Ima System: Other Honda Insight ZE1

Turning Off Power To The High Voltage Circuit

The following procedure should be performed prior to working on or near any high voltage components. Follow the procedure exactly. Otherwise, you may be injured or damage equipment.

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1. Turn the ignition switch OFF.
2. Remove the cargo floor mat (see «TRIM REMOVAL/INSTALLATION - CARGO AREA»(ref-219313-S19796719322006021300000) ).
3. Remove the battery module cover (A) from the IPU lid, and remove the locking cover (B).
4. Turn the battery module switch (A) OFF, then install the locking cover (B).
5. Wait for at least 5 minutes to allow the PDU capacitor to discharge.
6. Remove the right side trunk shelf support (A).
7. Remove the mid-frame cover clips and the IPU lid (A).
8. Measure voltage at the junction board terminals (A). There should be 10 V or less. If more than 10 V is present, there is a problem in the circuit; do the DTC troubleshooting first.

Intermittent Failures

The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the IMA system indicator on the dash does not come on, check for poor connections or loose terminals at all connectors related to the circuit that you are troubleshooting.

Opens and Shorts

"Open" and "Short" are common electrical terms. An open is a break in a wire or at a connection. A short is an accidental connection of a wire to ground or to another wire. In simple electronics, this usually means something won't work at all. With complex electronics such as the MCM, this can mean something works, but not the way it's supposed to.

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1. If the IMA system indicator (A) stays on, turn the ignition switch OFF. Connect the HDS to the data link connector (DLC) (B) located under the passenger's side (2001-2006 models: driver's side) of the dashboard. 2001-2006 models
2. Jump the SCS line with the HDS.
3. Turn the ignition switch ON (II).
4. Check the diagnostic trouble code (DTC): The IMA system indicator indicates a DTC by the length and the number of blinks. The indicator can indicate multiple problems by blinking separate DTCs, one after another. DTCs 1 through 9 are indicated by individual short blinks. DTCs 10 and above are indicated by a series of long and short blinks. One long blink equals 10 short blinks.
5. Refer to the «DTC TROUBLESHOOTING»(ref-219297-S27442497832006021300000) , and begin the appropriate troubleshooting procedure.

Motor Assist (acceleration)

During acceleration, the motor assists the engine by generating up to 49 N.m (5 kg-m, 36 lbf.ft) of torque. The motor assists the engine until the battery condition monitor (BCM) determines the battery state of charge is at or below a predetermined limit. At that point, motor assist will stop to prevent battery discharge.

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Regenerative Control (deceleration)

During deceleration, the motor functions as an electrical generator to charge the battery. Kinetic energy that is normally wasted during braking is transformed into electrical energy. The motor will charge the battery until the BCM sees that the battery state of charge reaches a predetermined limit. At that point, the motor stops regeneration to prevent battery overcharge.

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Starter Function (at start-up)

The motor starts the engine under normal conditions. Because the motor is directly connected to the engine's crankshaft, it is much quieter and smoother than the vehicle's conventional starter. When outside temperature is extremely low, when the battery state of charge is low, or if there is a problem with the IMA system, the conventional starter starts the engine.

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Auto-Stop System

Under certain conditions, the ECM stops the engine to conserve fuel and minimize tailpipe emissions when the vehicle comes to a stop. When this happens, the AUTO-STOP indicator comes on, either as a steady or a blinking light, to alert the driver that the auto-stop system is on.

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The engine will not enter auto-stop mode under these conditions

1. When the transmission is in the R position, L position, or S mode.
2. When the vehicle is stopped using heavy braking.
3. When the AUTO or DEF button of the climate control unit is pushed, or when the passenger compartment temperature has not stabilized at the set temperature.
4. When the engine coolant temperature is about 122°F (50°C) or below.
5. For about 2 minutes after starting the engine.
6. When the battery state of charge is low.
7. When the electric load on the 12 V system is high.
8. When the accelerator pedal is pressed.
9. When an auto-stop related component is faulty.
10. When the MIL is on.
11. When the climate control system is in the economy (ECON) mode and the outside temperature is below 41°F (5°C).

When the engine is stopped by auto-stop system, it will restart under these conditions

1. When the transmission is moved into any position other than neutral with the clutch pedal pressed (M/T).
2. When the accelerator pedal is pressed, the transmission is in neutral and the clutch pedal is pressed (M/T).
3. When the brake pedal is released.
4. When the accelerator pedal is pressed while the brake pedal is pressed.
5. When the vehicle moves while the brakes are lightly applied.
6. When the transmission is in the R position or the L position while the brake pedal is pressed (CVT).

IMA Motor

The motor is a synchronous AC type that serves three functions; it converts kinetic energy into electrical energy, it assists the engine during acceleration, and it starts the engine.

The motor is between the engine and the transmission. It has a three-phase coil stator and a permanent magnet rotor that is directly connected to the engine crankshaft. Three commutation sensors are mounted inside the housing to detect the position of the rotor.

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MCM (Motor Control Module)

The MCM controls the amount of assist that the motor produces and the amount of regenerative power that the motor absorbs based on input from the ECM and the BCM. The MCM converts DC power into three-phase AC power required during assist, and converts AC power into DC power during regeneration.

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The MCM also communicates with the HDS through the 16P data link connector for better serviceability. If any sensors or circuits in the IMA system are abnormal, the MCM turns on the IMA system indicator to warn the driver that there is a problem.

Battery Module

A light-weight, compact Ni-MH (nickel-metal hydride) battery supplies energy to the IMA system.

The battery has 20 modules connected in series. Within each module are six 1.2 V cells. The total battery voltage is 144 V, and maximum capacity is 6.5 Ah.

The battery module has four built-in thermistor-type temperature sensors and a PTC (positive temperature coefficient)-type temperature sensor for each cell.

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BCM (Battery Condition Monitor) Module

The BCM module determines the battery state of charge and controls the battery fan speed by looking at battery voltage, battery input/output current, and battery temperature. The BCM module then sends this information to the MCM to indicate the battery's state of charge and to keep the battery within predetermined limits.

Because battery charging and discharging generates heat in the battery module, the BCM module also controls a fan that keeps the battery module from overheating. The fan operates in one of three modes; off, low, or high.

If the BCM module detects an abnormality, it sends a signal to the MCM, which then turns on the IMA system indicator on the gauge assembly.

Junction Board

The junction board, mounted on the battery module, houses some high voltage components of the IMA system. The battery module switch, contactors, fuses, and current sensors are on the junction board.

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Battery Module Switch

The battery module switch is connected in series to the battery module fuse. Always turn the battery module switch to the OFF position whenever service or checks are required on or around the high voltage circuits. Follow these steps exactly

1. Remove the switch cover from the IPU lid, then turn the switch OFF.
2. Wait at least 5 minutes.
3. Remove the IPU lid.
4. Measure the voltage at the output terminals. Make sure the voltage is low enough for safe operation before any service is done.

Contactors

The high voltage contactor and bypass contactor are connected at the positive (+) output side of the battery module. These contactors are controlled by the MCM, connecting the IMA battery to the high voltage circuits. The current flows through the bypass contactor and bypass resistor when first, starting to charge the capacitors in the power control unit (PCU).

PCU (Power Control Unit)

The PCU consists of the motor drive module (MDM), the DC-DC converter, and a heat sink that cools these units. These components are integrated into a single, compact unit. The fan circulates air over the heat sink and cools the MDM and the DC-DC converter.

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MDM (Motor Driver Module)

The MDM consists of the MPI module, voltage converter module, capacitor, and the U/V/W phase motor current sensors. The voltage converter acts as a preamplifier for the IGBTs. The IGBTs are used to transfer electrical energy to the motor from the 144 V battery and vice versa. The IGBTs are activated by the MCM based on the amount of assist/ regeneration needed. The voltage converter module monitors voltage and temperature of the MDM, and sends this information to the MCM.

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DC-DC Converter

Instead of using an alternator to maintain the 12 V battery, a DC-DC converter is used. The converter converts high voltage direct current into low voltage direct current with little energy loss.

The DC-DC converter turns on the charging system indicator in the gauge assembly if a problem is detected in the 12 V charging system.

The DC-DC converter has a temperature monitoring system that signals the MCM if its temperature is abnormally high. If needed, the MCM can signal the DC-DC converter to shut down.

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MPI Module Fan Keeps Running, or Always Runs at High Speed

Note. Information marked with an asterisk (*) applies to the PDUFANH line.

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1. Turn the ignition switch OFF.
2. Remove the cargo floor mat (see «TRIM REMOVAL/INSTALLATION - CARGO AREA»(ref-219313-S19796719322006021300000) ).
3. Turn the battery module switch OFF (see «TURNING OFF POWER TO THE HIGH VOLTAGE CIRCUIT»(ref-219297-S06746409332006021300000) ).
4. Remove the IPU lid (see «TURNING OFF POWER TO THE HIGH VOLTAGE CIRCUIT»(ref-219297-S06746409332006021300000) ).
5. Disconnect MCM connector A (32P). Does the MPI module fan run? YES - Go to step 6. NO - Substitute a known-good MCM and recheck. If the symptom/indication goes away, replace the original MCM.
6. Remove the low speed MPI module fan control relay and high speed MPI module fan control relay.
7. Check for continuity between body ground and MCM connector terminals A6 and A7*. Is there continuity? YES - Repair short to ground in the wire between the MCM (A6, A7*) and the low (high)* speed motor MPI module fan control relay. NO - Go to step 8.
8. Check the low (high)* speed MPI module fan control relay (see «POWER RELAY TEST»(ref-219336-S02286166552006021300000) ). Is the relay OK? YES - Repair short to ground in the wire between the MPI module fan and high speed MPI module fan control relay. NO - Replace the low (high)* speed MPI module fan control relay.

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1. Turn the ignition switch OFF.
2. Remove the cargo floor mat (see «TRIM REMOVAL/INSTALLATION - CARGO AREA»(ref-219313-S19796719322006021300000) ).
3. Turn the battery module switch OFF (see «TURNING OFF POWER TO THE HIGH VOLTAGE CIRCUIT»(ref-219297-S06746409332006021300000) ).
4. Remove the IPU lid (see «TURNING OFF POWER TO THE HIGH VOLTAGE CIRCUIT»(ref-219297-S06746409332006021300000) ).
5. Connect BCM module connector terminal A11 to body ground with a jumper wire, and turn the ignition switch ON (II). Does the battery module fan run? YES - Go to step 6. NO - Go to step 7 .
6. Connect BCM module connector terminal A24 to body ground with a jumper wire. Does the battery module fan run at high speed? YES - Substitute a known-good BCM module, and recheck. If the symptom goes away, replace the original BCM module. NO - Go to step 20 .
7. Check the low speed battery module fan control relay (see «POWER RELAY TEST»(ref-219336-S02286166552006021300000) ). Is the relay OK? YES - Go to step 8. NO - Replace the battery module (see «BATTERY MODULE REMOVAL/INSTALLATION»(ref-219297-S01246074482006021300000) ).
8. Disconnect BCM module connector A (26P), and remove the low speed battery module fan control relay.
9. Connect low speed battery module fan control relay 4P connector terminal No. 3 to body ground with a jumper wire.
10. Check for continuity between body ground and BCM module connector terminal A11. Is there continuity? YES - Go to step 11. NO - Repair open in the wire between the BCM module (A11) and the low speed battery module fan control relay.
11. Turn the ignition switch ON (II).
12. Measure voltage between body ground and low speed battery module fan control relay 4P connector terminal No. 4. Is there battery voltage? YES - Go to step 13. NO - Check for: A blown No. 24 IMA (7.5 A) fuse in the under-hood fuse/relay box. An open in the wire between the No. 24 IMA (7.5 A) fuse in the under-hood fuse/relay box and the low speed battery module fan control relay.
13. Turn the ignition switch OFF.
14. Check for continuity between body ground and low speed battery module fan control relay 4P connector terminal No. 1. Is there continuity? YES - Go to step 15. NO - Repair open in the wire between G502 and the low speed motor power inverter module fan control relay.
15. Disconnect the battery module fan 2P connector.
16. Connect battery module fan 2P connector terminal No. 2 to body ground with a jumper wire.
17. Check for continuity between body ground and low speed battery module fan control relay 4P connector terminal No. 2. Is there continuity? YES - Go to step 18. NO - Repair open in the wire between the battery module fan and the low speed battery module fan control relay.
18. Turn the ignition switch ON (II).
19. Measure voltage between body ground and battery module fan 2P connector terminal No. 1. Is there battery voltage? YES - Substitute a known-good BCM module and battery module fan, and recheck. If the symptom/indication goes away, replace the original BCM module and the battery module fan. NO - Check for: A blown No. 24 IMA (7.5 A) fuse in the under-hood fuse/relay box. An open in the wire between the No. 24 IMA (7.5 A) fuse in the under-hood fuse/relay box and the battery module fan.
20. Check the high speed battery module fan control relay (see «POWER RELAY TEST»(ref-219336-S02286166552006021300000) ). Is the relay OK? YES - Go to step 21. NO - Replace the battery module (see «BATTERY MODULE REMOVAL/INSTALLATION»(ref-219297-S01246074482006021300000) ).
21. Disconnect BCM module connector A (26P), and remove the high speed battery module fan control relay.
22. Connect high speed battery module fan control relay 4P connector terminal No. 3 to body ground with a jumper wire.
23. Check for continuity between body ground and BCM module connector terminal A24. Is there continuity? YES - Go to step 24. NO - Repair open in the wire between the BCM module (A24) and the high speed battery module fan control relay.
24. Turn the ignition switch ON (II).
25. Measure voltage between body ground and high speed battery module fan control relay 4P connector terminal No. 4. Is there battery voltage? YES - Go to step 26. NO - Check for: A blown No. 24 IMA (7.5 A) fuse in the under-hood fuse/relay box. An open in the wire between the No. 24 IMA (7.5 A) fuse in the under-hood fuse/relay box and the low speed battery module relay.
26. Turn the ignition switch OFF.
27. Check for continuity between body ground and high speed battery module fan control relay 4P connector terminal No. 1. Is there continuity? YES - Go to step 28. NO - Repair open in the wire between G502 and the high speed motor power inverter module fan control relay.
28. Disconnect the battery module fan 2P connector.
29. Connect battery module fan 2P connector terminal No. 2 to body ground with a jumper wire.
30. Check for continuity between body ground and high speed battery module fan control relay 4P connector terminal No. 2. Is there continuity? YES - Go to step 31. NO - Repair open in the wire between the battery module fan and the high speed battery module fan control relay.
31. Turn the ignition switch ON (II).
32. Measure voltage between body ground and battery module fan 2P connector terminal No. 1. Is there battery voltage? YES - Substitute a known-good BCM module and battery module fan, and recheck. If the symptom/indication goes away, replace the original BCM module and the battery module fan. NO - Check for: A blown No. 24 IMA (7.5 A) fuse in the under-hood fuse/relay box. An open in the wire between the No. 24 IMA (7.5 A) fuse in the under-hood fuse/relay box and the battery module fan.

Battery Module Fan Keeps Running, or Always Runs at High Speed

Note. Information marked with an asterisk (*) applies to the BATTFANH line.

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1. Turn the ignition switch OFF.
2. Remove the cargo floor mat (see «TRIM REMOVAL/INSTALLATION - CARGO AREA»(ref-219313-S19796719322006021300000) ).
3. Turn the battery module switch OFF (see «TURNING OFF POWER TO THE HIGH VOLTAGE CIRCUIT»(ref-219297-S06746409332006021300000) ).
4. Remove the IPU lid (see «TURNING OFF POWER TO THE HIGH VOLTAGE CIRCUIT»(ref-219297-S06746409332006021300000) ).
5. Disconnect BCM module connector A (26P). Does the battery module fan run? YES - Go to step 6. NO - Substitute a known-good BCM module, and recheck. If the symptom goes away, replace the original BCM module.
6. Remove the low speed battery module fan control relay and the high speed battery module fan control relay.
7. Check for continuity between body ground and BCM module connector terminals A11 and A24*. Is there continuity? YES - Repair short to ground in the wire between the BCM module (A11, A24*) and the low (high)* speed battery module fan control relay. NO - Go to step 8.
8. Check the low (high)* speed battery module fan control relay (see «POWER RELAY TEST»(ref-219336-S02286166552006021300000) ). Is relay OK? YES - Repair short to ground in the wire between the battery module fan and high speed battery module fan control relay. NO - Replace the battery module (see «BATTERY MODULE REMOVAL/INSTALLATION»(ref-219297-S01246074482006021300000) ).