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Originally Posted by uhtrinity
I hate to disagree with Mike, but when I tested the sense resistors (if that is what they are called), they acted like normal resistors. I tried heating a few. They actually started at 180 - 190 ohms and dropped to 160 ohms hot. Is it possible there could be a few different kinds installed in packs? Or could you have mixed up your sense resistor and PTC notes?
Will be interesting to see how the system handles a larger pack and will answer the question of how large of can the Insights BCM go. Also, are you going to let the stock system do some charging? I can't imagine trying to fully charge a battery that size. Just charging under 8Ah seems to take forever 
As far as faking out the BCM, if you can use either 40 or 50 cells, then you wouldn't have to as you would have 11 points to tap from (the 11th point is the final (-) if you are counting all (+) terminals. I haven't checked the Insight pack closely, but the Civic pack adds a 12th by tapping both sides of the cut switch. I will know for sure about the Insight wiring when I start my visual load gauge next week |
I'll measure the resistors in the BCM subpack monitoring leads myself, I'm happy with your values for the ptc strips and I'm going to move the other 3 or 4 thermistors from an old pack and spread them around the new one.
Sadly the voltages don't work out even enough to use 40 or 50 cells (I would have liked to have done that) so I'll fake it with a PD made from 1% tolerance resistors this will mean the bcm thinks pack is in perfect balance and prevent any balancing forced charging as opposed to just low pack forced charging which I can disable with MIMA anyway as I wish. Of course if I do need to use all 50 cells in the end then I will just tie the leads to the cells at 5 cell Intervals. Yes the IMA battery cut switch does have connections both side to the bcm.
I'll see what the bcm makes of the pack but may have to do the BCM current monitor sensor output divide by 10 trick, we shall see.
Yes I will let the IMA system charge as normal when braking, descending hills etc, but I will make much more use of assist obviously and try to run the pack down on journeys and charge at home. I'll use MIMA to stop it force charging when low. Seems like MIMA is a pre-requisite for any sort of larger pack mod or you will find difficulty mangaging or using it's extra capacity.
Peter
