MSB Wilson
New
New Zealand
Offline
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One of my battery packs developed the "Cell broken" fault message a year or more ago and wouldn't allow the Mavic to fly. I recently did some searches on whether this can be fixed.
Long story short, I fixed it. I'm an electronics engineer and RC model flyer with a lot of experience with LiPo batteries.
What I learned was this:
1. If one of the three cells in the pack differs by more than about 0.1V, the "Cell broken" condition is reported and the pack can't be used
2. Discharging and recharging probably won't fix it. In fact in some cases it my end up over charging the other cells
3. The built in cell balancing doesn't seem to work very well, if at all. I did multiple tests on a slightly out of balance pack with no observable improvement.
4. As long as the pack is just out of balance and not otherwise damaged or severely discharged, the out of balance cell (or cells) can be individually charged (or discharged) to get them all matching
5. The tricky part is, you have to cut into the front of the pack to access the pack to access the cell balance connector. It is then possible (with a lot of care) to connect a cell charger, suitable power supply, or a discharge resistor accross individual cells. I used a typical RC model LiPo charger as a power supply to to the charging.
CAVEAT: You have to be *very* careful probing or connecting directly onto the balance connector to avoid accidental short circuits between them. If possible, it would be better to get on of the matching 4 way miniature connectors.
In my case, I managed the connection setup by:
1. Securing the pack in a clamp
2. Insulating at least one of the pin probes than I used to make the 0V connection
3. Securing both probes in a '3rd hand' clamp (with one of the probes isolated from it)
3. The built in cell balancing doesn't seem to work very well, if at all. I did multiple tests on a slightly out of balance pack with no observable improvement.
4. As long as the pack is just out of balance and not otherwise damaged or severely discharged, the out of balance cell (or cells) can be individually charged (or discharged) to get them all matching
5. The tricky part is, you have to cut into the front of the pack to access the pack to access the cell balance connector. It is then possible (with a lot of care) to connect a cell charger, suitable power supply, or a discharge resistor accross individual cells. I used a typical RC model LiPo charger as a power supply to to the charging. I used the fine tip of a hot soldering iron to carefully melt through the 0.5mm or so plastic. This is more controllable I think than using a knife or Dremel tool, particulalry on the right habd side.
CAVEAT: You have to be *very* careful probing or connecting directly onto the balance connector to avoid accidental short circuits between them. If possible, it would be better to get on of the matching 4 way miniature connectors.
In my case, I managed the connection setup by:
1. securing the pack in a clamp
2. insulating at least one of the pin probes than I used to make the 0V connection
3. securing both probes in a '3rd hand' clamp (with one of the probes isolated from it)
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Hole cut to access balance connector port
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Balance connector terminals
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Cell charinging connection to middle cell
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