Thanks for the values above.
I've knocked up a simple analogue Master circuit to provide visual and audible Over - Under Voltage indication and charger control. I intend to install this this week to allow me to actually test cells in situ and see how it reacts with the Insight BCM in more depth. I'll add a simple 0-200v voltmeter as well as a simple fuel gauge
http://www.solarvan.co.uk/bms/AnalogueMaster271208.jpg
While I'm doing this testing I shall move and adapt the Digital Master with some re-wiring, filtering.
I'm moving it out out of the IPU compartment which is an rf nightmare,
and am going to put it behind the now redundant battery cooling air vent behind the drivers seat with some rear aluminum screening.
I can then get at it by simply prising out vent grille, at the moment I have to go into rear compartment and disconnect far too much stuff
As it's out of the rf area it should be better for it as well.
I have found it is critical to ensure cells/pack can accept the first forced charge and are not full on first install. I would say charged to about 75% max is enough. The forced charge rate was about 6A for about 3-4 minutes until BCM had enough data to give an initial SOC.
The IMA then operated normally.
When I re-installed the nimh pack it did the initial soc forced charge, and then did a positive recal after that within about five miles, increasing soc to one bar from top. (That had been the indicated soc of the pack when I took it out)
I didn't run the lithium pack past the forced charge stage during my initial testing, so it will be interesting to see if it also does a positive recal as well when I put it back in, as it had a higher open circuit voltage than the nimh pack.
Hope to do this work within next week as I have a few days off.
