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Old 09-21-2014, 07:56 PM   #1136 (permalink)
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Originally Posted by MPaulHolmes View Post
Well, that was also carefully verifying the value of each part in the schematic though. The software is ready to start testing/debugging on the bench without the motor.
The parts verify would be more 'eyes go fuzzy' work if I were to do it.

I can't remember if I posted this - a plan for testing the AC controller:
- a netgain 9 inch DC motor with an existing 1000A 400V controller
- my 30 HP AC motor with Paul's AC controller
- coupled with the largest joy coupler that I can get to fit
- set up the AC controller for regen
- both controllers run from same battery pack - 400V
- battery charger set up to 'top up' battery pack as energy is removed
- run up the AC motor with the AC controller
- turn up the DC controller until the rpm begins to increase (AC current drops off)
- creep down the speed of the AC controller and begin regen
- increase DC torque output as required to stay around 1750 rpm
- increase regen on AC controller
- repeat until maximum regen or maximum current on DC motor
- log each step and max current when limit is reached

The second test will have the AC motor shaft coupler bolted to a solid frame, and the AC controller will ramp up quickly (maybe 10v/ms) to about 3X rated slip (150 rpm), which should get me 4X rated current, or perhaps a bit more, but at a low voltage. My clamp-on meter is not real accurate, but this should determine if the LEM Hass current sensors are in the right ball park
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