With Capabilities for:

.:6
-

i-

ng 240V took and applhnces Fa& charging Battery banks Arc Wadding i Fuskrr Welding . * R , e Spot Wdding +a ,?-' : . 4 -g @ Heuhg steel t near melting pint a Cutting thin plate steel @ Soldering

Using Low Cost Used Car Parts and Natural Energy Drive Systems

P u b l l by: ~

TRENDLINE PUBLISHING COMPANY (A Dlvlsion of Tmndllne l n t e r ~ t l oPty. Ltd.) ~l G.P.O. Box 1889, Sydney, 2001. Australla.

o Copyright 1983. Trendline International Pty Ltd

Revised and updated Edition 1 9 8 5

ISBN 0 - 86437 000 8.

Reproduction prohibited b y any method without prior permission i n writing from the publishers.
This manual is compiled from a special project headed by 1.T. Allowyn and commissioned. by Trendline International Ry. Ltd. The information contained herein i s believed to beaccurate, but i s soldas information only and no liability is accepted by either the publishers or research analysts.

WARNING
The information in this manual will enable you to produce high voltage from car alternators and car batteries. HlGH VOLTAGES CAN CAUSE INSTANT DEATH. Always insulate connections.and when produc~ng over 60 volts, clearly label - "DANGER HlGH VOLTAGE''.

CONTENTS
Introduction Basic Construaz+ion and Operafling Details P.?Qernators Output, Wirlng and Modlt~catlons .--

- How to Connect Alte notors in Parallel - How to Connect for Fa.? Charging of Batteries - How to Connect for Welding - How to Connect for Operating 240volt Drills, Lights, Power Tools etc.

Drive Line Options

- Lawn Mower or Motor Cycle Engine - Rear Wheel of Car Motor - V-Belt Drive off Car - Twin Alternator Drive off Car Motor - How to Calculate Alternator Speed - How to Calculate Pulley Sizes for Specific Alternator Speed

Drive Speed, Voltage and Power Strength

Battery Calculations and Hook-Up Sequence

- How to Connect in Combined ParallellSeries for Increased Amp Capacity and Higher Voltages
Battery Facts

- How to Calculate Power Strength; Amperage, Volts and Watts. - How to Connect in Series for High Voltages - How to Connect in Parallel for High Amp Capacity

- Factors Charging - Battery which Determine Battery Power - Causes ofFormulasFailure Battery Life Battery - Chemical to - How and Where to GetExtendUsed Batteries Good - Solidon Buying Inverters State Inverters - Tips
- Rotary lnverters

Invertem

Low Voltage Appliances and Tools

- Fridges, Radios, Colour Television etc - Heavy Duty Fencing Tool - 10mm Workshop Drill - Compact Battery Operated Welder - Using an Old Car Generator as an Electric Motor

- Using an Old Car Starter Motor for High Power, High Torque Applications - Regulated Direct Flow Water Power Direct Flow Water Power - Water Powered Onsite Gravity Unit - Wind Powered Conventional Propeller Type Windmill Water Powered Remote Location Gravity Unit - Arc Welding - Fusion Welding - Spot Welding - Brazing - Heating - Soldering - Cutting - Where to Buy Carbon Arc Rods

Home Power Plant Options and Combinations Alternative Energy Drive Systems

- Wind Chute Power Turbine

Welding Capabilities

Concluslon

INTRODUCTION
The ordinary car alternator can be easily modified and used as a convenient mobile power unit. It can be either mounted on a compact platform and driven by a small petrol motor, windmill, water power, etc., or driven by your car motor at the rear wheel, etc. r This power unlt has been designed with enormous versatility ranging from simple applications such as lighting and heating through to brazing and welding. The overall aim has been t o construct an alternative power source from low cost components and used car parts. The emphasis is o n used car parts, e.g. : used car batteries instead of the very expensive, but better suited heavy plate power plant batteries. The reason for the emphasis on used car parts is mainly their low cost and ease of availability anywhere in Australia. As an example of costs, second-hand alternators are readily available around Sydaey for $15-$20 each in good working order (often advertised in the weekly Trading Post). Presumably they are easily available at similar prices in other States around Australia. As an example of the capabilities of this unit, you can arc weld using welding rods up to 12 gauge (2.5 mm), solder, braze, braze weld, fusion weld, spot weld, cut steel, and heat steel to near melting point for shaping and bending. Note. This is all done by electricity, directly from your power unit. The unit is supplying power direct it n not even necessary to buy a welder. For most people, reading these types of clams In our advertisements is unbelievable and for some it is totally unacceptable. The thought of creating intense heat andflame capable of fusion (oxy type) welding and heating steel to near melting point is hard enough to believe even rf using the best of electric welding equipment.. but to d o all these things and more without a welder and using an old car alternator appears to be beyond the realms of possibility. In the following pages you will see the facts and realtze that our sdvert~sing claims are not an overstatement but rather a deliberate understatement of fact.

BASIC CONSTRUCHON and OPERATING DETAILS.

The modifications to the alternator are quite simple and straightforward. It does not require any complicated rebuilding - all modifications are t o external wiring connections only. Basically the concept is very simple: by-pass the regulator and ryn a constant 12 volts directly into the field wrndings (rotor) of the alternator. This energises a strong magnetic field in the alternator, and the faster it is driven the higher the voltage - up to 250 volts. Normally the regulator controls the rotor current t o keep the alternator output at its constant 12 volts ( 13.8 volts maximum). The regulator controls the input t o the rotor within the range of zero t o 12 volts which reduces the magnetic field thereby controlling the actual voltage and amperage output from the alternator. By eliminating the regulator completely and connecting the battery direct to the field windings, then the output is directly related to the speed of the alternator instead of being controlled by the incoming current. To set up your portable power unit, you will need an alternator which has a separate regulator (not an inbuilt regulator). The separate regulator set-up was standard equipment on most models prior to 1980, so it will not present any problem in buying this particular type. You will also need a 12 volt car or motorbike battery to supply current to the rotor, and an old lawnmower motor or preferably a motorbike motor to drive the alternator. That is basically all that is required as far as major components and modifications go. Alternators are capable of spinning a t very high speeds because of their solid integral type of construction, whereas the old generators tend t o explode or fly to pieces at high speed. This is mainly because in generators the individual brass segments of the commutator had to be electrically insulated from each other and therefore could not be fabricated from a single block of metal. At high speed the centrifugal force caused them to fly out. This problem does not exist with alternators, and they are quite safe at very high RPM;in fact double engine speed is normal, and they are quite safe up to 14000 - 15000 RPM. When your power plant is in operation the power drain on this battery is only about 3 - 4 amps, at the most, so, you can run the unit for quite a long time before you need to recharge the battery. For example, using a fully charged 100 amp/hr battery at a drain of 4 amps you could run the unit for close on 25 hours before recharging. In actual fact, your power unit has a fast charge capability, so you can virtually recharge a truckload of car batteries in that 25 hours if you wanted to, so this small power consumption is never a problem. Some people prefer t o use their existing alternator set-up on the car. This is quite OK, because there are no actual modifications to the alternator. The only modification required is in the wiring connections, that is, in by-passing the regulator etc. When you have finished using the power unit (alternator), simply switch it back through to normal operation and let the battery recharge itself in the normal manner as you drive along..

I/

However, the main disadvantage with this set-up is that you have to rev the engine up fairly high t o reach the hlgh voltages, unless of course you fit different sized pulleys to gear up the alternator speed, but then this is not suitable for normal driving. If you prefer that the power unit be in your car, we suggest you buy another alternator and gear it up, then you can spin the alternator at high speed without revving your engine too fast. Also your existing electrical system remains intact, and therefore keeping your battery charged up. (The extra alternator is titted on a bracket inside the engine bay, and driven off an additional fan belt and pulley - see details later.)

ALTERNATORS - OUTPUT, WIRING and MODIFICATWNS

The most commonly available car alternators are Bosch and Lucas. Their rated output ranges from 3 0 amps to 6 0 amps for the average car. Most of the larger cars in recent years are fitted with 55 amp alternators t o supply an adequate current for the ever-increasing array of accessories such as multiple lighting, power operated windows, airconditioning, etc. The 55 amp alternators are the best, at least as far as car alternators go. If you are able to pick up a truck or tractor alternator of around 100 amps or more, so much the better. In our research we found that 35 amp Bosch and Lucas were most plentiful, mostly off Holdens and Falcons, so in this manual we will base our explanations on these lower output alternators. The capabilities of a 35 amp alternator W o i i l 6 6 e X c T E a s e d - b y o v ~ W ~s o v e r f r a h ~ ~ ~ + ~ a & i As an example of the capabilities of the 35 amp alternators, we connected two in parallel (which doubles the amps but voltage remains single), and at 50 - 6 0 volts and 8 0 amps it easily ran a nice hot weld using 2.5 mm rods and easily cut through thin steel plate with a 7 mm carbon arc electrode. In fact the molten steel was dripping on t o the workshop floor, which gives some ideal of the intense heat and power generating capabilities. Alternators usually go to 5 or 10 amps above their rated output, then the amps level off and the voltage continues to rise as the speed increases. A 55 amp alternator will turn out about 6 0 amps - some go to 65, so if you connect these in parallel your amperage is around 120 which will easily run a good weld using the 1 q e r 3.25 mm electrodes. The two main types of alternators, Lucas and B w h , and the wiring sequence are illustraited below. General Notes You will only be using two connections on the alternators. All others are not used. 1. 2. It is advisable to use the standard automotive connection in the voltage input lead. (Use only one wire - blank the other off.) These connector plugs are a snug fit and well insulated. D o not use big m a t o r clips as they have a tendency t o vibrate loose and either short against the other connector lug or against tnecasing which can result in internal damage to the alternator. 3. The voltage input lead only requires light wiring because it only cames 3 amps, or 4 at the most. The earth lead has to be of heavy gauge insulated wire - ordinary car jumper leads are OK. The earth lead is not 4. necessary if you are using the alternator in your car, providing of course you are also using the 12 volt battery in your car for the voltage input. (The battery is already earthed to the car, and by virtue of the fact that the alternator is bolted on to the car, it is also earthed to it.) The output lead should be of heavy wire, particularly if you are using two alternators connected in parallel. 5. Most car jumper leads are heavy enough to carry 100 amps, so you can use this as a guideline. All output leads must be well insulated, particularly if you intend producing high voltages. 6. Alternators will stand a fair amount of heat and high rewing; however avoid excessive heat build up as it can 7. drastically reduce the life expectancy of the alternator. The diodes usually pop first. These cost $2 - $3 each for the Lucas, and the Bosch has an integrated rectifier assembly consisting of 9 diodes which come as a complete unit costin~Our$20I---------------

How to Connect Alternators in Parallel Connecting alternators in parallel doubles the amperage output, but the voltage output remains the same as if it were only one alternator. There are significant advantages in using this system especially where hlgh amps are required for welding etc. Also you can run your alternators at lower speed to maintain a low voltage, high amperage output for the charging of battery banks etc. The wiring sequence is exactly the same as for a single alternator, except that the output terminals are connected together. The alternators are earthed together and then both earthed back t o the same source, i.e. both to the earth terminal of the battery.

EARTH TO ALTERNATOR FRAMES

O U T P U T TERMINALS

CONNECTIONS TO APPLIANCE FIELD WINDINGS

\
FIELD

BLANK OFF INDICATOR TERMINALS

WINDING ENERGIZER TERMINAL

How to Connect for Battery Charging Simply connect the output wire t o the positive + terminal of the battery or battery bank. The earth wire is connected to the negative - terminal of the battery or battery bank. Warning: Do not have 12 volt appliances connected when fast charging batteries. The higher voltage can damage the appliances. ( See section on Battery Charging.)

Charging in Series

TO O U T P U T T E R M I N A L O N ALTERNATOR E A R T H TO ALTERNATOR OUTER CASING

Charging i n Parallel

E A R T H TO ALTERNATOR OUTER C A S I N G

TO O U T P U T T E R M 1 O N ALTERNATOR

AMPS/VOLTAGE VARIATION and CONTROL

'The arnps/voltage ratio is known in simple terms as khe "current strength'. Other factors and characteristics in electrical energy such as 'sine wave and square wave patterns' and cycles per second (Hz) d o not have a n y significant effect on current force for heating and welding purposes. In heating and welding for maximum efficiency, ease of operation and fo: the performance of wide ranging applications it is desirable that the amps/voltage ratio be variable arld controllable. In conventional single phase 2 4 0 volt comniercia!ly built welders this is achieved t o a limited degree b y having an adjustable amps control. The 'open circuit' voltage. i.e. the voltage bei'cre the v~eidingload is applied, is fixed usually a t a r o m d 35-50 volts. and the amps is manually zdjusted b y the operator in order t o vary the amps/voltage ratio, within certain limitations. In our design, the amps/voltage ratio is almost infinitely variable which enables you t o perform light soldering and gentle heating through t o heavy current applications stich as h o t arc welding, and cutting and melting steel. This is achieved b y having a progressively adjustable voltage o u t p u t , and limited adjustment amp o u t p ~ ~Tth e pro . gressive voltage variation alone is sufficient t o give a wide ranging amps/voltage ratio, but this can be varled and controlled even more b y 'switching on' a second, third, o r even fourth alternator (wired in parallel) to glve additional amps for a heavier a m p based current, yet still retaining the controllable intensity ratio with the variable voltages. If you d o not already have a working knowledge o f welding and the 'an~ps/voltageratio effect'. then the following simple experiment and explanation will enable you t o quickly understand, and follow the principles involved. Unravel a thin strand of wire about 6 0 c m long from a piece of clothes line wire, then attach one end t o the positive terminal of a 12v car battery, and the other end to the negative terminal. (Cautinrl: Use Insulated pliers t o avoid any 'arcing' burns.) T h e wire is thin enough and long enough ro restrict and control the heavy amp output from the battery while it is only at 12 volts. (The wire will glow red, b u t not melt). Now connect t w o batteries in series. T h e battery output remains the same in a m p power but the voltage doubles t o 2 4 volts. When the 60 cm wire is connected ro the t w o terminals, the wire will instantly melt and fall apart, d u e t o the stronger current intensity of the higher voltage. Amp power has remained the same, whlle t h e higher voltage has melted the wire. This clearly demonstrates the prlnclple we nave ~ n c o r p o r a t e d our design. The amps remain constant while thz in current force is either intensified or reduced by the variable voltage changing the: amps/voltage ratio. (Note: For safety ld reasons, your voltage s h o ~ ~ not rise above 60 -70 volts, so it is desirable that a voltage gauge be fitted so that the open circuit voltage can be monit0red.j A twin or triple alternator set-up will easily handle virtually all handyman field or workshop jobs, i.e., t w o 35 a m p alternators wired in parallel gives 7 0 amps, three gives 105 amps. I-Iowever, at times you will only require a low amper age for light or delicate jobs, in which case you simply disconnect or 'switch o f f one or t w o alternators. This in effect gives a variable a m p range, e.g., 35, 70, or 105 amps plus the vari?ble voltage at each anip setting. (As explained previously, voltage is increased o r decreased b y simply increasing or reducing the drive speed o f t h e alternators, while the amp output will rise and level off at t h e maxirnum rated output o f the alternator.) You now have a versatile fully integrated power unit which will easily match and often exceed the weld quality of commercially built 240v single phase arc welders. In addition t o this you have wide ranging inbuilt capabilities which far exceed that of commercial welders. Note: A single 5 5 amp alternator will give a low heat effect at low voltage, but is also capable of arc welding, melting and cutting steel at high voltages. A twin o r triple alternator set-up is not necessary, but does give added flexibility.

DRIVE LINE OFTIONS

Apart from natural energy drive systems such as wind and water (see later) there are three main options [or driving vour alternator(s). They are 1 . I,awnmou,er or Motorcycle Engine - This is a fully portable unit consisting of a wooden platform upon which th.i alternator and engine are mounted together with a 12 volt battery ( t o energise the field windings ). The dragram on page 5 (at t o p ) shows a twin alternator set-up. Note: If y o u intend drivirie: twin alternators at high speed you will need a large, powerful lawnmower engine o r small motorcycle engine, 5 - 8 HI) at least. 2 Rear Wheel of Car - This method is suitable for occasional use of the power unit such as running lights, tools o r welding in remote o r isolated locations such as a tractor o r equipment breakdowns etc. It is a very simple set-up consisting only of two alternators mounted on n board. T h e car battery supplies voltage for the field windings and an old wheel (without the tyre) is bolted or1 in place of the rear wheel. T h e flat centre of the rim is ideal foi running twrn V-Belts and the large diameter gives enough friction area t o provide good 'belt grip'. A!ternator speed ( a n d voltage) can be varied over a wide range by either idling in low gear thrsugh t o revving the m o t o r slightly in top gear. ( Note: T h e gearing ratio will turn the alternator very fast with moderate wheel speed. D o not It is only. necessary t o jack up one wheel of the car if it has a conventional rev the motor hard in t o p gear.) differential. If your car has a limited slip differential you must jack up b o t h wheels. Always chock the wheels securely because the resistance in turning the alternators can have a tendency t o 'drive' the car forward off the jack. This set-up is very convenient for occasional use of the powsr unit. You havr 3. V-Belt drive o f f Car Motor virtually unlimited power o n tap anywhere you can take your car. You can use the e x i s t ~ n g alternator o n your car without any modifications at all (providing it has a separate regulator). All you need d o is make up a lead and plug t o run direct from the battery to plug i n t o the field windings terminal on the alternator. No other modifications are necessary. T h e procedure is: Disconnect all wires and c o n n e c t ~ o n s from the alternator. (a) ( b ) Connect your special lead direct from the active terminal on the battery to the field winding terminal o n the alternator. (The active terminal is + on all cars except those with a positive tcl earth system - e.g: rarly Coninas, Morris ! 100's etc. : (c) The alternator being attached t o the car is already earthed so no earth connection:: are necessary foi energising the field windings.

'it

Start the motor and adjust throttle settings (screw a d j ~ ~ s t r n e on linkages near carburettor) to run the nt iliotor fast enough t o supply the required amps and voltage. (el Toois 2.111 l v l i a n c e s are connected in the usual way. N o t e : 'The car's char,,ing system is disconnected. Therefore your car battery is being slowly depleted, although this is not noticeable unle.is the use extends over 10 - 17 hours. C a u t i o n : Flectric welding t o the body of the car, particularly A<' arc welding, can damage alternator diodes. Always disconnect alternator and battery before arc walding on the car itself.
(dl

How f o Connzct far Welding

When using a single alterriator, you, welding earth is attached to the alternator frame, and the actual welding lead with tlle electrode holder is attached to the output terminal. If using two alternators in p?rallel, both frames are eaythed, then another earth lead goes on to earth the job in the normal way. Both output terminals are connected together, and this connection then extends on to your welding lead with the electrode holder. W E L D I N G ELECTROPE

L E A D S T O ACTERNATOR OUTPUT A N D ALTERNATOR EARTH

How t o Connect for Operating Drills, Lights, Power Tools etc. You can operate most 240 volt lights, tools and appliances on the DC voltage produced by your alternator. (Note: Alternators produce alternating current AC, b r ~ this is rectified and converted to DC by the diodes in the alternator. Batteries t cannot be charged with AC current - it is always collverted to DC first). Nearly all norinal 2 4 0 volt AC lights. tools and applia11ces c;111 e operated very efficiently with DC current. The only h limitations are induction motors such as fl-eezel-or w a s h i ~ ~ g n~acl~iile motors and appliances such as 240V AC stereo and for television sets which require the precise 50Hz Sine Wave current 11~1lse optimum performance. type electric rllotors ;lctually work with greater efficiency and longevity o n All power tools having the nor,nal b l ~ l s h DC current. Power and speed can be precisely controlled with voltage. A 3 4 0 volt drill will run quite effectively at low speed o n 70-80 volts DC, and speed and power increase as the voltage increases. A normal 100 watt 240 volt light bulb will sliow a bright red glow from the filament at 8 0 volts DC, and the brilliance and intensity increase with the voltage. 111 fact light bulbs actually last a lot longer b y using only DC current. Alternating 5 current on the 50Hz system 'pulses' or switches back and t ~ r t h 0 tirnes per second which when combined with other power surges in the main power grid tends to reduce the life of bulbs. (This pulsing can be clearly secw in the 'shimmering el'fect of fluorescent lights). When connecting your alternator. to the 3 p111plug on appliances, disregard the earth pin and, using the remaining active and neutral pins, connect one wire to the ultelrlator output terminal, and the other to earth anywhere on the alternator frame. It does not matter which way you corlnect tlieltl as long as one pin is connected tothe output terminal and one is earthed to the alternator casiiig. (Notc: The actual eal-th pin on the Lliree pin plug is not used). Diagram showing a twin alternator set-up being driven b y an old car wheel rim in place of the ol rear wheel of the car. T h e accelerator and gears of the car give c., - .- c o ~ ~ t rand variation t o the alternator speed. The car battery is kept in place, and longer leads are used to connect to the alternators t o energise the field windings.

DRIVE MOTOR

OIESEL,PETROL
OF ELECTRIC

/
BATTERY

Diagram showing the drive motor in position with a double pulley driving a twin alternator set-up. Note how the alternators are offset for belt clearance, and how the front alternator is driven b y a shorter V-belt to facilitate this compact tandem type layout.

4 Twsn Alternator Drive o f f Car Motor

-- This is relatively simple. Fit twin pulleys t o your existing alternator. One pulley is used for the normal alternator drive, and the second pulley drives another alternator mounted inside the engine bay. Always use the same type of alternator with the same pulley sizes if connecting them in parallel. If you only intend using one alternator, then it is a good idea t o use a very large second pulley attached to your existing alternator. High voltages can be achieved without running your car motor at high revs. Note: Do not connect them in parallel if you are using different pulley sizes. The differing outputs will not be compatible.

DRIVE SPEED, VOLTAGE and POWER STRENGTH

The voltage output of your regulator is directly related t o the drive speed and the actual shaft speed of your alternator. Even though your drive speed may be f i e d , you can vary the speed of your alternator (shaft speed ) by changing pulley sizes. With equal size pulleys, the speed of your alternator will equal the speed of your drive motor (assuming you are not losing speed through a slipping belt). By increasing the size of the drive pulley, you increase the speed of the alternator If the drive pulley is twice the size of the alternator pulley, the alternator will spin twice as fast as the drive pulley. The formula to calculate pulley sizes and drive speeds is:

To Calculate Alterrlator Speed

Alternator speed (RPM) =

W of Drive Motor x Diameter of Drive Pulley M

Diameter of Alternator h l l e y

For example Assume motor drive is spinning at 3000 RPM with a drive pulley of 10 cm and alternator pulley of 6 cm diameter, then
3000 x 10 6 Therefore the speed of the Alternator = 5000 RPM l o calculate the required pulley size when you want a specific alternator speed is as follows: For example the upper safety limit o n an alternator is 14000 RPM, so let's assume you have a drive motor capable o f 3000 XPM, but you want t o drive the alternator at its maxirnum of 14000 RPM. Usually it is more convenient t o change the drive rnotor pulley rather than the alternator pulley, so with an alternator pulley of 6 cm diameter and a diive motor spinning at 3000 RPM, you now want to know what sized drive pulley to use in order to spin the alterilar!~rat 14000 RPM. Hcrt; is rizi. formula pullpv diameter o f ~ r i vM~~~~ = Alternator W M x Diameter o f AlternatorPulley e RPM of Drive Motor Using t h c above example: Pulley diameter of Drive Motcir = 14000 x 6 3000 Required diameter of Pulley = 28 c n ~ . c .Vott7: In hes can be used instead of centimetres -- it makes no difference as long as you d o not mix the two. In other words a!l rnrasurernents must either be in inches, o r they must all h e in centimetres. Alternator Speed will be
=

CaicI" *r;!?;i of Power Strength, Amperage and Volts Ye).: > ' . ; I citieri want to know the exact current draw on certain tools and appliarlces in order to caiculate the required .)utput of your hattery bank or alternator. There is no point in using excess fuel and overdriving your alternator if you are nc?t going to us: the power. For sxalriplc, let's assume you have geared your alternator to put out 35 amps 3t 100 volts, you then want to know how 111;lllyI~gllts appliances you can operate off this. or The forniula is : Watts = amps x volts In the above exaqiple: Output in watts = 35 x 100 = 3500 'This nieans you have a power output capable of supplying 3500 \ ~ . I I I \ You will now want to know what this :rctually means in real terms. T o work this out. read the specificatio~isstanipcd 011 the appliances, the11 calculate 3 5 t'ollow ; For c~ua,r!pic.. One 100W light bulb consu~l;es100 watts of power wh~cti quite straightforward. flowever, most is appliances are marked In amps. s.g.1 most 101nmdrills are around I 5 arnps at 740 volts. This works out as: Watts = 1 .5 x 240 = 360 watts Therefore. the power consun~ptionof the drill is 300 watts. (The number of watts is a direct nieasureinent ' of energy a t dcttral ~ i i o t o ~ power.) For the purpose ot'cornpsrison, the 17 volt Rullc~aftd r ~ l l .IOrriril (3/8") draws 75 :lrnps at 12 volts t'or 3 rating of 300 watt$. . g Watts = 35* amps x 1 -1* volts = 300 watts ( * These figures are stamped on the drill) 7 hers :Ire O C L ' ~ S ~ ( I I Iwhen you know tlle watt$. but want to calculate the amps. This ]nay b e t o assess w~ring S size. !'t:sc s i t . . etc. 111 t h ~ case the k)rrnula 1s : s

Using the above Bullcraft drill example Amps

=

3 0 0 watts 12 volts

= 2 5 amps

Mote :This formula is important because high amps require thicker wiring t o carry it. If the wiring is t o o light, then the current i'iow is restrickd 2nd heat quickly builds u p burning the wiring out and can ignite buildings. This heat build up can be easily demonstrated by using light jumper leads t o start a car with a dead flat battery. These light jumper leads (or booster leads as they are often called) are usually only rated at about 2 5 to 5 0 amps. Most starter motors draw well over twice that amount. The result is the starter motor cannot get enough amps through the thin wire in the ieads, so ii turns over very sluggishly, then the leads quickly overheat t o the extent that the plastic insulation rrlelts within a very short while. As a general rule all tools and appliances operating o n !ow voltages require higher amperages t o get the same performance, and as a result heavier ,wiring must be used t o carry the extra amps. If the wire heats up, o r power loss is significant then heavier wiring is required. '9'0 assist you in compiling your projected power requirements for your home, we have listed the average power consumption of average-sized appliances : PO0 watt light bulb 100 W Vacuum cleaner 400 W Washing machine 500 W Frying pan 1200 W Fridge 300 W Water heater 2000 W Room heater 1000 W Solid state stereo 60 W Colour television 350 W Blender 600 W Iron 1000 W Radio 50 W Stove 12000 W Fan 80 W Toaster 800 W

Q a '

B A m E R Y CALCULATIONS and HOOK-UP SEQUENCE

Ordinary 12 volt car batteries, when hooked u p in series are capable of supplying very high (and lethal) voltagef -.You can in actual fact run a high voltage all-electric home off only a bank of 12 volt car batteries and your alternator power unit connected up for battery re-charging n o other major generating equipment is necessary. Befcre scoffing at this idea, read the chapter o n 'Battery Facts'. You will learn about buying good batteries for a dollar or two, and techniques t o add 12 - 18 months extra life t o each battery, so a bank of 2 0 batteries is quite reasonable and practical. Your alternator will fast charge these batteries quite rapidly, arld the actual stored battery power, i.e.: battery capacity in amp hours is enormous if you connect them in'parallel' at low volts. Also remember that you can run most things, i.e. : lights, heaters and brush type motors o n QC. In fact an ordinary 240 volt electric drill for example will run just as well o n QC. If you happen to have only 120QC, then the drill simply runs at half speed and half power. A good solid bank of batteries is practical and useful, particularly if your drive motor o r alternator fails unexpectedly. There are three ways t o hook up the batteries. These are: 1. In Series This steps up the voltage, but the amp hour capacity remains the same. For example t w o 12V batteries of 1 0 0 amps hours each, hooked up in series gives 24 volts with 100 amp/gr capacity. Ten 12 volt batteries give 120 volts, but still retaining the original 100 amp/hr capacity. I . IPIParallel This method steps up the capacity, but the voltage remains the same. For example, two 12 volt 100 amp/hr batteries in parallel gives only 12 volts, but 200 amplhr capacity. 3. Combined "In Series7'/''1n Pardlel" - This method gives any desired combination of either a specific voltage, or a specific capacity. For example four 12 volt 1 0 0 amp/hr batteries can combine to supply either 4 8 volts at 100 amplhr, 12 volts at 4 0 0 amp/hr, or 2 4 volts at 200 amp/hr. The hook-up sequence is as follows: "In Series" - Four 12 volts = 4 8 volts. h p / h r capacity remains t h e same as a single battery. -

&

CONNE C T TO A P P L I A N C E

"In Parallel" - Voltage remains t h e same b u t a m p increases, e.g.: 4 x 1 0 0 a m p / h r = 4 0 0 amp/hr a t 1 2 volts.

C O N N E C T TO APPLIANCE

Connect positive t o positive, negative t o negative (like t h e jumper leads o n a car).

Combined "In Series'7''In Parallel" - Voltage a n d / o r a m p capacity c a n b e varied.

In t h e above, t w o batteries are connected in series, a n d two in parallel. This gives: I n parallel connection = 12 volts a t 4 0 0 amp/hrs T h e n when it is connected in series = 2 4 volts at 2 0 0 amp/hrs

hrote: T h e amp/hr capacity of car batteries is rated o n a 2 0 h o u r discharge rate. If it has a heavy load o n it, then
t h e chemical reaction is not fast ellough to supply the full rated capacity. F o r example, 1 0 0 amp/hrs capacity will run a 5 amp appliance for 2 0 hours ( 5 x 2 0 = 1 0 0 ), b u t t h a t same battery will not p o w e r an appliance drawing 1 0 0 amps for o n e h o u r ( 1 x 1 0 0 = 100 ) as it would appear t o d o so in theory. In fact, recently the car battery terminology has changed, and t h e manufacturers usuaIly state t h e battery capacity in terms of cold cranking current, which means t h e capacity of t h e battery t o supply for example 2 4 0 amps for 3 minutes at 7OC below zero. A car starter m o t o r draws over 2 0 0 amps for 3 minutes while turning over the m o t o r , so this measurement gives a m o r e realistic idea of a battery's starting capacity. Ratteries become very sluggish in cold conditions - See Battery Facts.

Note: It is advisable t o build u p your battery bank using batteiies of a similar amperage. When connected in
parallel the current surge can damage low capacity batteries. High voltages combined with high a m p s are extremely dangerous. Always insulate all connectors o n voltages over 36V. Your standard 240V house supply has only 10 - 15 amp fuses )limiting the amperage), and this as we all know is very dangerous and capable of swift and lethal shocks. T w e n t y 12 volt batteries also give 2 4 0 volts, but the actual current force (amperage) is 1 0 t o 170 times stronger than y o u r household supply. (Household supply is limited t o 15 amps - car batteries can easily provide 3 0 0 a m p s for a short burst enough t o cause instant death when you combine that amperage with high voltages.)
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BATTERYFACTS
'The lead-acid type batteries (car batteries) w o r k o n the principle o f absorbing and discharging acid through the plates t o create electricity. Each battery cell is 2 . 2 volts, and consists o f a number of positive and negative plates arranged in alternating sequence and kept apart with inert separators. T h e battery plates are made from a lead oxide mixture, and are 'tied together' with strips of lead alloy connected t o the terminals. T h e sulphuric acid and distilled water act as an electrolyte and change t h e lead composition in the plates. When the battery is Sully charged the positive plate is primarily lead peroxide and the negative plate is primarily sponge lead. T h e electrolyte (acidlwater mixture) is then,mostly acid. However, when the battery discharges, both plates change t o lead sulphate as the acid is absorbed, and t h e electrolyte then becomes mostly water. In fact in a dead flat battery there is very little acid at all in tlie water, and if spilt o n y o u r clothing it usually won't have a n y effect at all. ( I n a fr~liycharged battery a n y small d r o p s spilt o n clothing will quickly destroy even the best of thread fabrics). Each battery cell isvirtually a battery within itself. A 1 2 volt car battery has 6 cells connected in series t o give a total of 1 2 volts actually 1 3 . 2 volts when fully charged (i.e.: 6 cells x 2.2V). A 6 volt battery has only three cells. By way of further explanation, if a hole was drilled through the wall of each o f the six cells in a 12 volt battery enabling the acid t o circulate freely anlong all the cells and plates, then the battery would become a 2 volt battery, o r a single cell battery. F r o m this it is easily seen that a n y 12 volt car battery can b e converted t o a lower% lltage b y adding another battery 'post' through a hole drilled in the t o p of t h e battery t o join u p with t h e connectors transferring current in series froin o n e cell t o another.
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Factors which determine Battery Power Battery power o r rnaximuni current strength is measured in amperage. and is directly related t o the acid absorption o n t h e surface area of the plates; the more plates a battery has, t h e greater t h e amperage capacity. Battery capacity is usually expressed as 'amp hours'. In theory this means a 12 volt battery with a capacity o f 100 a m p hours would keep a 17- volt light bulb with 1 a m p current draw going.for 1 0 0 hours, o r a larger drawing 20 a m p s o f power would keep going for 5 hours. As mentioned above, this is in theory only. Under actual operating conditions, as a general rule of t h u m b , the liiglier t h e amperage draw, t h e lower t h e total capacity. F o r example, a t a 1 a m p current draw, the 1 0 0 amp/hr battery would last for 1 0 0 hours ji.e.: 1 0 0 a m p s divided by 1 = l o o ) , but a t a current draw of 2 0 amps. the I~attery would not last the 5 h o u r s as expected. It would probably b e nearer 3 o r 4 hours. T h e reason for this apparent inconsistency is that t h e acid reaction is n o t fast enough t o 'recover" itself and generate power at its most efficient level. (Battery a m p hour rates are usually based or1 a 2 0 h o u r discharge period.) Batteries always operate m u c h m o r e efficiently in w a r m l h o t weather. This is because the 'pores' of the plates (similar t o the pores o n your skin) open u p and allow free movement o f acid, and a faster chemical reaction. Higher temperatures accelerate all chemical reactions and molecular movement. (However, in very cold climates special chemical additives can be used t o increase 'pore' size). Battery Charging As a general rule, the slow charge is the best charge, but fast charging using commercial fast chargers a t your alternator power unit is q l ~ i t e OK, and gives a good lasting charge. T h e r e are, however, certain facts you should b e aware of when fast charging, otherwise you can reduce the life of y o u r battery, o r even damage it beyond repair. When fast charging avoid heavy gassing and excessive heat. Bubbles and mild gassing are q u i t e normal during charging. (Note:This gas is explosive. Always remove the cell caps before charging t o enable this gas t o escape - and do ~ ~ use ra naked flame near t h e battery cells.) This gas is a mixture of oxygen and hydrogen, and is only the o water splitting into its t w o basic gases - the hydrogen gas is emitted from t h e electrolytic reaction o n the negative plate within the cell, and the oxygen is created at the positive plate. This is the reason w h y water has t o b e added periodically t o batteries - it gasses o f f in small bubbles during charging. (Acid does not gas o f f , and should not b e added during the normal life of a battery.) Overcharging o r excessive fast charging will cause a heat build u p in the battery cells and also causes heavy gassing and boiling. A cell temperature u p t o 60C isabout as high as it should go. A t temperatures above this tne i.rl1 c;tn be damaged o r even explode in extreme cases. Heavy gassing and bubbling can 'chip o f f t h e special paste used o n the plates. and lead peroxide can be broken off the positive plate and carried t o the negative plate where it is reduced t o pure lead. This causes lead crystals t o grow out frorn the edges of the plate and eventually extend around t h e separators and short o u t the plates.

This, o f course. 1s in severe cases. and occtris over a relat~velylong period. but it does shorten battery life and reduce efficiency, so ~t is useful to be aware of these facts. D o not assume from the above that all gassing is detrimental in fact tile opposite is true. Mild gassing is essei~tial full and cornplete battery charging. Gassing begins at 2.2 volts per cell (fully charged voltage) and is for rlloderate at 2.4 volts and heavy at 7.5 volts. Ideally, charging should always be carried t o completion, that is to the point where gassing begins. Usually o n e o r t w o cells d o not charge as fast as t h e others. particularly in old batteries. so t h e bubbling will begin in some before the slow ones reach a full charge. Regulators in cars are generally set to supply a fixed voltage o f 13.8 volts which gives 2.3 volts per cell - this being just within t h e voltage area which causes mild gassing. T h e cell voltage is a measure o f the end product, that is the actual state o f charge that the battery has reached. T h e speed a t which a battery can be charged depends on t h e charging amperage available. Fast charges supply a high amperage whereas slow charges supply low amperage. T h e car charging system via t h e regulator supplies a high amperage when t h e battery is flat (will overheat the regulator if t l ~ e battery is damaged). and the anlperage drops off as t h e battery charges up. This is an ideal conibination for trouble-free battery life. but it takes a long time to fully charge the battery. 12 - 7-0 hours of normal driving. This system is therefore not suitable for h o m e power systems where fast charging is desirable. 'Fhe safest way to charge a battery i n t h e shortest possible time is t o use the 'amp-hour. t w o hour rule o f thumb' technique. With this nlethod you can charge a dead flat battery up t o ')O/i;- capacity i l l a little over t w o hours. and full capacity i r about four hours. T h e rule of t h u m b is as follows T h e charge rate in amps is equal t o the nurnber of a m p h o u r capacity t o b e recharged. F o r example, assuming y o u battery which is dead flat, then y o u can p u m p i l l 100 amps for t w o hours and you will regain a have a 100 a ~ n p / h r 9Wc battery charge without damage or gassing. T h e amperage is then reduced at i ~ ~ t e r v a for the next t w o hours ls mainly to s t o p over-heating o f t h e cells and t o reduce excessive gassing. ( Note: This final I@%charge should b e spread over t w o hours.) If your battery is 44 flat fol. example, again assuming you have a 1 0 0 a m p hour battery. then y o u charge it at 75 amps for t h e first two hours - ( % of 1 0 0 amp/hr = 75 a m p / h r , therefore it is charged at 75 amps). This gives a 90% charge, and once again the final 1Wr charge should take t w o hoursgiving a tvtal of four hours t o fully and completely charge your battery. Your alternator set-up is capable of 3 wide range of slow and I;lst charging options. 111a d d ~ t i o nt o t h e standard automotive charging rate (reconnect the regulator') y o u can produce a wide range o f fast charging amp/volt c o n ~ b i n a t i o n s charging single batteries o r battery banks connected either in parallel or in series. for As a general rule a single 12 volt car battery can be fast charged at 13 - 2 0 volts with alnp rares of 35 -55 amps. li you want t o increase tile a m p rate but keep the voltage d o w n Iclw. connect the alternators in parallel, and don't spin them t o o fast (voltage rises with speed. whereas amps level off at t h e alternator's maximum rated o u t p u t ) . The voltage will stay low, but your a m p rate doubles. For example, t w o 55 a m p alter~latorsin parallel produce 1 1 0 - 1 1 5 amps. Batteries connected in series to produce higher voltages should b e charged at the higher volts. F o r example, four batteries in series producing 48 volts could be charged at 50 - hO volts. A'OIP: \%en in series t h e a m p rate is the same as a single battery. s o do not calculate four tirnes the a m p hour capacity. Caution: Heavily sulphated batteries should not be fast charged for long periods in a n a t t e m p t to 'boost' life into them they can in some cases burst or explode.
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Causes of Battery Failure T h e most c o m m o n cause of battery failure is sulphation in the cells. Sulphation is the hardening or cl.ystallizing o f t h e usually soft and chemically active lead sulphate. As it hnrdens and crystallizes. the battery capacity and chemical activity are reduced, leading to failure. Leaving a battery standing on a shelf' lor m o n t h s in a discharged (flat) state leads t o very early battery failul-e due to sulphation. Plate buckling is another c o n r n o n cause of battery failure. This is usually the result of t h e battery not being 'topped up' with water, and t h e plates being exposed t o t h e air. T h e air causes the plates to warp a n d crumble and in addition t o reducing capacity, t h e crumbled plates form a sedinieptary deposit which can cause shorting. Sludging is znother cause o f battery failure. This is caused b y peroxide crystals "growing" around the positive plates, then falling off and sludging up the batterv. How t o Extend Battery Life Battery life can be extended b y a n extra o n e t o t w o years b y reducing/disso\ving t h e suiphation. Thiscan he accon~plishedb y the addition of certain chemicals to the battery t h e formula being listed in this section. However, tllis is a very contrvversial issue. with many variables involved. Certain 'respected authorities' o n the matter have issued categorical s t a t m e n t s saying 'that a d d ~ t i v e s o not work'. O u r experience suggests t h e y d o work d Fpsorn salts (Magnesium Sulpliate) csed alone with n o o t h e r additives. increased battcr) life b y nearly 13 months. ( I t was sulphated and could not take (11- hold a c h a ~ g e . )
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Because of t h e many variables involved it is extremely difficult t o predict t h e life ol'a battery. For example. o n e which is continuously being discharged by a faulty starter m o t o r is more l k e l y to have a shorter life d u e t o s sulphation. T h ~ is because as t h e battery discharges b o t h positive and negative plateschange into lead sulphate and it is while it is in this lead sulphate state that they are prone to che~llicalreactions causing sulphation. When the battery is fully re-charged the positive plate turns back into lead peroxide, and the negative plate changes into sponge, and in this chemical state are tlor prone to sulphation. Obviously a battery kept in a fully charged state will have a m u c h longer life than o n e which is nlostly in a discharged (flat) state. However, t h e batteries are made t o be used, so during their use, particularly in a h o m e power plant, they will b e discharged quite heavily at times, a n d it is ngt always convenient to re-charge them immediately. Under these circumstances sulphation is inevitable, so the following facts and formulae will at some stage o r another prove useful t o you.

1. Magnesium Sulphate More commonly k n o w n as Epsom Salts. Buy it in a n ordinary packet at either t h e chemist and put a slightly heaped teaspoonful into each cell. Fully charge i t with a slow charge, then diso r super~tiarket, charge it (using ca'r headlights o r similar), t h e n add another slightly heaped teaspoonful t o each cell. It will take about a m o n t h for t h e Epsom Salts t o dissolve t h e sulphation and increase t h e battery's capacity t o hold a charge. 2. Cattsric Soda - d r o p a small pinch o f caustic soda into each cell w h e n the battery is flat. As i t charges and heats up, the caustic will foam and dissolve t h e sulphation. -3. Formula (No. 1) Power Additive Sodium Sulphate (salt cake) 15 parts Magnesium Sulphate (Epsonl Salts) 10 parts Magnesium Oxide (Calcined Magnesia) 7 parts t Mix all together (by stirring with a spoon), then add 7 - 3 I l e a p d teaspoonsf~ll o each battery cell. I t m a y be necessary t o repeat this treatment 4 - 6 m o n t h s later. 4. Formula (No. 2 ) Liquid Additive Aluminium Sulphate (also k n o w n as alum cake. papermakers alum, Pearl alum 88 parts 4 parts Magnesium Sulphate (Epsoin Salts) I part Cadium Sulphate ~nl Dissolve t h e Epsom Salts and cadium sulphate in water. then add the a l ~ ~ r n i n i i sulphate. Use only enough water t o i o make a s m o o t h concentrated solution. Use 2. - 3 teaspoonsful every sis months. 5. Miscellaneous Hints - Sludging can b e reduced q u i t e siibstant~ally( u p to 5 6 ; ) b l , adding very small a m o u n t s of vanadium and chromium t o each cell. When sludging has occurred. it can b e reduced and battery life increased b y operating it in a warmer area ( h o t if possible), reducing b o t h current draw and reducing the amperage charge rate, and adding Inore water than normal t o each cell, i.e., overfilling each cell. Lighter loads increase battery life, by a small amount. s o if you have 3 heavy current draw (e.g.: workshop tools) h o o k up 2 o r three batteries in parallel. This still glves only 17 volts. but t h e capacity is doubled or tripled, so this means what was originally a heavy current draw o n o n e battery now becomes a light current draw because it is spread over 2 , 3 o r 4 batteries. Always add distilled water t o batteries. Impurities in water such as minerals and iron can cause reactions within the battery a n d reduce its capacity and its life. D o not add additional acid t o a battery (unless i t replaces some which has been spilt o r emptied from the battery). Adding additional acid t o a battery will d o m o r e harm than good. and excess a m o u n t s will quickly destroy the battery. It is O K while t h e battery is tlat and t h e liquid in the cells is ~nclstly water, but with additional acid having been added t h e density is t o o great a n d creates adverse chemical reactions within the battery. ( Y o u r hydrometer reading would always be wildly inaccurate because o f the extra acid density, i.e.: a tlat battery would b e showing up 'fully charged' if enough acid was added.) E m p t y all the electrolyte (acidlwater) from each cell, and in its place 6. DissolvingSulpharion with Distilled Water put distilled water. Allow t o stand for a n hour o r so. then put it o n a slow charge of about 4 amps. T h e sulphate crystals will gradually dissolve (they are more soluble in p u r e water than acidlwater). a n d as they dissolve o u t , they turn into sulphuric acid. A combination o f battery charging a n d chemical reaction will cause a rise in temperature within the battery. If it reaches 45' - ~ o ' c , turn t h e charger off, and let the battery cool down. Keep t h e slow charge going while ever t h e 'specific gravity' reading is increasing. (Use your hydrometer for this). If the specific gravity goes over t h e normal figure of about 1.300, it means someone has added acid to t h e battery. T h e best move then is t o tip it all out and start again with fresh distilled water. When your reading stabilizes. i.e.: t h e specific gravity reading stops rising. tip i t o u t . then refill each cell with a fresh acid solution, then run the battery through t w o or three chargeldischarge cycies and check y o u r "specific gravity" reading.
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T h e fresh acid solution is made up of sulpliuric a c ~ d and water. lf y o u c~cnncltb u y a ready-made mixture, then [nix LL ~ ~ ~ i amount of acid and water together. (Caution : Always add acid t o water - - do nor add water to straight illl a c ~ d t perchance you d o get a c ~ d your eyes, flush them well for several miriutes with I'resh water.) I in With t h e mixture in t h e battery. and the batter). fully charged, y o u r hydrometer reading should show 1.265 t o 1.285 in sunlnrer and u p t o 1.300 in winter. If the reading is t o o low, add rnore acid.

HOWand Where t o get G o o d Used Batteries T h e best place to get used batteries is from sewice statio!is. Avoid i t possible buying from scrap ~ n e t a ! niercliants and jr~nkyards. because the batreries are probably dry. damaged o r been b t a n d ~ n gt o o long witliout a charge. Serv~ce stations often have good batteries which have gone llat for solne r e a w n . such as a laulty slarter rriotor drawing t o o r i ~ l ~ c h current, o r incorrectly adjusted regulator o r fBult1. generator o r alter~iator. Quite (;<ten t h e niotorist assumes the battery is n o good and simply asks tlle service statloll attend,~ri:to I'it a new o n e . These 'dead' ba!!eries are classified as jurik and can o f t e n be picked u p fnr a dollar nr two. Ari aierage o f about 1 in 3 is a good !~atterycapable of llolding a full charge. R u ) . half'a dozen of tf~ebebatteries arid put tllein o n a slow charge o f ahout 3 alrips and leave them until fully charged m y w h e r e fro111o n e to tliree days. I)~scc~~?ne,:t charger, arid leave the battery s t a n d ~ n gfor four o r five the days, then tebt it with a load testel, o r ilrider o p e r a t ~ n g ionditiorls. I f it stnrids ~ i OK. and has held the charge, and is p al)le 1 0 deliver i t , ihen you have a good secondhand battery. Tliose tliat di.)!l't starid rip to thr. test (:ill be sold t o a scrap 111i.lnlmercliant so in effect the useless batteries have not ((.st you nnytllirip. ant1 11re good ones have been a,:qnird t i ) r a niini~rr:il o ~ l t l a y a few doltars. of
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INVERTERS
I n ~ ~ e r t earc devices t o change voltage and current frorr. a tow DC' (Direct Currelit) voltage t o a high AC (Alternating rs Current) voitage For example, using an inverter. y n ~ can convert 1 3 volts DC i n t o 1 4 0 AC, 5 0 1 1 ~for operating i . 1:t)rnlal household appliarices. Tliere are two main types of inverters in general use. T h e y are: i. Rotary Inverters T h i ~ no st suited t o very heavy current use. I t is actually 311 alternator being driven b y a low is witage DC rnotor. and t~ll.ns current (AC) at 2 4 0 V . 50IIz. ( ;I:ore: Your car alternator generates 3 phase AC out current, but this pasles through rectifier diodes t o p r o d l ~ c e voltage.) IIC Ttre rotary i~lvelter, sonietimes called a 'motor generator', is not really suited fni- very srnall power plants. Although they d o a very good job generally they have o n e disadvantage in ter:rrs of power use efficiency. T h e y are 1ic.t as efficient as the solid state inverters. T h e rotary inverter has about a 6055 efficiency rate whereas the solid state invertel has about 80% efficiency rate. This ill effect ineans t h e rotary nit is e:~ting u p quite a tot of power just to operate the inverter alone. 17. Soliti State Irz~lerters - These are a comparalively recent development in inverters and as mentioned previor~slj, they make m ~ r c h more efficient use o f available power. As a general rule. the solid state inverters are rr:ore s u ~ t a b l e o t smaller applications. In fact we found i t best t o use 4 o r 5 small inverters around the h o m e rather than one big rotary inverter. However, amorigst other things, it all comes d o w n t o y o u r available DC power, and y o u r actual power requirements. Tips o n Buying Inverters Solid state inverters are readily available frorn nearly all electronic stores. and second hand rotary iriverters can ot'ter: be bougllt at reasonable prices from arnry disposal stoles, o r if y o u are huildii~gup alternative power syctems for friends o r to sell commercially, you are well advised t o contact t h e Dept. o f Defence direct and b u y in bulk either by tender or b y auction. The foltowing facts should b e kept in mind when buying inverters: (a) T h e o u t p u t has t o be 2 4 0 V with a 50 cycle per second rate. i.e.: 50FIz. I r i Austr:ilia oul- power s>.stem.and all appliances, run o n SOHz. (In tlie U.S.A. t h e rate is 601-Iz). e' ( b ) T h e inverter should ideally produce a ' s ~ n ~ w a v rather than a 'square wave'. T11e 'wave' is tlie fluctuating o f . the current as it pulses o r alternates. T h e 'sine wave' 1s necessary for induction riiotors. static-free stereos and distortion-free television. Incidentally. the rotary Inverters have an exceptionally good 'silie wave' capability. (c) I t is desirable tllst t h e inverter have an autoinatic switclririg capability so t l ~ a ti t starts LIP when an appliance is switched o n . a l ~ d shuts off when t h e applianie is switched o f f . ut ( d ) It should have a heavy st:irt u p capability. tlrat is i t should br. able t o exceed i t ; rated o ~ ~ t p for a feu, seconds for acconlniodating tlie sudden lieavy culrcrit draw wlien m o t o r s rtart. (e) T h e inverter shoiild also liave a n ar~tolrratiicrverload cut-out to avoid damage 0 1 1 occasions w!iere i t is Iicai8ily overloatied fur Inore than five ci:- ten seconds. When buying inverters yo11 should shop around - look u p tile s u j > p l i ? ~111 the Yellow I'ages and either pliclne o~ write s to them for brochures. pri,:es and details.

For the convenience of those of you who live in isolated or remote locations, the addresses of several Sydney manufacturers/suppliers are listed. Jaycar Electronics 117 York S t , SYDNEY 2000 Ph. 267 1614 Dept. of Defence, Navy, Navy Supply Centre ZETLAND, N.S. W. 2 0 17 Dept. of Defence, RAAF, Air Force Supply Officer, 59 GouIburn St, SYDNEY 2000 Dept. of Defence, Army, Public Relations, Victoria Barracks, Oxford St, PADDINGTON, N.S. W. 202 1 Inverters and Constavolt Electronics Pty Ltd 1 19 Robey S t MAROUBRA, N.S.W. 2035 Chloride Batteries Aust. Ltd, 23a Nyrang St. LIDCOMBE N.S.W. 2 14 1

S.T.C. Moorebank Ave., LIVERPOOL, N.S. W. 2 170 Power Electronics 6 McLaughlin S t , ARTARMON, N.S.W. 2064

Electronic Technologies 3 Potts St, RYDE, N.S.W. 21 12

LOW VOLTAGE APPLIANCES and TOOLS

Virtually a11 household appliances and workshop tools are available in the low voltage, i.e.: 12 - 3 6 volt DC power range. With the ever-increasing demand for camping and leisure equipment, manufacturers and importers are beginning to cater to and cash in on this enormous market potential. As a result of this upsurge, particularly with regards t o recreational vehicles (four wheel drives), campervans and caravans, there is now an impressive array of 12 volt appliances and accessories ranging from fridges, radios and colour televisions through to heavy duty drills and winches. These are all readily available throughout Australia at caravan, camping and recreational vehicle suppliers, so it is pointless listing them in any further detail here. We have, however, listed below items of a more specialized nature which are somewhat difficult t o obtain through

ordinary retail outlets. 12 Voltfleavy-dutv Fencing Tool: This unit is basically a heavy-duty drill capable of driving a soil auger of 3" to 7" diameter, and %" to 1" wood auger. It is two-speed plus reverse and available from : BISHOP ENGINEERING. 46 Buffalo Road, Gladesville, N.S.W. 2 1 I I . Write and ask for a brochure. 12 Volt lOmm Drill: We have had difficulty in locating 12 volt workshop drills within a reasonable price range, so are including details of the Bullcraft lOmm drill manufactured in Japan. At this stage, it is not being imported in bulk, so we have made special arrangements for small orders to be purchased direct from the export agents in Japan. At the date of publication of this manual the drills were priced at Y6,820 (Yen) each. This is about $30.00 Australian. At this price the minimum order is 6 drills. A number of accessories are available including sanders, drill stands, jig saws, bilge pumps etc. If you prefer to buy them individually, or in bulk, then the price will vary. that is higher for individual drills, lower for bulk orders. In any event write first to confirm price and availability. Write an ordinary letter in English and send b y airmail t o : Mr Y. (A.J. ) NAKAYAMA, SHOEI INDUSTRY CO. LTD, P.O. BOX Minami #49, Osaka. Japan. Mr Nakayama will write back to you in English confirming prices and availability and other information you might require. He will be quotlng prices in Japanese Yen so you take the letter to your local post office and ask for an International Money Order, show them the company name and amount, then the post office will write out a Money Order and give it to you. Post this b y airmail t o Mr Nakayama together with a letter specifying what you want. (Note: It is not necessary t o show the post office the letter - it just makes it easier for them t o understand what you want.) Rather than buy an International Money Order you may go to the bank and ask for a bank draft o r an International Bank Cheque as it is sometimes called. Depending o n t h e bank, this is sometimes a dollar or two cheaper than the post office.

Small orders up to six drills will arrive through the mail, and the post office will give you a card specifying the amount of import duty and sales tax to pay. You then pay the post office that amount and collect the goods. I t may sound involved, but it is quite straightforward and doesn't require any effort other than writing a couple of letters and going to the post office twice. 18 - 36 Volt Welder: It probably appears superfluous and unnecessary to include details on low voltage DC welde~s when you can easily weld direct off you car alternator. However, for various reasons some people prefer to weld direct off the batteries instead of connecting up their alternators. A small compact unit weighing only 1 kg and small enough to fit in a car toolbox has been designed specifically for this purpose. It is called the XP Welder. It is a very simple, easy to use device which has a small inbuilt oscillating arrangement to control the amperage from the car batteries, and will run a very neat weld using standard 12, 14 and 16 gauge rods (i.e.: welding rods up t o 2.5mm). It works very well with 2.00mm welding rods using two 12 volt car batteries connected in series to give 24 volts. They are available from P A W POKER TOOLS, 280 Parramatta Road, Granville, N.S.W. 2142. At the time of researching this project their stocks were limited and it was un!ikely that they would be restocking. If you are not able to purchase them direct from Para Power Tools, write to: XB WELDER COMPANY, Essex Road, Basingstoke, Hampshire, RG21 ISZ, England, and ask for the name of the importers or distributors nearest to where you live. Using an Old Car Generator as an Electric Motor Old car generators are In plentiful supply and easily acquired for five dollars eacla or less. Generators are no longei used on cars, having been replaced by the more efficient and reliable alternators. As a result there is little or no demand for generators and most people clearing out their sheds are quite happy to give them away. Generators can be used in a similar manner t o alternators for power output, but lack the overall efficiency and and reliability. They do however make excellent fast running low power consumptlasn electric motors. There are two ways to connect them: 1. Fast mnrring - light power consrimption: Connect the positive "'+" lead from a 12 volt battery to the large terminal "Dmon the back of the generator. Connect another lead frorn the negative battery terminal to anywhere on the il generator casing. The generator wl spin very fast in an anti-cloclcwise direction. It has low power consumption (about 12 amps) but although it spins fast it has no real driving power. It is frcswever very usefill for running small fans and other appliances not requiring much power. (Note:For a generator t o operate in this manner the brushes, commutator and all connections must be clean and in good condition. j
IVotes on cleaning G e n e r ~ l o r s

(a) Rennove two long screws - see diagram. (b) Rear section holding rear bronze bush and brushes slldes out, and gc~neratos casing slips forward off front bracket. (6) Clean the commutator with a petrol rag or very fine emery paper Undercut the ir~sulators between the segments t o a depth of 1 - 2mn1 using a broken off hacksavr blade ~ T O U I down to the width of the I ~ insulators. ( d ) Clear] or replace brushes, ensuring that they slide up and down OK, and ride evensly on the commutator. (Brushes only cost $ 2 - $3 per set.) (e) Replace rear bronze bush if worn and ensure bush and front bearing allow easy unrestricted rotation. (f) Oil at regular intervals through rear oil hole if used for long periods.

2. Greater driving force - slower speed, less power co~asurnption The drive power of the generatni csri be in: creased (but speed is substantially reduced) by connecting both terminals together and then connecting to the positive
terminal of the battery (see diagram). Power consumption is about 4 - 6 amps, which is very light when compared to the heavy current drawn by starter motors under load (100 - 245 amps). Note: When using generators in this manner d o not overload them. If heat build-up in the field windings is excessive, reduce the load or allow them to cool down. (The field windings on generators are attached to the inside of the main casing, so by placing your hand on the casing any heat build-up is easily felt.) Using Old Starter Motors as High Power Drive Units Old starter motors, particularly those off early model cars with a separate solenoid switch, are the best to use and also the easiest to acquire for little or no outlay. (Similar t o old generators, they are often classified as unwanted junk.) Starter motors develop enormous torque and driving power. The actual power consumption is very heavy under full load, but decreases to an acceptable level under moderate loads. (About 5 0 amps with a light load.) Note: Starter motors are designed for only short runs under full load, and therefore the continuous running load should be reduced substantially to avoid overheating. It is advisable to remove the brush cover band t o facilitate -.increased air circulation and more effective heat dissipation. Power Connections: On starter motors with a separate solenoid, disregard the solenoid and connect the positive lead

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t o the terminal o n the end. The negative lead is earthed to any point on the casing of the starter motor. On starter motors w ~ t h solenoid attached, connect the positive lead t o the main starter motor terminal, then the run a short l ~ g h wire t o the terminal o n the solenoid. The negative lead is earthed to any point on the main casing t

Machining Shafr for Fitting o f V - B e l r f i l l e ~ v :Remove the pinion and spring etc. from the starter motor. (Take care
in compressing and removing the spring - it is very powerful and can be dangerous. You are advised to follow procedures set out in the car workshop manual.) The exposed shaft will be uneven and unsuitable for the fitting of a V-Belt pulley. The procedure for machining the shaft is as follows: Fill slots and build u p shaft as required using your arc welding unit. Fit copper or steel clamps,and wrap a (a) wet rag around the base of the shaft t o dissipate heat and prevent excessive heat affecting the field winding insulation. After welding, remove the clamps and rag and hold the starter motor securely, e.g.: in a vice. then connect it (b) to a battery and allow to run a t full speed. (c) Using either a high speed disc grinder or abrasive disc in drill running at high speed, move the abrasive disc slowly in against the spinning shaft. The abrasive disc turning against the spinning shaft will machine it down and centre it up perfectly. Finish off with fine emery paper. The end result will be a perfectly round, perfectly centred, highly polished shaft of any diameter you desire. All you need d o now is fit a standard type V-Belt pulley and mount the starter motor securely, and you have a powerful low cost 12 volt electric motor suitable for a wide range of home and workshop applications. Note: Starter motors usually run on bronze bushes instead of ball bearings, so it is wise to oil them regularly on a daily basis if using them for long periods under continuous running conditions.
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Fitting ofDrill Chuck: If you require a drill or drill chuck for using the standard type flexible drive attachments.
slniply cut a thread o n the end of the starter motor shaft using a die with a thread size and pitch the same as the required drill chuck. The standard Jacobs type drill chucks can be purchased from [nost hardware stores and all power tool supplier\ The specifications on the box will detail thread size and type. After cutting the thread on the shaft you simply screw the chuck assembly straight on to it. You now have a heavy duty 12 volt 'drill' with enormous power, capable of the most arduous of tasks. It IS advisable to bolt a handle on t o the starter motor because the enormous starting power and torque will twist it out of your hands if the bit sticks or catches. Use an alligator clip as the positive connection so that it can be easily flicked off to stop the drill illstantly if need be, otherwise fit a trigger type switch, either to the positive or negative lead, preferably the positive - in fact it should be fitted to the positive lead because the negative lead is only an earth and if you happen to be drilling on the car body to which the battery is earthed, then the switch will be useless because the drill is earthing itself on the car. Old starter motors fitted with a V-Belt pulley have endless applications both around the workshop and in the home, and are particularly useful in place of 240 volt induction nlotors. For example. in washing machines or work benches etc. Cogs or sprockets can be fitted in place of pulleys for heavy use such as winches etc. The fitting of a Jacobs ch\ick opens the door to a wide assortment of uses - - in fact any ordinary drill accessory

such as grinding wheels, sanders, jig saw attachments, circular saws, bilge pumps, flexible drive lines, etc., can all be used, often with greater efficiency than in the conventional drills. Fan Operated Room Heater Room heaters can quite easily be assembled by coiling a thin piece of wire around in the shape of a spring, then connecting one end to the positive terminal and the other t o the negative terminal of a 12 volt battery bank. The wire will quickly heat up and glow red hot. Amperage draw is heavy until the wire glows red, then it drops and stabilizes at ar, acceptable level. For example, a thin strand of wire taken from a piece of clothes line wire 60cm long will draw about 4 0 amps initially, then quickly drop t o about 2 0 amps as the wire glows red, and then rernains at this level. Attach a small fan blade t o a light motor, e.g.: generator 'motor', and the soft current of air blowing through and across the heated element provides warm air for home heating. Note: Heat output can b e increased b y using thicker wire. However, power consumption will rise accordingly.

HOME POWER PLANT OPTIONS and COMBINATIONS

Your entire home power plant layout can b e tailor made to your own specific requirements. There are so many combinations and variations available that it is neither practical nor desirable that we specify exactly how you should set it up. We have, however, listed below guidelines , suggestions arid recommendations. On an overall basis we re ommend using a 12 volt household system with inverters for operating specialized appliances at 240 volts. The reasons for this are: 1. A wide range of 12 volt appliances are readily available from retail outlets. These range from radios, fridges and television sets through to heavy-duty drills and workshop tools. 2. 12 volt power is easy and cheap t o keep in 'storage' and o n tap, whereas 2 4 0 volts is more difficult to store and is dangerous. It is dangerous because the average person refuses t o believe that an old car alternator or a set of old 12 volt batteries can produce high and lethal voltages. This leads t o situations where careless handling can result in serious accidents. We have had automotive mechanics inspecting our power set-up and when cautioned against fiddling with connections while the unit was in operation, their typical comments have been 'Look, mate, I work with these things (cars, batteries, alternators) all day, so I know what I'm doing'. This attitude has nearly resulted in serious accidents on more than one occasion. In a normal situation their reasoning is quite valid because a human cannot feel 12 volts and alternators only go t o about 2 0 volts on a car, which only gives a mild tingle. ( N o t e :Spark plug leads will give a sharp shock because the coil lifts the voltage from 1 2 volts to several thousands of volts.) However, the main point is that most people are over-confident and casual in handling batteries and alternators, therefore regardless of how well you have it all insulated and labelled with high voltage danger signs, there will always b e someone who thinks he knows best and i'orges ahead prodding and touching with fingers and screwdrivers. for You are therefore well advised to use inverters with standard 240 volt 3 pin plug ii~ltlets stepping up your voltage from 1 2 , 2 4 , or 36 t o 2 4 0 as required. (See section o n inverters.) It is essential that you have a dual wiring system in your home. Low voltages. e.g.: 12 volts, require higher 3. amps to produce the same performance output from an appliance. Hidl amps require heavier wiring, and in any case you cannot run high and low voltages through the same wire at the same time. We recommend you run your home on a basic 12 volt system. Your auxiliary wiring is then the 240V system. The usual set-up is t o have an inverter box in whir:h your inverters draw the standard 12 or 24 volts from your battery bank and convert it t o 240V. This inverter output is wired directly into the 240V c system. When you plug in a 240V appIiance and switch it on the inverter automatically starts u p and delivers 240%' through the safely enclosed wiring system when you need it, and as often as you want it. Always have your battery bank in a warm dry well-ventilated room. Do not use the battery room as a store 4. room for tools and instruments. Batteries give off hydrogen gas during charging which when in a confined space reaches an inflammable and explosive density which can be easily ignited by sparks. In addition to the explosive qualities of hydrogen, the 'other minor gases and vapours are highly corrosive and have a tendency to creep into the inner workings of expensive tools and measuring equipment, hence the other reason for not using the battery shed as a store room. Note: Naked flames should never be used near batteries at any time. Your 12 volt wiring should be protected b y fuses in the normal way. You will require heavier fuses, e.g. : 3 0 5. amps, to carry the higher amperage. It is suggested that you build a small control panel wit11 amp gauges, voltage gauges and fuses all together so that you can easily i n o ~ i i t ).our power use, storage and charging rates, or in the event of breakdowns ~~r you can easily isolate the fault and rectify the problem bzfore it cailses any inconvenience or interruption to supply.

All the gauges, fuses, etc. for a 12 volt systelll are I-eadily availabl~ through any car accessory shop. If you are runriing a 1140 volt DC system then > , ~ I will reqr~il-e 1 5 0 V DC gauge. These are difficult to locate I a through ordinary retail outlets, but most gauge or instrument manufacturers will either have them in stock or have access t o them. Nnrn!ally the nrdinary autor~ioiivc 3:n;: :,:ll?!Tero to hC is sufficient. but if you are corlnecting two . r .np ;~li:~rnatc!rs pal.slit.1 i'cli.- \r~z!dir!gc.::.. :,o~s in wiil require the 150 amp gauge. (Most alternators will !:o a liit :;b<.~ve their r:lt?il aiitpiai, scr two 55 a![!:>alternators will probably put out around 125 - 130 amps.) l!;-ii.l:ir?:;: With high :imperagc c ) ~ i p!,:;i;~ i!-equir? h?avy wiring. Always use insulated wiring rated above ~ ;:oil!- mtended output. Any elecirical .:fore will b e able to show you the correct wire size if you tell them the z a p s and voltage it has t o carry.
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Idow voltage, high amperage e!ectriczl systerns require heavy switches. Light duty switches such as those used in the normal 2 4 0 voit household supply are /lot suitable. They are only designed io handle 15 amps. They for are dangerous and i!ladec,~:i:~te 17, \loit systems. The high amperage of a 12 volt system will cause them to overheat, arc acrcss and can easily cause fires in addition to the inconvenience of switch failure and disrupted supply. Heavy duty switches and power outlets are available from caravan and recreational vehicle (campervan etc. ) suppliers. As a general rule, you can run 905%of household power requirements on a 12 volt system, and the remainirlg 10% o n inverters changing 12, 2 4 or 36 volts DC into 240 AC. If you live in a remote location, you can have a comfortable all-electric home without incurring the horrific expense of having the local county council or electricity authority constructing lines and installing all their meters and paraphernalia.

ALTERNATIVE ENERGY DRIVE SYSTEMS

For maximum performance, convenience and ease of use, we have recommended that the power unit be driven by your car engine or a separate small petrol engine. However, there are other driving methods which can be used, and apart from the initial set-up cost the running cosis are virtually zero. They are: Direct from Water Power The most common of these types of drive systems is a waterwheel (similar t o the old paddle steamers) which is turned by the force of fast running water flowing against it. The drive shaft is fitted with a V-Belt pulley which then drives the alternator. If the water flow is reasonably constant then the alternator speed can be calculated and adjusted by changing pulley sizes. (See previously fcr method of speed calculation) The main disadvantages with this system are problerns and damage caused by floods and floating debris, and of course the adjusting of alternator speed current is not really practical in the sense of convenience and ease of operation. Regulated Direct Flow Water Power 2. This method is basically the same as the old water wheel, except a large chute is constructed, channelling the water

I.

WATER D I R E C I E D B A C K

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directly down on t o the fins of the water wheel. The chute is fitted with a large 'gate-valve' which can be partly closed t o restrict water flow, and therefore control the drive power and speed, o r it can be closed completeiy in times of flooding t o protect the water wheel from damage. Note: The fins of the water wheel should fit within the walls of the chute. This means the water has no escape except t o turn the wheel. Water captured in this manner exerts enormous driving force, particularly if you have a long deep enclosed chute funnzlling into a tapered driving point. Water Powered O n S i t e Gravity Unit This unit is designed for locations where the actual speed and volume of water are limited, or in cases where a more precise form of shaft speed control is desirable. (Provided the shaft load is constant) The water intake is a large diameter pipe fitted with a tap or valve t o control water flow. The gravity wheel con sists of a large spoked wheel with water troughs fitted t o it. The water flows down, fills the trough which then drops down, turning the wheel, and it empties o u t at the bottom, so there is no counterbalancing weight as it travels up. A series of troughs filling and following each other provides constant rotating power. Speed can be easily controlled b y closing or opening the tap, o r b y adjusting the tilt (and therefore the capacity) of each trough. This unit can be made to develop enormous power b y simply increasing the capacity of each trough. and increasing the length of the 'spokes'. It is only limited by the volunle of water and the speed with which the troughs fill. A gravity unit is quite capable of providing enough torque and driving power t o easily twist and snap a 25mm solid steel drive shaft. As an example, if you could imagine the shaft power of a one tonne weight pushing down o n a 10 metre bar attached to a shaft, then you will understand how and why enormous power is possible with this system. (This is an extreme example which assumes your water flow is adequate, and your troughs are big enough to hold orie tonne of water, and your 'spokes' are 10 metres long and strong enough t o support one tonne.)

3.

WATER FROM RESERVOIR (ELEVATED SUPPLY

THE WEIGHT OF WATER I N THE BUCKETS TURNS THE WHEEL

BUCKETS ARE EMPTY ON THE ' U P ' STROXE

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SPEED STEP-UP UNIT .CHAIN5 OR GEAR BOXES

Water Powered Remote Location Gravity Unit 4. The mechanics of operation are exactly the same as the on-site unit, but has the added advantage of being located anywhere you want it to be, provided of course you have access to plenty of free water. This unit is more suited to occasional use) such as charging a bank nf batteries or supplying the peak load power requirements, because constant water fiow in high volume is not always practical. In such cases s s this we recommend the use of a large storage tank and a hydraulic water ram. The hydraulic ram

is a siri~ple highly effective little piece of engineering design which operates on the principle of compressed air but pumping the water. It costs absolutely nothing lo run (except A ~ occasional lubber valve, which can b e made from the I heel of an old rubber boot'" but it pumps continuously d a y and night for years. hesc hy6rzillic rams will pi!rTip water t o heights of several hundreds of feet and over distances of several kilometres, st: 1: yt!u 2 larze S L O T S ~ Ftank you can operate youi. gravity unit for quite a while with the force and flow of the : .:ti,. :..' :.i:.;i;;. 'G:e c l ; r . - . g s ti!\\'.i:t ,! ,..-! F ! hzve .P. contin!!o:?r flow of water coming into it from the hydraulic ram as the ram ,.,[il b-. - , :... .~.., c ~ t n ; i i i ~ ; 0 ! . i ~ 1 ~ ~anri rrir!l.i r!nless ;low ""it the valve' and shut it off. :iiqi *he - r ; , : :.nd lol~:r:heing !pirn~<:ctd ; I - G I I ~:1"c j.a.117 j: ; i ~ really enough t o directly power a gravity wheel. Therefore t i l : ~ laroe slci:j;:e t:rxk. is esserltia'. 't~i!/drai~lir rams are availatrle in an assort~nrmtof sizes and pumping capabilities from STEVCO SUPPLIES PTY LTD. i A i<.t!sso!i Siree!, Riverrvoocl, MSW 221 0. Prices range ?'ram about $300.00 upwards.
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The rams use the intake of water t o compress air in a metal d o m e and part of the intake water is then pumped while the majority spurts out as waste, and flows back to t h e main stream. These rams will pump to heights well above those specified o n the brochures - in fact 2 or 3 times as high. This is done b y increasing the length and diameter of the intake pipe. The only drawback is that the valve rubbers cut out faster. However, the rubbers are only a circular piece of thick rubber and you can easily make them yourself for a few cents. Wind Power - Conventional Propeller Type Windmill Construction of windmills can become involved, and there are many lengthy detailed books already o n the market so in this small section we will only outline the main principles. This basic information will of course enable you to make a reasonably efficient windmill, but if you intend to fully power your entire place with wind-generated energy you would be well advised t o purchase a book which is devoted entirely t o this subject. Here are the basic facts: (a) Most windmills for generating power seem t o operate best on 2 or 3 blades set up with long slender blades similar t o an aeroplane propellor but not the same pitch (see illustration). (h) Multi-bladed mills (i.e.: with more than 3 blades) have a higher starting torque under load but d o not spin as fast. They are more suited for pumping water or for areas with low winds where the multi-bladed units catch the breeze better and spin with a slow powerful style. The alternator can be geared up to be driven Lister b y using either a chain drive or V-Belt or pulleys t o spin the alternator much faster than themill is sp lnning. ( c ) Tlie alternatol. is usually set up as a dlrect drive from the windmill shaft because it changes direction t o catch the wind. A gearing set:up with cogs or pulleys etc. can still be set up in a similar way, but it tends to be more cumbersome and on a high windmill lubrication and maintenance (belt replacement etc.) are inconvenient, so usually the manufacturers opt for twin bladed units t o spin faster o n a direct drive system. (d! Windmill power does not incrense in the same proportion as the actual wind speed - the power output actually increases much more rapidly. The actuai power output is proportional to the cube of the wind speed. For example, i!' the wind speed doubles you get eight times the power, not twice the power as you would normally expect.

5.

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Windmill power increas -; dramatically by lengthening the blades The power output is proportional to the square of the diameter. This means that by doubling the blade length you will get four tinzes the power, not twice the power as rnight first be thought. The travelling speed of the propellor tlps automatically Increases with length. w h : ~ hmean; the long bladed i t tip has t o travel a much longer distance with ~ a c i s t ~ o l u ~ ' oIn .tlierefore tias to travel much faster to cornplete one turn in the same time as a short ,-fie Thls IS t 1 1 i m p o ~ t a n t because a long bladed windrnill spinning at high speed is dangerous and cdn fly apkrt through centritugal torce. When constructing a w1ndmi:l you are advlsed to fit a 'wind brake' to limit the speed In high vdi~ids. The wind brake works o the prlnclple of sprlrng..loaded 'wings' opening up with centrifugal force and creating an effective sl; ed b~ aklng system (see d~agram).
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Corzver~t~onal W,ndmill Siruc:u:-e The blades are llke an aeroplane wing a thick rounded leading edge tzpering to a thin trailing edge. Note: These diagrams are not drawn t o scale. The "wind brake" IS actually very small in relation to the blade length. In the diagram the "wlnd brake" sectlon has been increased in slze t o show the constl-uction details more clearly.

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6. Wind Chute Power Turbine This particular unit works o n a similar principle to ventilating rotors. It spins at very high speed and con~parativelylow torque, so it is often necessary to gear the alrerrzaror down, not gear it up as is desirable with a conventional windmill This unit IS designed specifically fo: con .truction by the home handyman, and because of its layout and ease of and various power plant combinations - both high operat:on it is more suited to a wide range of drlve r h a n ~ s m s n and ow voltages Basically the collector wings on the wind chute scoop the wind in' and blast lt against the fins o n the rotor (slmlla~ the water wheel), and the flared wings on the opposing side act as a venturi systern (sucking system) to to create a vacuum within the rotor chamber t o draw the air blast through with greater force.

The unit is designed t o sit at ground level and only turn within 180' radius. This means it collects wind from all directions and automatically aligns itself with the direction of the breeze. Alternators operate just as effectively in either direction, so a northerly breeze blowing the rotor in an opposite direction to a southerly breeze does not create any problems.

THE U N I T CAN B E ROTATE0 1 0 8' TO S U I T W I N O D I R E C T I O N . INLET AND OUTLET A R t E X C H A N G E A B L E ALTERNATOR WORKS JUST AS W E L L IN REVERSE

CAUSES A V E N T U R l (SUCTION1 E F I TAPERED INLET C O N C E N T R A T E THE W I N D FORCE ONTO THE ROTOR B L A D E S . W H I C H A D D S E X T R A I M P E T U S TO 1 ROTOR W H E E L

At this point it is useful t o know the main disadvantages of a conventional propellor type windmill so that a realistic and accurate comparison can be made between the t w o systems, and a deeper more complete understanding will evolve as you read o n and mentally compare the two. 1. Construction of a windmill is difficult because of the need t o build a high specially strengthened structure and the need t o fabricate the correct blade angle in accordance with other design features. (This is quite involved and entire books have been written o n this subject alone.) The wind chute, o n the other hand, is at ground level and does not require any special shaping or strengthening. The turbine rotor consists of straight wood or steel plates attached t o a shaft ( a piece of pip ing is OK), and these fins d o not require any special shaping or graduated curves. 2. The wind chute unit only turns within 180' radius or less, so you d o not have problems of tang!ed power leads or having t o fabricate a special 'transfer ring' to accomodate the 360' turning and twisting as the conventional windmill moves around t o line UD with the breeze. 3. Speed power of the wind chute turbine is easy to control by simply fitting a sliding door to shut off wind going into the turbine chamber, and because the turbine is enclosed it is always safe. The conventional propellor windmill is very dangerous in high winds, and the fabrication and effectiveness of the wind brake set-up does pose difficulties, and speed and power regulation is neither precise nor convenient. (The spring tension has to be changed to adjust the brake cut in point and even then speed cannot be properly regulated.) Publishers'Note: Our policy in general content, layout and presentation of facts in our manuals is t o provide practical information and knowledge t o the average home handyman with an average set of tools, using readily available materials and components. The dangers of disintegration of conventional windmills in high winds does not apply t o commercially manufactured units. Stresses are carefully calculated and the entire construction is expertly designed and re-inforced at all stress points to withstand the severest of conditions and still retain a more than adequate safety margin.

WELDING CAPABILITIES
Your power unit with its wide range of amp/voltage combinations gives you a tool of working flexibility equal to the best of electric arc welders. In fact its capabilities are far in excess of the average 240 volt arc welders o n the market today. There is however a minor disadvantage in that the alternators tend to overheat if welding for long periods. This is no real disadvantage for the average handyman as this unit is quite capable of performing all that is required by the D.I.Y. enthusiast. Arc Welding Arc welding is performed in exactly the same way as with a conventional welder. The job is grounded by connecting the negative lead t o the alternator casing in the normal way and clamping the other end to the welding job.

The electrode holder welding lead is attached to the output terminal o n the alternator. Note: The welding lead is simply an insulated wire thick enough to carry the high amps without overheating. Electrode holders can be purchased from any welding suppliers. The actual arc welding style and procedure is exactly the same as if using z convention a1 welder. Electrode holders, leads, etc. and books o n arc welding are available from SIEVERWATER WEEDING SLPPEIES. 37 Newton St, Auburn, NSW 2144, ph. 648 1868. Basically, arc welding is simple and easy to master with practice. Scratch the electrode on the steel as if striking a match, then hold the tip of the electrode just above the surface. This stabilizes the arc, then move it slowly along. If the electrode spits and sputters the amperage is probably too high. If t h e electrode sticks to the job, the amperage is probably t o o low or the distance between the electrode and the job is not wide enough. If the slag chips off easily, the weld is OK. Note: Set your alternator speed t o produce about 40 - 50 volts, and the amps setting will depend o n the size electrode you are using. The recommended amp lange is printed on the box of welding rods (electrodes). Warning: Always use the proper arc welding shield or helmet. The intense light given off during welding and heating will instantly 'sunburn' the eyeballs. If this occurs use eye drops, and rest with the eyes closed. Your eyes will feel as though they have sand or glass in them, but will normally be OK in a day or so. Fusion Welding Fusion welding is heating the metals t o a molten stage and they fuse together.This is usually only possible with the intense heat of an oxyacetylene flame. However, by using a special copper coated DC carbon arc electrode in conjunction with your alternator power unit, this intense heat can be genkrated almost instantly, and is fully controllable both in direction and intensity. A special adaptor has t o be fabricated for attaching t o your normal electrode holder (see diagram). The carbon arc rods are too thick t o fit in the average electrode holder. (Jumper leads can be used in emergencies; the carbon arc rod being held in the jaws of the jumper lead clamp.)
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INTENSE B L U E F L A M E ARKS ONTO METAL SURFACE MELTING AND FUSING METAL TOGETHER

The connecting procedure is exactly the same as for arc welding. The carbon electrode arcs down on to the steel with an intense blue flame. The heat and intensity can b e varied b y regulating the alternator speed. Experirrrentwith amp/voltage combinations t o suit your own style and requirements. As a guideline 20 amps at 3 0 - 40 volts gives a ,moderate flame for thin metals. Seventy amps at 4 0 - 50 volts using a 7mm carbon rod will easily melt and cut steel .plate or fusion weld heavy steel. Note: O x y welding wire is used in the normal way as a filler t o build u p the weld. Spot Welding Spot wclding is used for joining thin sheet metal such as car panels. I t is basically melting a spot of steel and fusing it together. In the past this was only possible using special equipment costing over one thousand dollars and arcing clamps had to be fitted t o each side of the panel. Using your carbon arc adaptor and power unit, yc)u can spot weld from one side of the panel only, and still create a strong solid neat job. Spot welding is particularly useful for rust repairs because it eliminates the complications and problems of heat distortion of flat panels in areas such as car doors, etc. When using the single carbon for spot welding, use an alternator of about 35 amps and run the voltage to about40.

Place the carbon tip on the metal for a few seconds until it glows re('. then slowly lift it straight up until a strong flame arcs on the metal. Hold it for 2 - 3 seconds depending on metal thickness, then lift it straight off to extinguish the flame. It will melt the two metal panels together forming a strong spot weld. If you have difficult in holding the arc steady, then you can purchase a spot welding 'gun' from SOVEREIGN WELDING CENTRE, P.O. Box 792, Murwillumbah, NSW 248.1. It is a pistol grip arrangement with an interchangeable 2 or 4 prong base t o hold the carbon in pnsition :>nd a trigger t o precisely control the arcing distance. For quick convenient spot welding it is a very useful tool. Heating For heating purposes use two carbons arclng tugether (see diagram). The positive and negative leads are each connect- , ed to the carbon arc rod holders. The job is not earthed at all because the carbons are arcing together and the heat and flame is maintained regardless of whether it is near steel or not.
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This torch is very useful for all heating jobs ranging from burning paint off and loosening rusted bolts through to heating steel t o near melting point for shaping and bending. (Note:For very precise bending of heavy steel, the single arc creates a more fiercely concentrated flame.) The twin carbon torch has a larger heatlflame area. and is more versatile in so far as it does not extinguish itself when taken away from the metal surface as does the single carbon. Use both a positive and a negative DC carbon arc rod when using the twin carbon torch. (Either positive or negative can be used with the single carbon arrangement.) Both carbons must be nearly touching each other t o ignite the arcing flame, then draw them apart slightly until a steady intense flame stabilizes. The diagram shows how t o make your ou!n twlri car-b,!~: torih iiowever, ready-made units with a convenient :!r: carbon adjusting knob on the handle are ai,ailable f:om SILVERWATER WELDING SUPPLIES. The cost is reasonable and for outright convenience and ease of operation, they are i~nbeatable. Brazing About 30 - 4 0 amps is best, and use the twin carbon torch t o braze in the normal way. Single carbons can be used for precise heating, by sharpening the carbon with a pencil sharpener. O n thin metal keep the carbon in contact with the metal until it glows and heats up, then reduce the current strength and arc a soft tlame oiito the metal. Soldering Use a single carbon and keep it in contact wlth the metal. Do not arc it on t o the metal. It will begin to glow and heat the metal. Reduce current strength if too intense. O n thin metal it is often easier to solder by heating the metal from the opposite side. T h e solder will follow is along the cleaned and heated area. Very fine solder~ng best accomplished by using a piece of wire abour 30cnis long held in the elecrrode holder in place of the carbon. Keep the tip of the wire in contact wirh the metal surface, and it will heat up (and glow red if required). Cutting Use a single carbon. sharper1 the point and clamp in your alternator so that about 4cms are protl-udlng below the adapror. Use a high amperage set-up. then arc it on t o the steel, starting from one edge which should be slanted down t o enable the molten metal to flow away from the cut. If yo11 cannot tilt the job up c n a sharp angle. start the cut from the underside. hlien cutting Iaige holes in steel plate over 61111n thick, it is btst to drlll a series of holes nearly touclilng each other. In this way the carbon has oniy to cut through the thin walls separating each hole, al!d rlle holes ~ h e m s e l ~ e s assist In clearing away :lie molten metal. By using this n~etliod you can cur steel rlp t o 5 - 60nlrn thlck. The holes 0 should be close together and the drill size should be at least 6mm. preferably larger I3min 1s ideal.
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