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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 · #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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Discussion Starter · #333 · (Edited)
Finished wiring the Nimh MCM into the Lithium power assembly.


Careful checking revealed that the OEM Lithium contactors are driven/switched differently (highside) rather than the (low side) for the Nimh.
Hopefully with a bit of rerouting I have sorted that.

It powers up on the bench with a current limiting psu, no apparent shorts and I can hear the contactors operating. (y)
 

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Discussion Starter · #334 ·
For next time it occured to me it might be fairly easy to fool the BMS side of the Lithium MCM with a fake voltage in the sweet spot of the normal operating range.

The Lithium MCM constantly receives the cell voltages from the 4 BMS boards (A,B,C,D) on the IMA can bus.
It doesn't request that info the BMS boards simply squirt it out.

I know the BMS id's so could make a PIC device squirt out a constant stream of perfectly balanced optimal cell voltage data..

The Lithium MCM does also have a standalone HV input, so that would have to be fooled with an equivalent total voltage generated by the pack and a zener diode or isolated dc-dc power supplies.
 

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Discussion Starter · #336 ·
I have added the Juntek 0-400V 0-300A wireless meter into the 'Frankenstein' setup so I can get some (real) readings during the Yes/No testing.
64232

If I can't get the higher voltage setup to work at all then there will be no point building a 60 Cell lightweight mega pack...

This is just to help during initial tests. (y)
 

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Discussion Starter · #339 ·
It's in and running upto about 75A assist at 180V.

I have an IMA code but my HDS laptop has packed up :mad: so I can't interrogate that today.

I suspect it is a current sensor mismatch, so I may have to put in the Nimh phase and battery current sensors in place of the Lithium car ones.

 
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