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Old 10-28-2014, 07:47 PM   #1 (permalink)
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Building a grid charger for my insight?

I won't go into it again today, but I got a IMA light today, I don't have the money to buy a grid charger, so I need to build one. Problem is, I can't find a good comprehensive guide anywhere on how to build one! I'm not the smartest person, but I am willing to learn. Does anyone know anywhere I can find a a comprehensive guide?

View my thread on IC here: It... Has finally happened... - Insight Central: Honda Insight Forum

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Old 10-29-2014, 09:00 AM   #2 (permalink)
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Balto,
check out 99mpg.com/resources/downloads as there is a simple schematic there. Also check out the youtube videos of Mike Dabrowski. I believe that install v4 shows a step-by-step access into the Insight battery area.
Now, before you operate on it, if you haven't already, go to Home Depot and buy a pair of the blue rubber gloves and when working on the car, drape a towel over any metal areas that you might lean on. Those two steps will keep you from making a very, very rapid trip out of the garage. Good luck.
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Old 10-29-2014, 09:10 AM   #3 (permalink)
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In my three installs, we never used any gloves. Unscrew, flip the switch, unscrew, unplug, pull out. 45 minutes to remove two, swap them, and reinstall.

I can't help you, but I am commenting because I am interested and hope this turns into Cheap Insight Grid Charger Build Thread.
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Old 10-29-2014, 09:21 AM   #4 (permalink)
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You get an IMA light because one or more of the cells are flat sooner than the others, triggering the BMS to report this and shut the pack down, because the pack is only as strong as the weakest cell, just like a chain.. bla bla.

From what I know about the Insight battery, you just need a constant current charger like any cheap nimh charger, but souped up to a higher voltage for lots of cells in series. The "balancing" would work because nimh cells (unlike lithium) stay the same voltage and convert the excess energy to heat when they're full, allowing the "low" cells to catch up and also get a good fill back.
I could easily design something simple, but I assume theres plenty of designs already on the web..
In the crudest form, you might get away with just a DC power supply and (a few) 12v light bulbs in series as current limiting resistors.
[edit] read the link you posted to the other forum, I like the charger/discharger they linked: http://dmr-architect.com/~locouki/In...ischarger.html even if you skip the discharging bit, that should be easy enough to build.

In the long run, you might need to find the bad cell(s) and replace it (if nothing else, with better used cells), but in the short run, just charge it and don't push it too hard.

Last edited by AlexanderB; 10-29-2014 at 09:32 AM..
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Old 10-29-2014, 11:01 AM   #5 (permalink)
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Problem is, I don't understand that schematic on the one they linked. Way to complicated for me.
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Old 10-29-2014, 02:11 PM   #6 (permalink)
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I could simplify it by removing the discharge bit and re-drawing it?
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Old 10-29-2014, 06:35 PM   #7 (permalink)
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Quote:
Originally Posted by AlexanderB View Post
I could simplify it by removing the discharge bit and re-drawing it?
I would really appreciate that tbh
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Old 10-29-2014, 06:36 PM   #8 (permalink)
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Why dont you ask some of your new friends on the insight forum if you can borrow one of theirs?

Quote:
Originally Posted by Baltothewolf View Post
Problem is, I don't understand that schematic on the one they linked. Way to complicated for me.
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Old 10-29-2014, 10:32 PM   #9 (permalink)
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Quote:
Originally Posted by Cobb View Post
Why dont you ask some of your new friends on the insight forum if you can borrow one of theirs?
It's not that easy, the wire harness is not an easy chore to get hooked up.
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Old 10-30-2014, 07:20 PM   #10 (permalink)
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Yeah, it takes 2 men and a small boy to lift the ima pack out to install it. Some say you dont need to remove it, but if you are going through all that trouble. You just as well do it and clean all the crap out and do some minor modifications too.

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