In my experience, charging at 200 ma or less will not require the fan be operated. I use 170 to 200 without any detectable heating at all.. However at 250 ma I can detect SOME heating, though not enough to worry me...except for the long run.
At 200 ma over night (10-12 hours) you are replacing a little over 1ah of charge. Since the Insight normally uses about 4ah from stop to stop, if you keep it above half on the SOC during the day, the overnight charge should be sufficient for daily use. This amount of charging will not hurt the battery in my opinion. If you want to "balance" the pack, give it 36 to 48 hours at 250ma and watch the charge curve on the "deepest" stick (the one that can hold the most charge) till it dips in voltage to indicate a full pack.
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Jim Isbell
2000, 5 speed, 250,000 miles
"If you are not living on the edge, well then,
you are just taking up too much space."
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