I agree, my multimeter and wiring isn't of such high quality that it can accurately read fractions of a mV.
After many more measurements I am thinking that the current difference is a wild goose chase since it varies quite a bit and I'm not measuring them at the same time under the same conditions.
The 19psi is static, from GPS and Google Earth I though I had about 100' of drop but it turned out to be half that. Due to some fun with the pipes I don't have the pressure gauge on it at the moment.
If I should only be making 200W after all is said and done, perhaps it's all working like it should be and I just have over inflated ideas of how much power I should be getting due to going off the raw output of the hydro.
I noticed that now that I am running 4 1/2 nozzles that some air is getting into the pipe, my intake is a 3" pipe through a damn and even though there is water above the damn it doesn't seem to be letting quite enough through to keep the intake pipe fed. I guess I'll put one one of the smaller nozzles back on.
I fiddled with it some more and this time was more scientific about it, here are my results:
Full Field:
At the power shed ( 750ft from the turbine ) voltage was 109V to the charger and the batteries were are 50.1. Later when the sun was on the 800W of PV the battery voltage went up to 53V and the hydro voltage went up to 114.4V so there is a correlation between the voltage of the batteries and the loaded hydro voltage.
I went down the the turbine and measured 108.8V when the voltage at the shed was 109.2V, I then shut it off and connected my multimeter to read current and got 8.4A which then fluctuated a bit and even went down to 5.2A when some air was in the pipe.
To test the water pressure I then measured with nozzles off:
1 nozzle 1.5A @ 107.7V
2 nozzles 3.1A @ 109.4V
3 nozzles 4.6A @ 109.6V
4 nozzles 8.4A @ 108.8V
I noticed that there was more load on the unit with my meter than with the IOTA alone, it spins slower when I measure amps than when I measure volts.
I then started playing with the field strength:
1/8th turn off full field:
1 nozzle 1.5A @ 109.3V
2 nozzles 2.7A @ 111.8V
3 nozzles 3.9A @ 113.3V
4 nozzles 4.8A @ 113.8V
1/4 turn off full:
1 nozzle 1.5A @ 108.7V
2 nozzles 3.0A @ 111.2V
3 nozzles 3.8A @ 112.7V
4 nozzles 4.5A @ 112.8V
3/8 turn off of full:
1 nozzle 2.8A @ 106.9V
2 nozzles 5.8A @ 105.8V
3 nozzles 5.8A @ 106.5V
4 nozzles 5.8A @ 103.4V
1/2 turn off full field
1 nozzle 3.7A @ 79.6V
2 nozzles 3.8A @ 77.7V
3 nozzles 3.8A @ 77.7V
4 nozzles 3.8A @ 77.7V
I left it at 1/8th off of full then took readings for a while, the voltage slowly dropped down to 110.3V.
Back at the power shed it was 108.8. A bit later when the batteries got up to 52.2 from the solar it was 112.8, then 114.4 @ 53.3V.
I tried connecting the hydro right to the batteries and it drops the hydro voltage down to match the batteries, it didn't seem to make much power like that but I don't really have any way to measure it besides seeing what the battery voltage is in the morning.
I can set the TS-60 to diversion mode but I've never come close to needing a dump load so far.
Right now the hydro alternator is set for high voltage wye, I could wire it into delta and try hooking it directly to the batteries like that? Perhaps line losses at the lower voltage would be offset by the inefficiencies of the charger?