Hi all,

While connecting ZIPPY 2200mah lipo battery to my HK 6S 50W 5A charger, it show "connection break" and not able charge the battery and also no voltage output

So I opened the battery pack to check any issue with each cell.

I tested with Multimeter and all the cells individually shows 3.9v, but no overall output. can anyone guide me what is the issue.

I have attached the photo with output voltage in each cell.

Only 1 possible reason that i can think of is that the small Pink wire might have gave up.
Check for continuity at the leads on the both ends of the pink wire.

I think red wire is not working to joint both cell. check here , if no volt,then replace red wire:

IndianHobbyShop : The pink wire is working fine, I have tested it.
Ayub: I hope both the marked cell are -ve

Please provide the voltage reading as per Ayub's suggestion.
The issue has to be in the pink wire.

Here is the reading...

Exactly what i thought.

Remove the pink wire and solder another wire instead.
Use some quality and heavy gauge wire like strands of the 'old type' 7/22 wire.
Or just about anything heavy in copper that you can find and it should work fine.

Use extreme precaution while dealing with LiPo
They don't even take a second to burn whatever you use to unintentionally short circuit it with.

If the pink wire is not working.. how Red color voltage 3.9v and 7.9v is show...

Hmm, the 7.9V and 3.9V in Red doesn't make any sense to me. That should also be 0.
Before soldering as mentioned above, can you check the voltage output inside the XT60 connector terminals.

If it shows 0, then proceed with the soldering as suggested above.
This is quite interesting.

Also, before proceeding, double check each and every voltage reading that you have mentioned in the latest image.
Let us know if all voltages match as per what is mentioned in the image.

The XT60 connector output is also 0v.

Ok, What about Reply# 9?

The voltage are same, just verifying after ayub post

Quite interesting.
Let's have a Skype Video Call.

Have sent you a PM with my Skype ID

Just had a detailed Skype video call with Purushottam and it indeed is exactly as described in image.
It's kind of as if the pink wire is acting up as a diode which certainly is not possible.
Mindboggling

Any inputs experts?
Would love to see someone solve this puzzle.

The pink wire was not required in the first place when there is a copper PCB track existing.

If the red and black colour lines at the voltages indicate the polarity of multimeter probe then i don't agree with polarity of voltages indicated.

please indicate clearly with positive and negative sign with voltages with probes reversed for each combination.

definitely one of the cell is in reverse polarity in series, even if one cell is reversed the indicated voltage combination is not possible.

if all multimeter probe colours are correct then may be it is this?

If this is factory setting battery, no cell should be in reverse direction,

@Purash,
If the reading is 0 at my point, your pink wire(which I said red) is not working, you should replace it. at my point the voltage should be 3.9 or something.
this wire is not working.

The pink wire intrigued me as well since the PCB already have the copper track.
Not sure what is the brown part (Circle in the attached image) on the PCB. Looks like the PCB is burnt.

I was not paying attention to the polarity since he said that he had been using this LiPo for over an year and have just opened it up when it stopped working. So i kept the focus only on voltage between the leads.

What truly amazed me was:
(A- B-) = 0V
(A- B+) = 7.9V

Please see attached image.
This simply does not sound possible.

Should have recorded the video of the Skype Call for ease of everyone.

Can it be that there's a diode or something inside the pink wire. (I don't see why there should be, but this thing is making me  )
And the PCB is burnt (Brown part)

One more experiment Purushottam >
Use a Compass with Double Divider (metal) to make a temporary connection between A+ and B- (To act as a substitute for the pink wire) and then check the voltage at the XT60 connector.

Give it a last try mate.
Maybe the Pink wire is drunk? 

if the pink wire is broken and the PCB track is burnt the voltage highlighted in red cannot be.

Exactly.
That's the thing making me pull my hair out.

That simply is not possible.
But i saw it with my own eyes!!!

if you isolate and remove the pink wire and short circuit both ends there will be an explosion  >

 

if red circle is 7.9 blue circle cannot be zero.

Exactly.

Basically we all are on the same page.
The LiPo is not

as if the pink wire does not want to follow the laws physics.

we need the -A to +B voltage too which purush has not indicated.

I did saw it while being on Video Call with him.
Please check Reply #18

I was just working on the lipo, I soldered the pink wire thinking the PCB could have got damaged, but I removed the pink wire and before replacing different wire, I check the voltage and its the same, that shows the PCB is in good condition and no additional wire is required.

The little brown circle in the PCB, I dont have any idea, I noticed it when I opened the lipo.

Still no clue what could be the problem...

Purush you have to post the -A to +B voltage as per india hobby's picture.

Further please do post reverse polarity voltages of  each terminal combination including your dean. Which will identify and isolate the cell with the problem

You may also be surprised to know your multimeter might be having the glitch. Try with different multimeter too.

@purush
With 3 cells, no matter what the voltage of each, even if reversed, if the total shows zero, it has to mean a connection break. (Break could even be inside a cell)
I dont think you have posted any pic showing voltage of each cell so far.
Can you do that please?

Here is the video......

You have still not shown reverse polarity voltages of the two cells between which the problem exists after interchanging probes

Here is the pics with reverse polarity....

Cell A and B put together in reverse polarity where the problem exists is it showing 0 or -7.9V?

Obviously its a case of poor connection at the PCB, how it is making one way is bewildering. Just remove the PCB and add a new PCB. If you want can send you one free.

Sundaram: I have sent you a PM...

I removed all lipo cells separately and the PCB, while removing the cell A -ve lead was broken which I noticed, check the attached photo.

I checked the flow of the PCB, it look good I tested with multimeter. check the attached photo.

Question: I have a rhino 2630mah Tx battery with 1 cell dead. can I remove the working cell and connect with zippy 2200mah and make a 3cell battery

The Tx Cell is not going to work since it's a low C Rating cell.
The overall C Rating of such Battery will deteriorate a lot and it can not be used for flying, etc

However you can use it for any other less Amp starving DIY projects.

BTW, we do have Turnigy 2200mAh 20C DIY cells but it's costly:
http://www.ebay.in/itm/Turnigy-2200mAh-1S-20C-Lipoly-Single-Cell-/191040629775?pt=IN_Toys_Games_School_Stuff&hash=item2c7ae8ac0f

Doesn't sound like an appropriate investment since the damaged LiPo is already an year old.