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QuickSilver Controls, Inc.

712 Arrow Grand Circle, Covina, CA 91722 888-660-3801 626-384-4760 Fax: 626-384-4761 www.QuickSilverControls.com

ATEX Thermal Testing Report -- October 24, 2011 Testing was performed October 18, 2011 at Consolidated Laboratories, Covina, CA. Setup starting 8:00AM October 18, 2011. The QCI-N3-E3 controller had previously been downloaded with Rev 54-05 code (M0554.hex), as is used on production ASTS units, and was initialized using a 30 cable (Factory Default Initialization 16 52v 8500 torque.qcp), running from a 48v power supply. A second motor was configured to act as a variable speed load to allow operating of the test motor at maximum load at each speed. Both motors were connected to a common brake unit between the controllers and the power supply. The Test System was configured on bench top and allowed to come to equilibrium with the lab temperature for 45 minutes while thermocouples are attached. Thermocouples attached to front bearing housing, middle of stator, back bearing housing and back cover of electronics housing (see picture below). Thermocouple reported temperatures agree within 0.8F at start of test. Nominal room temperature at start of test was 74.5F (average of thermocouples). The chart recorders started at 9:00 and allowed to record baseline before energizing the motors. Previous testing had indicated that the highest heating in this application occurred at the highest speed range in this application: 2000 RPM. To verify the previous testing, this test was started at 2000 RPM, with subsequent settings reduced in steps of 500 RPM within the day to verify that each of those speeds produced less heating. About 9:15 AM, the unit under test, QCI-A34HC-1 with a QCI-N3-E3 controller, was energized and commanded to 3000 RPM, while the load motor (generator) was commanded to -2000 RPM. (The negative direction of the load motor causes the unit under test to be rotated in the clockwise direction as the load motor and test motor are facing each other. The load motor speed of 2000 RPM causes the driving motor to attain 2000 RPM). Reported torque from unit under test was 8500 counts, as seen from the Register Watch Panel. Speed as measured by the unit under test controller velocity register (read via the Register Watch Panel) was approximately 533100 counts per second, at 16000 counts per revolution, this corresponds to 33.32 Revolutions per second or ~1999 RPM. Speed was measured with an optical tachometer to 2000+/-1 RPM. Power supply voltage measured at 48.2v at the power supply. Test Unit was allowed to come to Equilibrium (approximately 1.5 hours) (10:45) Temperatures at all 4 thermocouples noted and recorded. The ambient temperature was measured at 74F. The speed was dropped to 1500 RPM to verify that 2000 RPM was indeed the highest temperature operation over the used speed range. The speed was measured as1500 +/-2 RPM using an optical tachometer. Unit was again allowed to approach equilibrium. Measurement taken at 11:50 and logged to test sheet. Ambient temperature was measured at 77F.

The speed changed to 1000 RPM. The speed was verified to 1000 +/-1 RPM using the optical tachometer. The Test Unit was again allowed to reach temperature equilibrium. Temperature at 4 thermocouples logged to report at 1:08PM, Ambient temperature measured at 80F. The speed was changed to 500 RPM. The speed was verified to 500+/-1 using the optical tachometer. The Test Unit was again allowed to reach temperature equilibrium. Temperature at 4 thermocouples logged to report (1:54 PM). Ambient temperature measured at 82F. The speed was changed to 0 RPM with torque applied to simulate locked shaft. The shaft was verified as stationary. The Test Unit was allowed to reach temperature equilibrium. The temperature of the 4 thermocouples was logged to report (3:12 PM ) Ambient temperature was measured at 83F. The units were turned off and the test was ended. The charts in the Consolidated Laboratories test report show that the highest temperature did correspond to the maximum speed of 2000 RPM. The highest external temperature measured was the center of the laminates, and was 207.5F (97.5C) in an ambient of 74F (23.3C). The following pictures show the test bench set-up as well as the location of thermocouples. Note: the fan seen in the background was not plugged in and was not operating in the course of the test. Sincerely, Donald P. Labriola P.E. President, QuickSilver Controls, Inc. 626-384-4760

Test bench setup (Note: fan in background was not powered.) TC4 TC3 TC2 TC1 Unit Under Test

TC1

Load Motor TC2 TC3 TC4

Unit under test 30 Cable

N3 Drivers

TC1 & TC2

TC3 & TC4 (channel 1 and 2)

Thermal Chart recorders

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