Couple of videos showing modification of the Civic switch board to accomodate the MCM fooler resistor matrix, 3kw mains charger and four battery connection points.
Need to make an aluminum tray for the boot to mount the batteries. I think Unfortunately the only way the 2 x 28S3P A123 packs will fit is long ways in the wheel well which means I will have to carry a can of tyre sealer instead of the spare wheel. Oh well.
To do. (Lots)
Extend the wires on the Civic OEM battery temp sensors so they can reach the A123 packs.
Add resistor to fake the PTC sensor.
Fit the Anderson connectors to the 2 battery packs so they can plug into the connectors comming from the switch board.
Fit resistors to the various current sensors to increase IMA current by 18.5%.
Might have it working by end of January.
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OBDIIC&C $50 inc software, pcb, switch and obdii plug.
IMAC&C HCH1 $50 inc software and pcb.
Wow, Pete can't believe how you can jump through so many diffrents project and get so much accomplished. Fantastic.
As I promise, here how to beef up your back coil spring and carry I say if you want around 800 pound of lithium batteries
I have a sun roof put in that about 45 lb, a special car freezer/ ice box Australia 55.lb
Solar panels 145 watts,in car front and back to. tons of electric and hdd mobile equpments, a fold up bicycle, chair, etc, together with my friends sometime we got about 600 lb in the car. The good part about this lift is it doesn't go down, and gives better air flow. I like it higher than stock 2-1/2" above the tire look good. Even with this weight I still get the same good mpg, and can beat most car at the stoplight, it's all because of my torque mod.
Look at the left spacer,use it so the bottom rest on the coil spring base edge it's round so perfect. Skip a coil and use the next coil, (so it's about 30%) get the car up high so you can screw the top bottom nut as far up pulling the bracket and spring up as it will go, that my hight 2-1/2" , "put 2 one each side left and right" it's makes the 3 coil solid to the base as one and stiffen the spring so you can raising it as you want
it's a very soft ride, but get a harder the more air in your tire, mine 53lb and still not bad but for a bump road. reliability? about 2 years.
That was quick, I guess the work you'd done on the I1 was pretty portable then? I suddenly feel the need to start harrassing the HR people at my work for an electric charging station .
A lot is compatible but there will be a few issues to overcome i'm sure. I'm using some of the wiring I took out of the G1 insight as well so I don't have to make up a load more connectors.
One likely issue is the fact you can't use a BCM interceptor to fool the car soc into being at 19 bars all the time like i did in the G1 because the BCM and MCM are combined in the HCH1. So the battery SOC will change as if the car only had 4ah of capacity available.
I think that issue will be solved by one of two methods in this case.
1) I'm using 56 cells in this setup which is 56 x 3.2v nominal is 180V so when not under load that is over the pos recal voltage point so i might find it just keeps recaling to full.
2) I can program the OBDIIC&C to send the reset to 19 bars command to the car evey minute or so, so it keeps resetting to full.
Because of the higher pack voltage I will add a 47k variable resitor to the positive side of the MCM fooler 10 x 10k resistor matrix so i can turn down the voltage the car sees if necessary. (I forgot to add this yesterday)
So if the variable resistor is set at 20k then the car would see a perfectly balanced
(180 / 12) * 10 = 150V
set at 10k it would give (180 / 11) * 10 = 163V
__________________
OBDIIC&C $50 inc software, pcb, switch and obdii plug.
IMAC&C HCH1 $50 inc software and pcb.
I plugged the packs into the switch board on the bench and the BCM fooler powered up correctly. The combined voltage of the two packs is 192.5V at the moment but they are fully charged and well balanced at about 3.42V per cell group.
Got to make the battery support in the boot now. Need some dexion to mock something up get the sizes right then get it made properly in aluminium.
Re cooling I'm not going to provide any active cooling for the packs. These blocks have a much bigger surface area (3 to 4 times greater) compared to the 50 cells I shoe horned into the G1 battery case. Plus they will be running at a much lower average current drain, 60A will only be 1C and is hardly likely to generate much heat. They also have aluminium spreader plates in between the cells which bring the heat out to the sides/base of the blocks.
__________________
OBDIIC&C $50 inc software, pcb, switch and obdii plug.
IMAC&C HCH1 $50 inc software and pcb.
Last edited by retepsnikrep; 12-29-2012 at 10:37 AM.
Mini Master BMS talking to modules.
Bit of a faf to get it going as one slave board had a bad joint
BMS Reports 187V and my old multimeter reports 188V pack voltage so pretty good.
Uses the 12F683 as you might expect.
Has a single button to toggle the charger on/off.
Has pwm output to control charger current/voltage and a 5v 250ma relay control output.
I'll use my solid state mains relay.
Edit
Simple spreadsheet showing battery voltage data today.
__________________
OBDIIC&C $50 inc software, pcb, switch and obdii plug.
IMAC&C HCH1 $50 inc software and pcb.
Last edited by retepsnikrep; 12-27-2012 at 01:32 PM.
Waiting for straps to arrive and need to get two hinges to allow battery tray to tilt upwards approx 2-3 inches to allow the spare wheel to be extracted from under the battery.
Battery tray will be lined with insulation to prevent any leakage issues from cells to car chassis. The two A123 blocks will also be insulated from each other by 1mm plastic sheet.
Need a friend to come over once I have them lashed into the tray so we can trial fit them in the car. 75kg is a bit heavy for me on my own! Need to allow for tilt etc.
Need to pump up the rear tyres to 50psi to compensate for the extra load.
Made up a second temp sensor harness with OEM sensors set for permanent 25C with 10k resistors, should give full assist potential.
__________________
OBDIIC&C $50 inc software, pcb, switch and obdii plug.
IMAC&C HCH1 $50 inc software and pcb.
Last edited by retepsnikrep; 12-29-2012 at 10:39 AM.
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HCH1 A123 60ah Pack Install
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