Everyone,
Because of HobbyCity's replacement policy on bad lipo batteries, please:
1.) If a package has any damage to it, AT ALL... REFUSE DELIVERY and RETURN TO SENDER! - Bahh. I've never had a something arive damaged, and all the boxes look like the mailmen used them for a soccer match. Open the box, take a look. They pack my large LiPo orders in multiple layers of foam, wrapped in bubble wrap, and double boxed. The box can look like hell and the LiPos are all fine. This would not apply if you were just ordering gold 4mm connectors, epoxy, etc. but when your ordering lipo, electronics (of any kind) or motors from HobbyCity (or any other overseas operation) your best option is to refuse delivery (and pay with credit card / paypal)
2.) Before charginng anything, before even connecting to a charger... use a digital volt meter and test the discharge plugs of your lipo packs for proper voltage. If you have a pack that tests 0v at the plugs then you have bad pack, move on to the next pack.
3.) If all your packs test within specs at discharge plugs then it's time to check at cell level. Using the same DVM, test the voltage at each tap in your balance plugs. With lipo, each successive cell you read should add between 3v and 4.2v to the total sum voltage. If you find a cell below 3v, you have a bad pack (actually only a single bad cell but if you want HK to replace its all the same) and need to finish testing all your packs then move on to step 4.
4.) If your here... we all feel for you (I am not just saying that).
Because of the HobbyKing return / replacement policy on LIPO packs you need to think about how to proceed very carefully!!!
The safest thing to do is simply contact HK, inform them of the number of bad packs you have received and inform them that you have done nothing with them yet but test the voltage using a DVM. They will instruct you on how to return ship the item(s) to them for testing / replacement.
** (someone should start a thread to report receipt of bad packs, having a public log of bad cells and hobbyking's replacement would be a benefit to all of us))
If you are bold, just dont care or are not about to ship a 30.00 pack back to China on a slow boat (since it would be illegal to ship lipo via Air and ground is not possible - would require hazmat certification anyway) or just impatient and figure you can fix anything then...
Order some aluminum solder and rosin and crack out the high powered soldering iron!!
Most of the time, packs which test as 0v are actually fine and have just been shipped (assuming a non-damaged box was received) with broken solder joints somewhere in the pack. Unwrapping these types of defective packs and resoldering may not even require aluminum solder. On this type of break, normal rosin core solder works fine. Just repair the defective joints and let the packs cool.
On the 0v packs it is also possible that one of the cell tabs (weld tabs, but soldered after crimping?) has broken. This will require aluminum solder and flux to repair (or a spot welder if enough tab is still exposed).
I will publish my personal experience repairing these packs (and blowing two up - ok, puffing them out not blowing them up) along with pictures either to help you repair your packs or (if your smart) to scare you into just sending them back to HK!
Hope this helps, would have helped me!
-Mike