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It's not very clear what you are actually wanting. :unsure:

The battery current sensor has two outputs one coarse and one fine.

There is a workshop manual on here I believe for the Nimh cars, that will have a circuit diagram and connector pinouts etc.
I do have access to Honda's iN system, and the nomenclature for the connector shows (in order):
N_FAN
PRE
ISOC
R2
R1
CNTPG
CNT
TBATT2
ISOCF
SGISOC
S3
S1
VCCISOC
TBATT3
TBATT1
SGTB
S4
S2

Just having a hard time determining which of the above denotes the coarse and fine current sensors. Thanks.
 

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Discussion Starter · #322 ·
I do have access to Honda's iN system, and the nomenclature for the connector shows (in order):
N_FAN
PRE
ISOC (Coarse current)
R2
R1
CNTPG
CNT
TBATT2
ISOCF (Fine current) 5-0-5A IIRC
SGISOC
S3
S1
VCCISOC
TBATT3
TBATT1
SGTB
S4
S2

Just having a hard time determining which of the above denotes the coarse and fine current sensors. Thanks.
See above these signals rest at 2.5V = zero amps. Output range is 0-5V
 

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Or you can order the manual ( for 2011-12 cars) here Honda CR-Z 2012 Shop/Service Information or as @PeterPerkins mentioned there are a few on here who have it as a PDF.

It's not very clear what you are actually wanting. :unsure:

The battery current sensor has two outputs one coarse and one fine.

There is a workshop manual on here I believe for the Nimh cars, that will have a circuit diagram and connector pinouts etc.
 

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Discussion Starter · #325 ·
Right it's time to get back to power hacking my Nimh car and going for 30kw plus!!

This 'Frankenstein' pack will be made up of parts from an OEM Lithium pack and an OEM Nimh pack.

From the OEM Lithium pack I will just use the MPI IGBT power module.. (That's the bit that does the hard work driving the IMA motor)
From the OEM Nimh pack I will use everything else except the MPI module and the DC-DC converter.
I will use the DC-DC converter from an HCH2 Civic.

The above mix should get me the highest voltage headroom possible.... Hopefully around 200V or so..

The project will be split into two parts.

1) The electronics, MPI, DC-DC, MCM, Phase current sensors, wiring harness etc etc etc

I will assemble the electronics on a simple flat alloy plate (Mocked up with mdf first for a pattern that can then be laser cut)
It will probably mount using the OEM brace bars but that's not a deal breaker. I might not bother with those.

2) The Lithium battery itself and independent Orion 2 BMS.

This will be made from the brand new 5ah Honda LiPo cells I have and probably be a 50S2P configuration initially.
This will give an abs max voltage of 207.5 at 4.15V per cell and about 10ah capacity...

My Orion 2 BMS can cope with 60S so I do have room to go higher voltage if the other parts will tolerate it.
I will probably try and assemble the pack from blocks of 20 cells (10S2P) so I can add/remove blocks as needed..

My only sort of requirement for the battery itself is that it fits in the OEM IMA space.

The electronics does not care what battery is fitted so I have free reign here.

First job disassemble my old supercap Nimh pack and the spare OEM Lithium pack to get the various parts I need.
 

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Hello Peter. Thank you for great work done so far. I just have a small question. I can't seems to find any info as to why you use igbt/rectifier unit from lithium pack. I'm sure it can work with higher voltage then NiMH one. Dcdc aside what the higher voltage one could go on NiMH MPI?
TA
 

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Discussion Starter · #329 ·
I started getting errors with the stock Nimh IGBT MPI module at over ~160V.

It may be possible to fool it and go higher, but I have simply opted to use the higher voltage rated Lithium unit with more headroom.
 

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Discussion Starter · #330 ·
I found this chart of OCV versus SOC for LiPo.
Might be useful for my 2P 50S pack.

Code:
Look-up Table for Cell SoC Estimation Based On Cell OCV
Cell OCV(V) SoC
[4.2-4.1) 100%
[4.1-4.05) 90%
[4.05-3.99) 85%
[3.99-3.945) 80%
[3.945-3.983) 75%
[3.983-3.847) 70%
[3.847-3.812) 65%
[3.812-3.7755) 60%
[3.7755-3.7405) 55%
[3.7405-3.670) 50%
[3.670-3.658) 45%
[3.658-3.618) 40%
[3.618-3.565) 35%
[3.565-3.505) 30%
[3.505-3.430) 25%
[3.430-3.350) 20%
[3.350-3.240) 15%
[3.240-3.140) 10%
[3.140-3) 5%
[3-0] 0
 
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