Ok, after a long delay I can now report that the 60 Ah cells that originally were in Perth are finally installed in my iMiEV in Melbourne.
There is some good news and some bad.
As far as the physical work of fitting the CMUs into the frames and base I am quite proud of what I have done. Once I had the pack out, it became obvious that a lot of re-engineering was necessary to accommodate the varied aspects of securing the modules and ancillary equipment and also retain to some extent the airflow both from the aircon and the hot air exhaust fan.
and a view of the front row with the A/C duct and service plug base. I had to build a special jig to suspend the service plug base in the correct position in mid air to fit the busbar to the negative of CMU 07.
I think I did a reasonably good job of pre-balancing the cells, the half pack volts both read 175.3 V and full pack 350.6 V (both EvBatMon and i909 confirmed the pack V at 350.4 V.
And now the bad news: All CMUs report their correct total voltages and cell volt differences of less than 0.01 to 0.02 V.
Except cells 33 and 34 (CMU 05 cell A & B) where the voltages jump from as low as 0.57 to as high as 5 (!) V.
CMU 05 cell monitor IC and all other data reports normal except volt underflow and volt overflow on cells A &B FAIL .
Nevertheless the car goes into ready and with the traction control off it happily spins the wheels.
Sadly ,but not unexpectedly, it refuses to charge, i909 reports (P1A39 =charge state signal error [BMU] (1/3)s well as
P1A62 = CMU 05 cell voltage high.
So what did go wrong there? Did I damage the BMS board? The cell monitor reports normal as do the voltage sensor and reference volts.
Is maybe the connection from the cells to the board poor? Could I despite the double and triple checking of the connections have missed this one?