• This guide gives the process and guidelines for testing the motor and high voltage system of the car while it is not on the vehicle. This is only for system bench testing purposes
• Equipment needed
  • Motor: Emrax 228
  • Motor Controller: Rinehart PM100DXR
  • HV Battery
  • HVJB
  • Control module
  • Table for mounting equipment (the one that was made specifically for testing)
  • Test mount for motor
  • HV Safety equipment
• Setup
  • The testing shall occur in a space that is closed or blocked from bystanders
  • The motor shall be attached to the mount designated for testing. This mount shall then be bolted or clamped to the table
  • The battery and motor controller shall also be mounted to the table
  • HV Cables can then be connected between the components accordingly
  • The control panel harness can then be connected
  • A computer with a serial monitor can be connected to the USB output of the control panel to monitor outputs
  • The test setup is now ready to be run
• Testing procedure
  • Verify that the potentiometer on the control panel is turned to the zero position
  • The LV switch on the control panel can be flipped on to power up the system
  • When the contactors on the battery have closed and the setup is verified to be ready, the potentiometer can be turned up slowly
  • The motor should begin to spin
  • The speed of the motor should be monitored with a tachometer and compared to the speed on the serial output to verify they are the same
  • When the motor is ready to be turned down or stopped, the potentiometer shall be turned very slowly to minimize the risk of reverse current to the battery
    • Because the motor controller is being sent speed commands, if the commanded speed is decreased too quickly the motor controller will attempt to “brake” the motor. This will essentially turn the motor into a generator to slow it down and send current backwards into the battery.
  • When the motor is stopped, the contactors should be verified to be open and HV is no longer being applied to the motor controller.
• Safety
  • The area around the motor shall be cleared before turning on the control system
  • Nobody should be standing in the plane of rotation of the motor
  • Nobody shall be in contact with the system at any point while the contactors are closed. The system needs to be completely powered off before any connections or disconnections are made.
  • Nobody shall be within 3 ft of the motor while it is spinning except to measure with a tachometer