Questions and Answers.
If you are
looking for F.A.Q. about the TLG-500 please see the Product Reviews link on
Questions from customers or other interested
individuals that I think sharing the answer with all of you would be
Please remember that my answers are like advise and my advise is
only worth what you are paying for it. ;)
With that said lets get started.
Q. I built one
of the boss99 systems and I have never seen it produce anything more
than 8 amps of power unless it does more when I am not home.
My battery stays charged but I guess I was expecting more.
A. If you are staying
charged then you are doing good. One thing to remember is
this; a completely dead battery draws hardly nothing until the electrolyte
gets excited, then it goes into a harder charge mode where the
amperage goes way up. Once it is almost charged it will once
again draw very little amperage until it reaches full charge.
This activity can seen by watching a standard battery charger
on a pretty ran down battery. My guess
is your battery is more than likely at the top area of charge and
just not demanding the amperage from the generator.
Q. What is the
best thing to use for wire to run from the generator to my battery
in my garage?
A. I personally like a good 10/2
or 10/3 extension cord from a discount house. If you can find
a reasonably priced 8/2 or 8/3 that would be even better. An extension
cord is flexible and not to expensive to buy. Plus you can buy
two of them and wire them together to increase your ability to
deliver the amps if needed.
Q. I made my
generator from the 30VDC motor and it puts out good charge for me as
long as the wind is blowing. After the wind dies down it runs
until the battery is dead. Is my motor bad?
A. No, your 30VDC generator is
just fine. I have a strong feeling that you do not have a
blocking diode in your system. Please see my
and Tricks page and read my long winded version about a blocking
Q. I saw
something last week that is making me wonder if my generator is going
bad. We had a pretty steady wind of about 14 mph all day and
my meter was reading about 3 amps of power. The blades were
spinning and looking good, by the end of the day I was only getting
about one amp and the wind was still about the same but I could tell
the blades were spinning much faster. Is the generator getting
hot and slipping?
A. It could be getting hot and
breaking down but I really doubt that is what it is. You said
that the wind was about 14 mph all day. That gives me the
impression that the battery was reaching full charge by the end of
the day and just not loading the generator down very hard.
That would allow the blades to roll much faster due to not having
Q. I saw an ad
on ebay for a set of blades that some NASA scientist designed and
approved. There was a comment in the add that said something
like (some cupped sets claim to have power below 10 mph and there is
no power below 10 mph.) I assume that was aimed at your blades since
yours are the only cupped ones I have seen. Is it true that
there is no power to be had at 10 mph or below?
A. I will try to answer
this in a way so that it doesn't sound like a mud slinging presidential
debate... If that comment from the NASA blade people was
really a pot shot aimed at me and my design then that makes me feel
pretty dang good. :) In trying to
figure out what was meant by the comment you read, if these NASA
blades were only 12" to 24" in diameter they may not able
to give out any power at below 10 mph and could be where that reference
came from. I don't know? If not then maybe the next ad
may read "Aaaah Houston we've got a problem" :)
All I know for sure is I have a lot of "customers" that
will say yes there is power below 10 mph with my blades. And
our TLG-500 with its 5 foot diameter rotor delivers 1 full amp into
a 12 volt battery bank at only 5 mph, and almost 4 at 10 mph and it
goes up drastically from there.
I can safely say that all owners of the TLG-500 will strongly
disagree with the statement about there being no power to be had
below 10 mph.
Q. How do I go
about making a bracket so my generator will turn with the wind?
A. See my
and Tricks section and look at my mounts on the
page for lots of details.
Q. You say to
run the wire down the inside of the pipe but how do I get the wires
out of the bottom. I am afraid that it would weaken the pipe
if I drill a hole in it.
A. If you have a triangular
tower, or a break over pole you can just run the wires down
inside. If your pole is going to be more solid like 2"
pipe down to 1.5" pipe then what you need to do is weld a short
piece of 1.5" on the outside of the top of the 1.5"
pipe. This short piece can be about 18" long and have
about 6" or so inches overlapping the main pipe. In this
setup the wires would run down inside the 18" long pipe and
down the outside edge of the main pole. A "loose" eyelet
every 5 foot or so should keep the wires going straight down the
pole and still allow them to twist as needed.
Q. I have four 6
volt batteries how can I wire them so that I end up with 12
volts or is that possible?
A. Yes you can wire up all
4 batteries to have a 12 volt battery bank. Here's what you
do; set them up the way you are going to store them.
Next hook the positive of one battery to the negative of another
battery. You just wired those two batteries in series and you have
one 12 volt battery made out of two 6 volt batteries. Do the
same exact thing with the other two remaining batteries.. At
this point you should have two sets of batteries wire up from the
positive to the negative and you should have one negative post from
each set, and one positive post from each set with no connection.
Next hook the positive of each set together positive to positive,
and then the negative to the negative.
You have now wired four 6 volt batteries into one 12 volt
Check out the Battery Bank Wiring
Q. Are the
little holes in your hubs for mounting nose cones? I did not
see any nose cones on your site. Don't they give you more
A. The holes are there for
other mounting options, not for cones.
The only reason to have a cone is if you have moving parts that you
need to protected from the elements. A nose cone will actually
cost you power not gain it! Since I am sure (why) would
be the next question I will go ahead and answer that too. As
the wind passes over a nose cone it directs the wind away from the
center of the blades and causes the wind to not be able to make a
direct straight-on contact with the root of the blades. It is
not a great loss but a loss none the less. If you want to be
able to visualize this effect think about what water looks like in
front of a moving "V" bottom boat.. The air being
split by a nose cone folds over kind of like the water does under
Q. What is the
max wind speed before your blades will be destroyed?
A. I do not really know where the destruction
rate would fall. I have pushed every rotor design I offer to
100 mph with no damage. I have several MM series rotors flying
in Florida that I feel received a hard field test in the 2004 Hurricane
season with winds over 100 mph and driving rain on top of
that. I have received comments from Florida blade owners about
their survival but no reports of failure.
Q. In one of the
discussion groups there was talk about metal fatigue. Have you had
any problems with metal fatigue with your aluminum blades?
A. I feel that my design is sturdy
and should provide many years of use. Out of all the rotors
that I have sold I have had two sets of blades that were damaged by
an unknown force. Both of those sets showed groves in the
blade where the washer cut into them. I feel it was from over
tightening the bolts on the blades. But I am not sure if that
was the only cause.
Rest certain if I was seeing failures in my rotor line I would be
letting everyone know what I had found out.
Q. What is
the difference between an up wind and a down wind system?
A. The definition for
either an upwind or downwind system is the direction of the wind in reference
to the tower or pole. If the wind would strike the rotor
before it would hit the tower, the system is an upwind unit. Generally
there is a Vane or Tail that follows. Likewise if the wind
would strike the pole before the rotor the system would be a
For more clarification of the confusing terms we have in the
renewable energy world you may want to read my
Glossary of Terms
Q. Why do you
not like wooden blades?
A. It is not that I don't like
them, it is just that for many people they are very hard to build,
balance, and maintain. I have seen several very pretty wooden
blades over the years, I have also seen several broken wooden blades
Q. I was
wondering how would someone connect a wire to a generator that is
able to spin freely in the generator mount. Isn't it possible
that the constant direction change will cause the power wire to
become twisted? Is there some kind of power connection that I
A. The connection you are asking
about is called a Slip Ring. They are
expensive to buy, a pain in the butt to build, and they can be VERY high maintenance!
I run my wires down the inside of the tower or pole... I use a
10-2 or 10-3 extension cord as my down wire. I leave the male
plug on the extension cord and put a female connector on the wires
that go on to the batteries. IF it were to ever tangle or
twist up just unplug it, let it unwind, and plug it back in.
Based on your question I see I had an important piece of information
missing from my site. So I created the
to battery page for better instructions.
Q. I like your
blades and all but after I read your product disclaimer it made me
wonder if there is any kind of warrantee with your products.
If I buy a rotor and it breaks in a month am I screwed?
A. No not at all.
The Product Disclaimer is for my protection against accidents or
things that may happen in relation to one of my products. For
example: if someone forgets to tighten their arbor nut and it allows
the rotor to come off in a high wind and it flies through the garage
door and sticks in the hood of a car. It was not
"MY" rotor that came off, it is "YOUR" rotor and
you are flying it at your own risk per my disclaimer.
I was raised up with old school values, where a man is only as good
as his word. Rest sure that I stand behind my products and I will
replace the product if there is a problem with the material or
workmanship within a reasonable amount of time. All you have to do is contact me.
Q. The voltage
coming out of my 40 VDC Ametek generator goes higher than 40 VDC at
high winds, will this burn up the charger, or blow a fuse, or can it
A. What is happening is the
motor is very capable of reaching well over 100 volts DC. This
is normal. When you hook it to a battery the battery will control
the voltage level like a regulator. Meaning if your battery is
at 11.0 volts when you hook it up, the open voltage from the
generator will drop to 11.0.. As it charges it will rise 11.1,
11.2, 11.3, etc until the battery reaches full charge. Once
the battery is at full charge is when a charge controller comes
in... At that point the charge controller will kick in protect
your battery from over charging.
The higher the open volts that the generator has the potential to
produce the higher the charge rate, or amperage will be.
Q. I have a
whole bunch of 1 amp diodes how do I wire them together to make one
strong diode, or is possible?
A. It is possible, but it will
NOT LAST, and may be a fire hazard!!! Cheap diodes are not
perfectly matched. If you have 5 diodes, one will fire first
taking the brunt of the load and it will burn up, then another will
being firing sooner than the others and it too will burn up.
This will continue until you have no diodes left. If you use 100 of
them it will just last a bit longer, but in the end all 100 will
burn up. Buy the right size diode.
Q. Hi Terry, is
everything is ok? I have your site set as my home page and I noticed
that you had not added anything to it for a while. I hope you are
not going away on us.
A. You're right and I bet you
are not the only one that noticed this either. The search
engines out there sure did.
I don't really see any reason to hide what happened, besides maybe
it would be better to just get it out in the open.
I could make this answer detailed but it would be really loooooong
if I did so here it is in a nutshell.
I was married for 13 years, we had
two beautiful girls, She decided she wanted a divorce in 1999, we
were divorced in 2000, She took her
life December 5th. 2004 throwing an unexpected twist in mine and my
children's life. So the last couple of months has been pretty
much spent making sure my children are going to be alright.
I kind of figured that there would be people noticing that I was
letting things slide here and I probably should have said something
Sorry for the scare.
Q. You talk
about primary generators, do I need a primary and a secondary for my
A. If you use it every day yes,
if you use it on the weekend or a couple of times a month I would
bet that a primary is all you need. Time is not only money,
but charge time as well. ;)
Q. Your new
generators sound like they are going to work well for you. I
was wondering if this means that you are going to stop making blades
for us guys that still want to make our own after you get your
A. NO WAY..
There will always be people that want to do things themselves, and I
started out building blades and helping the do it yourself type of people
and they are my roots. If the roots die so does the
Q. I keep
checking your site hoping that you will get the information on the
Amatek 50 volt motor I have. Are you going to be offering more
information on these motors soon?
A. I have not gotten my hands on
an Ametek 50 for close to a year now. I don't have any plans
at this time to even look for one since they too are getting harder
to find. About the only ones that seem to be left are the 30's
and 40's. I will at least try to get the data on the 40 I
still have. I think I might still have a 72 out there as
well. I'll just have to look.
If I run across one cheap somewhere I'll be sure to test it and post
Q. Have you seen
the new blades made from high quality Douglas Fur? Do you
think they will hold up?
A. I recently seen an ad on ebay
with blades made out of a Pine Tree (OPS, I mean Douglas Fur).
I have no idea if they will hold up in the air or not. I have
to say the ad itself brought a smile to my face to know that Pine
Trees have found a job in the air rather than their old job of being
made into a Pine box and put 6 feet under. ;)
Q. Hello Terry,
I love the look of your blades but others are claiming they have
faster blades than yours. Please be honest and let me know is
speed really what is important to me?
A. Speed is important to a
certain extent, but speed without horsepower is like putting perfume
on a pig. (I think I may have already said that in my site, but oh
well) The point is nothing replaces power. It takes power to
produce power. I am sure you have rode a 10 speed bike
before. If you shift the bike into 10th gear you better have
some strong legs or you will not get any speed at all. I have
rotors that will go well beyond 3000 rpm, but they are for small
generators that don't produce a huge amount of power.
Creating power from the wind requires horsepower. And mine
produce the horsepower needed. We just need to match a rotor
to your generator.
Q. My neighbor
and I are going to built a simple wind generator with you quad al
rotor. At first we (were) thinking about using some big hose
clamps to hold the generator to the mount but afterthoughts have us
thinking it may not be too smart. What are your thoughts on
A. I am really glad you used the
words "may not be too smart"! this way I can just be
straight forward with my answer since clearly common sense has
The answer is NO. Do not use "hose clamps"!
For the safety of others that may read this I will continue with some
It is fine to use them for testing, but if you plan on mounting it permanently
do not use hose clamps. That would be just plain stupid UNLESS
it was mounted WAY away from anything or anyone. I have seen
hose clamps used, and even have one pictured on my site, but that
unit is clear of anything or anyone.
Anyone that mounts a generator permanently with hose clamps that may
end up being sited near people or property either has not seen what
mother nature can do, doesn't care about anyone's safety, or
knows absolutely nothing at all about "wind energy".
In time it will come down!
Hose clamps crack, break, vibrate loose, etc. then you have a 10 to
30 pound weight with high speed rotating knifes falling to the
ground. Trust me, this will not happen on a calm day it will
be when mother nature is showing what she can do and somebody may
get hurt. I use 3/8" U-bolts for a reason on my mounts.
Q. I need a
generator now and you don't have your ready yet. Do you know
anything about the units from Mikes Windmill Shop?
A. I have not used one of Mikes
units personally, but I have spoke to them. I know they are a
family owned and operated business just like TLG Windpower and my opinion
based on talking to them is they do their best to offer a good quality
I wish they would convert to the new Boast Buster rotor, but maybe
in time they will.
Q. How much of
an increase can I expect out of my hornet with the Boast Buster?
A. I feel extremely comfortable
saying 40%, but most are seeing a great deal more than that on both
the Hornets and Mallards.
Q. Why would you
show a crashed set of your blades?
A. When you consider that a 100
mph wind can throw a 2x4 through a brick wall, I think the pictures
show that we are doing our best to deliver as safe of a product as
we can. Sure the blades in the pictures are ruined but the
damage stopped there, I think it would be interesting to
see what some of the other brands of rotors would look like after
debris struck them in an 80 plus mph wind. My guess is there
wouldn't be much left on the tower to see and probably the reason
why they don't show them.
Q. I know you
don't deal with Axial Flux Generators but if you were going to make
one would you use single or double windings?
A. It would make sense to use
double windings in each coil. That way you will double the
amperage at the same voltage. You may have to use smaller
wire, but the theory looks good on paper.
Q. Does the new
unit you are going to be selling me have a slip ring?
A. No, we are building them to
last for many years of trouble free service. If we were to put
a slip-ring on them that would be a weak link.
Q. How do you go about
grounding a tower?
A. I run a piece of solid Copper
wire from the tower to a long ground rod..
I made a page that explains this in more detail.
Read Grounding your Tower /
Q. I read the
spec sheet on your new generator and seen it was an AC unit. How is
this going to be able to charge my DC battery bank?
A. It is going to work and
work even better than a DC motor/generator would. Here's why;
Putting out 3 phase AC means that you can run smaller wires down the
pole which will save you a lot of money over a standard DC unit, and
depending on the length of run you may save enough money in the cost
of wire alone to be able to buy a second unit. Once this
smaller wire is at the battery bank you will have a 3 phase bridge
rectifier that will turn the 3 legs of AC power into a DC Positive
and Negative terminal which you can hook right to your battery bank.
Q. Are you going to do
the ratings on some of the new blades you have? I am interested in the
power star express but would like to know how fast it turns.
A. I can hardly wait to know myself.
This winter has been really strange for me. I have not had any days in
the last (almost) 3 months of no wind. It takes between 1 to 3 hours
to get accurate data on each rotor. During the last 4 months TLG has
not only added the Power Star Express, but the Boast Buster, the Power Star
Elite, and has redesigned all the AL series blades along with the all MM
series. So I actually need to re-graph all the rotors except the Elite
and the Extreme. Those are the only two that did not undergo a major
As soon as the wind will cooperate I will be posting that data. I am
sorry for any inconvenience that this may have caused anyone.
I looked over your web site. Why is
it really advantageous for me to purchase your wind gen verses a Slant-Core
PMA Technology! Isn't the longevity the same for both? Even though yours is
heavier won't they both still be up on the poles 10 to 20 years from now?
Besides the longevity issue, your price is more than 3 times the cost of
your competitor in Calif., Why is that?
Thank you, for your time!
George. You asked a couple of questions that happy owners of the
TLG-500 were able to figure out on their own. Sadly it is clear to me that
you read the available information on the site and were not able to derive
at any clear advantages of owning the TLG-500. Since you seemed to be
extremely concerned with the TLG-500 costing 3-times as much then I have to
assume that you did not read the comments from the disgruntled owners that
had purchased one or two of the different models from your friends in
California. The only thing that I can say to you with utmost certainty is
this. Those that bought the TLG-500 at a cost of 3-time a unit from your
friends in California are completely satisfied with it.
I am thankful that after some of them buying one or two of the units from
your friends in California that they were even willing to try a wind
generator afterwards, let alone one that costs 3-time the amount.
Here is a quote from a TLG-500 owner that had bought one of your friends
from Californiaís units for less money.
"The way I see it if you cannot make power in common winds of 10-15 mph, you
should get solar panels. Now Most of these other wind products on the market
today are JUNK! As you state, there 600 watt unit is really 120 watts at 50
MPH, and in 10 to 15 MPH, do you know what a Condor puts out? ZERO Amps!!!
I know there are a lot of people buying these types of units, and I feel bad
With what he said
there I really think the advantage would seem clear to anyone. It seems to
be a question of do you want it to work or not? The fact remains, so far
every owner of the TLG-500, even though it is 3-time the price is completely
satisfied with the unit. Satisfied owners are something I feel I will
continue to have. Can your friends in California say that? You donít need
to answer that, dissatisfied owners of your friends units are scattered all
over the Internet for everyone to read.
One other thing, I
noticed that you said you looked over my website. I am amazed that you
asked this question in ebay. Given the chance that there might be someone
else that would ask such questions I will not only reply to you on ebay but
I will post this in the Q&A page on my website for all to read.
I appreciate the straight up approach you take but I have to
agree with the other person about your rating system. If everyone else
is lying to us why shouldn't you? People might buy your units even
faster if they knew it way out powered others out there.
A. I cannot, and won't say that
others are lying, they are simply using the old way of rating wind
generators. I say the old way because I see it changing.
Back in 2003 TLG started
talking about output and referring to our ratings as "Real World" output.
I am very happy to say that the concept of telling it like it is for output
is really catching on. I see the term "Real World" now being used on
several site. Although not the way I mean it in some cases, but none
the less it is coming around.
Unfortunately the most common method now days seems to be the even more
confusing, but impressive looking rating of Kilowatt Hours Per Month.
Which sadly is still based off of the old theoretical Instantaneous Output
rating. It makes a unit look like it could run a whole house when in
reality AKA "Real World" you would be lucky to run a couple of lights...
I have to agree that my method of rating a wind
generator has certainly slowed the kick off for our wind generators, but I
can say proudly that every single owner of a TLG wind generator is 100%
satisfied with their unit and its performance. And I feel I can say
with utmost certainty that TLG is one of the very very very..............
few wind generator companies that can say that.
So with that said I have to stick to my guns and keep on rating them by what
you will actually get into your battery bank at a given wind speed, AKA
You can also read the TLG-500 FAQ page.
There are a couple of repeats on it.
the top of this page.
The menu will join you shortly. It's kind of fun. ;)