where tandem gas hot water heaters are used for domestic water heating and act as the boiler(s) for a hot water heating system as well.  this causes me to wonder about uses for a discarded unit? If you use one of these as a cooling tank, could you use a small blower to push the hot air up through the center and into your living space?

What would happen if you used the center of a gas water heater as a muffler for your diesel engine? Some might suggest it would get full of carbon and lose it’s transfer efficiency, but maybe it could be set up to clean out with a brush on occasion?

More conventional co-gen ideas can be found here.

Got a co-gen idea? write me…

Posted in CHP/ Co Gen, UtterPower Articles | 4 Comments

Kill A Watt Plug-In Meter

A while back, I thought those big ole panel meters were really cool, but after working with generators a bunch, they have lost some their appeal.  They are just another thing to find room for, to mount, and to fix when they break.  If you have some antique gauges, and you are displaying them for the vintage appeal, that’s still cool.  But if you just want to know what’s going on, that’s a whole different matter.

The ‘Kill A Watt’ plug-in meter is throw-a-way cheap, and many of us can get by on this and enjoy some outstanding features. One of the things I like most is you can plug it in where you use the power, and monitor generator performance where you most likely are. For a reasonable price of about $29.95, some of us can afford to plug one in at the generator room and one at the load.  And if one breaks, we have the other for backup.

After my experience with this device, I wouldn’t be without it and I wouldn’t spend a dime more for instrumentation for my generator systems.

To learn more, click > Kill-A-Watt

Posted in Recommended Gadgets & Tools, UtterPower Articles | Leave a comment

Independence Station

There was a time when every factory supplied it’s own electricity, heat, and other necessities.  They were often powered by slow speed engines burning a wide variety of fuels. At one time gasoline was burned off because there was no market for it, as we investigate the history of these engines, we often note they were multi fuel, and the fuel burned, was the cheapest available at that time. Kerosene, gasoline, and natural gas, to name a few.

Steven Ribeiro has an interest in using bio fuels ,especially waste streams like veggie oils that can be burned with little emissions. The potential for net metering, generating a portion of the building’s requirements in the basement, and all manner of building efficiencies is being studied here.

I will be watching this project.  Maybe the past will become the future once again?

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HHO Generators! Get yours now!

This topic comes up often, you need only calculate energy in and energy out to form an accurate conclusion. If you made time for the Air Car article, you will find that HHO generators are designed to sell to the same audience.

One thing our ‘hands on’ group of experimenters has pretty much concluded, fuels of all kinds seem to add value to the combustion process based on their BTU value, and little more! With that said, read on.

Per your email and links.. read my response below.

—–Original Message—–

From: redavis

Sent: Saturday, June 06, 2009 7:41 AM

To: gbrecke

Subject: Smoke and mirrors??

Well George Here’s a couple of articles that

tell about the best thing

since sliced bread or are complete B.S. I

personally think the media are

just suckers but I could be wrong about this

one…….

http://www.wired.com/autopia/2009/06/wonder-engine/

http://www.toledoblade.com/apps/pbcs.dll/article?Date=20090530&Category=BUSINESS03&ArtNo=9053003 38&SectionCat=BUSINESS02&Template=printart

Reply from George

This is nothing at all, it certainly is all about a fool that is too lazy to do the simple math necessary to calculate what the car requires in the way of horsepower and then to calculate the theoretical limits of efficiency in an internal combustion engine. But this is mild compared to other claims designed to attract people who will never take responsibility for doing their own thinking.

Now Consider this…

http://video.google.com/videoplay?docid=-2238805429946487167

As you watch this, remember the HHO generator is fused at 30 amps, therefore we assume a max of 14.4 volts times 30 AMPS = 432 WATTS OF total POWER  INTO THE HHO GENERATOR. Since 746 watts = one horsepower, we need keep in mind we only have 60% of a single horsepower to drive the HHO generator available.

In this universe, we always get far less energy out of any conversion, that is to say, the energy we make available to the HHO Generator for the manufacture of hydrogen will always be more than the energy value of the hydrogen gas manufactured. But we will be generous and assume we get back the full 432 watts of power out of the HHO generator, this of course is a perfect conversion with zero losses, and we will give him this even though we know of no other device that has achieved same in the entire universe!

We have some more accounting to do, as we don’t want to be accused of Enron type accounting do we?? Auto Alternators are notoriously inefficient, likely no better than 70% efficient, so whatever energy is used to power the HHO generator, it is costing us dearly BECAUSE of the poor efficiency of the alternator, (that is the power source right???) since we have encountered these KNOWN losses, it’s clear that the output of the HHO device >MUST< be well over unity to break even, but the engine actually runs, so it is clear (according to the video) that we are viewing over unity plus a rather significant amount more, after all, there’s a fan turning, pistons going up and down, and the normal friction in the engine, and of course, our Alternator has to make the power to run the HHO generator.

So now that we have the worlds first over unity power source, (actually a rather significant amount over unity) we can easily see how we could chain the units together and get an infinite amount of power. With this kind of power, we can easily achieve the speed of light, and actually travel into the future, this is what Einstein’s theory predicts, and there is a lot of evidence the theory holds up well. In fact our current GPS system makes use of the theory to make critical adjustments for time differences in the ring based on this theory, we know it is relevant!

This is all rather profound, why is this idiot wasting time powering his truck when he could be using this energy source to travel across all space and time and why not use it to travel into the future?  I say buy one now, and be the first to build your own time machine!

In reality, HHO Generators have been around for a long time, and fact is, you dump a lot of energy in and get almost no energy out, what you need to make any kind of hydrogen power viable is an energy source so cheap you can afford to throw it away. When we make Hydrogen, we are often left to ask, why not use the original energy without the huge losses in the conversion?

Consider one last thing, there are men in Africa who believe that if they have sex with a virgin it will cure their AIDS. Many people who read of this attempt to rationalize the behavior, many say the men come from primitive cultures and have no schooling, others think they don’t have the mental capacity to process reality. The truth (as I see it) they are no different than the people who buy HHO generators, as they want to believe so badly that they will totally ignore the fundamentals of science that has allowed us to travel to the moon, build super computers, and far more. If these basics were that flawed, would we have done this well so far? The basics tell us that hydrogen is a loser.

If you read the Air Car article, and do a little research, you will see how the ‘targeted audience’ will help to build a stronger case for buying the appliance, we see testimonials about how it can reduce emissions, keep the inside of your engine cleaner, and more. If the appliance worked and all of this were true, we’d have a tool to appease the irrational people who dictate to CARB! But remember, the true believer doesn’t want to read about anything that could destroy his belief in magic! this fact assures you won’t get through to them.

But we have had a plethora of useful idiots for far longer than many of us care to note. Consider Global warming, the leaders are COCKSURE of their convictions, or are they? Imagine men with brains so large they can unravel all the inter dependencies on the planet, yet they are too inept to tell us what is going on inside a single cancer cell! The truth is likely far simpler, regardless of man’s roll in climate change, there is great power and influence given the leaders of the global warming cause. Those who sell HHO generators receive money from the believers, (useful idiots) in the same way. If you are a believer in Global warming, you will NOT be swayed from your convictions, at the heart of it all is a belief you’ve been denied something you know you were entitled too, once you have invested years into this thinking, how can you abandon it?

Think of all who have screwed you! The Government can’t allow you to have free energy, Corporate America would go broke over night if you had it, they (Corporate America) buy up secret patents, on an on. How many times have you heard of the 100 MPG Carb that just all of a sudden disappeared? At some point HHO sales will drop off to near zero, and 10 or 20 years from now people will be saying the same thing about them, “the government stopped it, or shell oil went around and made a deal with all who were selling them”. It’s what useful idiots do.

Al Gore ‘looks’ like a stupid man, I do agree, but he learned as a politician how to market to the useful idiot, he learned of the power and money he could make. He now has a personal wealth of 100 million and he’s just gathering steam. If he can pull off the carbon credit scheme there will be a huge transfer of wealth right into his pockets and his Friend’s pockets. Those who believe in global warming movement know there are plenty of people that need to be punished, this is at the heart of the movement. At the end of the day, the useful idiot has made many things possible on this planet, they have transferred power to dictators, ruined economies, funded genocide, and far more, it all begins when you are too lazy to do the eight grade math and discover how nuts something like the HHO generator is. If you read this far, you are NOT a believer, as most believers will not invest in an sentence that does NOT support their beliefs.

All the best,

George B.

Posted in UtterPower Articles | 2 Comments

Chevy Volt Announces 230MPG in the City

August 12, 2009

Now that the Government Owns GM, and the present administration is running things, are you surprised by today’s Claims? 230MPG!

Is there any difference between a lying used Car Salesmen and the Average Senator or Congressmen we have in office that isn’t outraged by these lies?

Anyone with a shred of ethics or morals left would break down the car’s performance based on energy in, and mileage out. Certainly the Administration has had time to read about these claims AND apparently it is OK with them that this whopper of a lie can be told about their car and their Company.

Did you notice the Volt doesn’t look too much different from an ordinary car? It likely has a drag coefficient not unlike other cars, maybe it does have some weight advantage, but just how far does that get you down the road? Five, six, seven, eight times as far? I don’t think so.

Here’s what they are NOT telling you.

IF WE use their same measurement criteria, a 1974 VW Rabbit diesel gets over 10,000 times better mileage per gallon of gasoline than their VOLT!

At this point you say… “I know I know, I read the article! It’s obvious there’s a LOT of electrical energy pumped into the car as well.”  I answer, obvious to you, but not the bubble heads that will help pass Cap And Trade thinking we have a quantum leap in energy saving devices at our door step! There’s nothing magic about a Chevy Volt other than the way it’s being promoted!

They don’t count all the energy they dumped into the car via an electrical charge, they only count the Gasoline burned in the engine to get the car to the next charge station.

What they don’t tell you is the GRID is not capable of delivering the charge current necessary to charge all these cars that would be built, and this administration is dragging it’s feet on producing any viable power sources that could really help us (Modern, Clean, Safe, Nuke energy). Yes there are a few old hippies out there that think you can tie a solar panel to the roof of your Chevy Volt with a good hemp rope and drive all over town, but those with hands on experience know it’s all about BTUs, weight, drag coefficients, and all the same ole stuff.

A123 Lith Ion batteries are a wonderful innovation, BUT they don’t make power, they only store it, and the battery and charging system does not return all the energy that was put into the system.

Why would you buy a Car from folks that tell whoppers this big? I say it’s a good reason to buy a FORD! I’m thinking there’s an ACORN community organizer running the marketing campaign at Government Motors.

For folks that are interested in what’s really happening here (I don’t expect folks that have the bumper sticker “change we can believe in’ Still stuck to their car to read further.

When we pour fuel into the tank of our car, we convert that fuel to mechanical energy inside the engine, we know the thermal efficiency of the engine, the loses in the transmission, rear differential, tires, the drag on the car at any given speed, etc.

With the Electric car, we STILL need a fuel source, without Nuke power, all we are doing is creating a lot of added losses over what we have in the gasoline powered car! We start at our energy source, (maybe a coal burning power plant) we incur the losses as we convert to mechanical energy, then we convert to electrical energy (more losses) then we move power over the transmission line, (more losses), then through a battery charger (more losses), then into the battery, and guess what, there are losses in the battery too, you don’t get out what you put in). Now when we need power, we take it from the battery and use the energy to power an electrical motor (more losses, substantial losses!)

Some will ask about the regen system on board, it makes electricity as you brake you know! For any who care to think, you need to get it to the top of a hill before you can roll it down the other side, and there are severe losses in the regen braking  system, you don’t get out what you put in. All we do with the electric vehicle is use a remote source of energy, power from solar and wind is hugely more expensive, and the main reason people invest in it is to get the Government subsidies, and of course the subsidies are nothing more than debt our government has heaped on you, a way to further decrease the value of any dollar you were stupid enough to save.

There are no free rides, the electric car is no more than a good propaganda tool at the moment.. so you ask about the Toyota Prius about now? If you follow cars, you’ll know the Prius is no where near as efficient as the small economical diesels made by Honda, Suzuki, and others, and FEW prorate out the cost of that VERY expensive battery! will you buy a used Prius with a used up battery over an highly efficient diesel with a life expectancy of 400,000 miles or more?

What you see in the news today is consistent with “Change you can believe in!” The math doesn’t work, BUT what you may not understand is the message is NOT for those who think, it is for those who are too lazy to do any level of thinking on their own, they’ll bus them to the voting booth if they are too dumb to get there on their own.

Obama Volt? More BS you shouldn’t believe in..

I guess the answer will be to sell the Chevy Volt to the French, with all their problems, at least they were smart enough to build Nuke power plants and not be so dependent on the Saudis and others we should have no dealings with. What we all need to visualize is that the energy conversion for the electric car just over the horizon, and then feeding it into the gird, incurring all the losses, and then shoving it into a battery where we give up a notable portion of the energy VS doing the energy conversion in the car as we do now. To make claims of 230 miles per gallon is about as dishonest as telling folks you’ll be selling dollar bills next week for 50 cents each, but we do understand that this BS is packaged for the ‘Believers’ and not those who have ever owned a pencil and read the instructions on how to use it.

Another note, imagine these Bureaucrats losing even a dime in Road Taxes! they’ll scream bloody murder, that electric car will have a charger that takes road taxes directly out of your bank account for every kilowatt hour of power you put in the battery! Imagine how it will all work, as soon as someone is caught bypassing the road tax, they’ll be screaming for some big brother apparatus on the car that alerts the State and Federal Tax collectors.   These addicts are not prepared to give up a thing, imagine Pelosi flying first class commercial and sitting with regular people.. won’t happen, these out of touch Bureaucrats will likely suggest that you pay even higher roads taxes on these electrical energy units since they made it all possible for you to drive for near free. The Tooth Fairy is far more believable, one day the children in grade school today will ask their parents. How were voters so dumb to believe all this Dad? Were you one of the dumb ones?

The math is rather simple, what are the energy units you started with, and what were your overall losses between the energy source and the rear wheels? Obama voters simply don’t want to know, sure it’s only 8th grade math, but knowing the truth will destroy their dream of a free lunch. Electric cars could be good, but for God sakes, can’t we have some honesty in the discussion?

The real goal of the Left is to destroy the Golden Goose, once it’s gone, you’ll be looking to them for crumbs. It’s possible they’ll pull off this scam on the American people with subsidies, many Americans don’t know or care how a subsidy works, so if Government Motors starts selling $42,000 GM Volts with a $20,000 Government Subsidy, they’ll likely have no clue how the subsidy affects them and their children.

The message to the rest of the world will be……. Sell your US Dollars while they’re still worth something!

Posted in UtterPower Articles | 1 Comment