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.