Secretly, I like it when things break, sort of

Not that I am a glutton for punishment or anything, but I enjoy troubleshooting. There is a certain satisfaction in the analytical aspect of tracking down a problem and fixing it, hopefully in a permanent fashion.  Figuring out where a problem is requires a good bit of detective work;

  • Examining the clues; what happened before the failure, what are the fault indications, are there any external factors
  • Round up the usual suspects; a good maintenance log is helpful here to track re-occurring failures.  If the failure cannot be attributed to an external source (such as a power surge or lightning storm), what was the last thing that was changed or worked on?
  • Following the trail back to the origin; Often the first failed part found is a symptom, not the actual problem.  It takes some skill in reading schematics and making sense of a failure to trace it back to the real problem.

It can sometimes be exciting, like turning on the 25 KV high voltage supply and having big blue flashes issue forth from the top of the transmitter.  Sometimes it can be quite frustrating, like when the station owners refuse to spend money to fix a problem.  Sometimes it can be dull, like fixing the same problem over and over again because of the previously stated money problem.  It’s also disheartening when the problem was caused by the stupid DJ spilling soda in the console.  Not that all DJs are stupid, just the ones that spill things into consoles.

The challenge of finding the root cause can often be enlightening.  I have often discovered unrelated problems waiting in the wings while investigating the why of an outage.  It is great to fix those things before they burn the house down, but this approach often goes unnoticed by the ownership or management.  Lately, for some reason, an ounce of prevention goes unnoticed or unappreciated.

There is quite a bit of science to troubleshooting, but there is some combination of personal traits that make a good troubleshooter.   These are:

  • Inquiring or curious disposition.  It is fairly easy to get to the first failed module or part.  Discovering the reasons behind the failure and or getting down to the component level takes a good deal more effort.
  • Patience.  This goes with the second part above, it takes some stick-to-it-tive-ness to trace out the not readily apparent problem.
  • Good analytical skills.  Often failures generate a cause-and-effect scenario.  The effects can be startlingly distractive and mask the causes and the underlying problem.
  • Ability to view the large picture.  This is critical to discover outside influences and other issues that are indirectly connected to the system or issue at hand.
  • Ability to analyze the system design.  This requires background training and experience to look at a circuit diagram and discover non-error-tolerant systems.  Sometimes these systems can be modified for better fault tolerance.

Poorly designed equipment is the bane of the broadcast engineer.  Equipment manufacturers can sometimes fail to follow two key principles: KISS and maintainability.  KISS stands for Keep It Simple, Stupid.  There is no better design criteria than the KISS principle.  Adding layers of complexity increases the failure expectations.  Maintenance can be something as simple as cleaning or changing air filters.  Making maintenance tasks difficult almost ensures that they will not be done.

Bathtub design curve
Bathtub design curve

Eventually, all things wear out.  It also takes some large-picture skills to know when it is time to replace equipment and that can vary greatly from situation to situation.

Stay tuned, 1994 redux

In case you haven’t heard, May 21, 2011, will mark the beginning of the end of the world. It is on this date, according to Harold Camping, the rapture will begin. For those not versed in bible lore, this is when God will take all of the saved souls directly to heaven, body, and all. Further research reveals that it will begin at 6 pm local time, in every time zone.

I’d imagine you can listen for updates on Family Radio stations or shortwave if there aren’t any local stations to listen to.  Those on the west coast may want to tune into the shortwave broadcast (transmitters are in Okeechobee, Florida) for a preview of coming events.  You can try:

  • 5950 KHz 22:00 through 0100 UT (6 pm through 11 pm EDT)
  • 11470 KHz 22:00 through 23:45 UT
  • 15440 KHz 22:00 through 23:59 UT

The full shortwave schedule is available here.  I am setting my clock so I can tune in and see what happens because I am curious; dead air? Does the station sign off?  I really want to know how a station plans for the end of the world.  Hopefully, it will be marked by some program, announcement, or something special.  Operations as usual would be very boring, as most Family Radio programming is mundane and predictable.

Frankly, Camping has made these predictions before, the last was September 6, 1994, when the faithful gathered in the Alameda’s Veterans Memorial Building, bibles open, hands outstretched, awaiting the moment.  After a while, it became clear that something was amiss and everyone went home, wondering what went wrong.  There have been many religious-based predictions for the world ending: 1806; October 1844; December 21, 1956; November 1982; January 1, 2000: etc.   The Jehovah’s Witnesses alone have predicted the end coming in 1914, 1915, 1918, 1920, 1925, 1941, 1975, and 1994.

It’s either a really good radio stunt, which would go down as one of the greats of all time or they actually believe it’s the end of the world.  In the case of the latter, does this mean they will be selling their radio stations?  There are several around here that I’d be interested in getting my hands on.  I’d even give a fair price, considering the circumstances and all.

Update: How do radio stations prepare for the end of the world?  T -40 minutes and the answer appears to be play canned programming, or in other words, business as usual.

Rants

Keeping Public Radio Public has a good one.

And the lame-stream press — how dare they be called the “liberal media”! — only parrot the script prepared by the puppet masters, as corporate “largesse” and control has turned the media into toothless old watchdogs. They make good company for the regulatory agencies once charged with protecting the public from the excesses of corporate greed. They’re good dogs now, too.

Exactly why independent media outlets are not just a nice feature of a democracy.  If one were to read the entire constitution of the United States, a theme, loosely known as “checks and balances” becomes apparent.  You could also call that theme “Trust Not.”  I recommend anyone who is interested in freedom read the Federalist Papers.  Even with the watered-down press, US Congress has a 9% (Rasmussen, April 2011) approval rating.  Surely, the public understands that something is amiss and needs to be fixed.

While the internet and new media are great, it is too easy to mess with the internet.  True independent media needs to have independent distribution, and not be beholden to corporate ISPs, search engines, data centers, and so forth.  Radio fits that bill, to the extent that it is not broadcasting homogenized safe, automated, faceless music formats programmed from afar or content from  The Borg-like collective of NPR.  Independent radio still exists in small pockets scattered here and there.  Where it exists, it often thrives in spite of corporate conglomerates.

Of course, consolidation has reduced the radio business to a shell of its former self.  The FCC has no interest in reigning in those corporations, or, so it seems, enforcing many of its own existing regulations.  Money talks, screw the public.

What is the answer?  Get involved. Don’t buy into the lies.  Use your God-given senses and do some research.  Draw your own conclusions.  Make noise.  Confront the corporatists with the facts.  Use every means possible to get the word out.  Write your representative or senator (after you register to vote).  Talk to co-workers, friends, family people on the street, etc.  It’s time, in fact, it’s now or never.

Overhaul of the Onan 12JC4R generator

I was fortunate enough to acquire this generator last fall.  It was new in 1969 and has unknown hours on it, but it appears in decent shape.  I am going to do a level two overhaul and install it as backup power for my house/shop.  The first order of business is a complete inspection.  I discovered a few problems; the starter didn’t crank, the distributor was loose, and the carburetor had some burned-out chunk of metal attached to it.

Onan 12JC4R generator
Onan 12JC4R generator

First, the starter:  These units use a Prestolite MEO3006 starter, which is common to several Chrysler products from the late ’60s and early ’70s.  This is obviously a replacement unit, as it is not “Onan Green.”  When I hooked a battery up and tried to turn the motor over, the start relay clicked but nothing else happened.  I dismounted the starter and removed the starter solenoid.  The interior of the starter motor looked in good condition, which points to the solenoid.  Sure enough, I removed the back of that unit and found two wires burned through and a large blackened area.  While I had the starter off, I hooked it up to a 12-volt battery and it worked fine.  A new starter costs $469.00, and a new solenoid cost $59.00.  I opted for the solenoid.

Onan 12JC4R burned out generator starter solenoid
Onan 12JC4R burned out generator starter solenoid

The next thing is the distributor.  I was checking the points and contemplating replacing the breaker points with an electronic ignition when I discovered the distributor could turn 1/8 of a turn in each direction, as when making timing adjustments.

Onan 12JC 4R distributor clamp
Onan 12JC 4R distributor clamp

I used a 3/8 box wrench and tighten up the clamp holding the distributor shaft.  It took several turns and makes me wonder why it was loose.  I will have to check the timing with a light once I get it running.  This also could be why the generator was not running when we took it out of service.

Onan 12JC 4R rotor and breaker points
Onan 12JC 4R rotor and breaker points

As for the points, they look brand new, as do the rotor and distributor cap.

Onan 12JC 4R generator spark plug, champion H8C
Onan 12JC 4R generator spark plug, champion H8C

The spark plugs look well used and the plug wires look original.

Finally, there was an electric choke mechanism on the carburetor which is completely unnecessary for a propane-fueled unit.  The choke plate itself was wired open.  The electric choke was burned open, so I removed the assembly.  I then spent some time at the local NAPA cross-referencing parts.  Here is a tune-up list:

NomenclatureOnan part (old)Onan part (new)Napa PartAlternate
Oil Filter122A185122-01931084Fram PH16
Points*166P245166-0245CS709 
Rotor166P234166-0234AL58/AL52 
Distributor cap166B307166-0235AL91 
Condenser*166P310166-0310AL38 
Ignition Coil**166B310166-0859-02701002PRX 405011
Plug wire #1167A1410167-1602701064 
Plug wire 2,3,4167A1409167-1602701063 
Spark Plug167-4167- Champ H8C***
Air Filter140B640140-19077-02241 
Starter191C324191-0324 Prestolite MEO3006
SolenoidN/A191-0433AST103 
*Electronic ignition setN/A166-0825 Pertronics 1545**
**Ignition coil W/PRX 1545   PRX 405011

*Condenser and breaker points can be substituted for an electronic ignition kit, either Onan 166-0825 or Pertronics 1545 with Pertronics PRX 405011 coil.
**Pertronics electronic ignition must be used with Pertronics coil
***Champion RH8C plugs should be used with replacement wires without noise suppression plug boots.

This is for an Onan 12JC generator circa 1969 with a Studebaker engine. Other models/years may vary.  The other issue with this unit is there is no supervisory monitoring and control.  There is no oil pressure loss, overheating, or over-crank faults.  This is why the starter solenoid failed.  To remedy that situation, I started to design a better control circuit.  Then I looked around on the inner tubes and found somebody had already done this.  DynaGen makes the GSC400p which can monitor oil pressure, engine temperature, frequency, engine RPM, hours, voltage, and current.  It can fault for any out-of-tolerance condition, as programmed by the user.

Retrofit generator controller
Retrofit generator controller

I plan to install this in the original control box, leaving the original control circuit intact by using the remote start/stop connections.  I keep the original remote/start/stop switch and hand crank switch in place for use if the fancy controller fails.