M,
Thanks for contacting me privately. You MUST get the error codes so that we can help with the repair. Common codes that you are looking for are P0A7F, P1446, P1570, etc.
In answer to some of your questions:
The Gen 1 Hondas (2000-2006 Insight and 2003-2005 Civic Hybrids) used identical battery subpacks inside very similar housings. Your 2006 uses a totally new pack.
It is smaller:
It has 22 sticks instead of 20:
And the sticks are physically different. Here is a picture of a Gen 1 stick (yellow) with Gen 2 stick pairs:
The subpacks are pairs of sticks that are welded together on the far end. They are also about 1/2" longer.
Despite this, they are basically the same electronically, and suffer the same problems and respond to the same treatment as the Gen 1 sticks do.
Where can you get them? I sell them. They cost $125 per pair. Shipping weight is about 6lbs per pair. Customs/duty is paid by you.
-I understood that something like CBA battery analyzer is good.
But it won't buy you anything over the Duratrax/Robitronic/Team Checkpoint unless you get a 10x amplifier for it (at $600 above the cost of the CBA alone).
-I need a charger/discharger.
Yes.
-I have a multi-meter and the necessary wrenches and .... etc.
10MM, 12MM and Torx T30.
-What is the best charge/discharge current?
With a fan: 5A for a 12 stick pack.
Without a fan? 2A max
The cost is a real issue ATM. Do I need both the CBA analyzer and the charger/discharger?
No.
I found many chargers/dischargers on eBay. I can get a friend to ship it to me. The charger cost ranges from $35 to $200+. What do I need to exactly look for? 5A+? 10A? 6+ cells balance support?
Balance support is for Lithium cells. This is NiMH. You need it to support 12 cells.
I do not want to spend more than three weeks at most doing this job.
Do the math: a single charge at 2A from empty will take about 3.5 hours.
A cycle (discharge-rest-charge-rest) takes about 8. You need to run 4 cycles at least on each stick pair. That means at least 14 days straight.
You cannot drive the car without the battery, and you can't use the battery until you've reconditioned ALL the sticks, or you will damage it.
You should budget to rent another car for the duration of the repair.
The Overloader 1 and the Duratrax ICE (and the Team Checkpoint TC1030) are basically the same unit (the TC1030 does 10 amps instead of 8 in the Duratrax). The Overloader 2 is a new model.
These units are rated for performance with sub-C packs, not D (which is what these cells are). I can tell you that a Duratrax ICE is rated for 8 amps discharge on a six cell pack and will die at more than about 4 amps on a honda stick. They literally go up in smoke. At 12 sticks, you might have to keep it under 2 amps discharge.
I have had much better luck with MRC Superbrain 989s, but they don't do a histogram.
IMA battery repair question
