It happened to me a few times where the Lipo battery balance plug got sucked, and damaged by fast spinning propellers during flight. Not only it’s not convenient to use this broken balance plug, it’s very dangerous as it can be shorted easily and cause fire.
I put some Lipo balance plug saver on, they might help take a few beatings, but it does not stop it from damaging your plug.
If you have a damaged balance plug, first check the voltage of all cell and make sure they are all healthy. If they are you don’t have to buy a new LiPo, and you can simply just fix the balance plug.
The best solution is to replace the balance plug, but if the plug isn’t damaged badly, you can attempt to fix it with Epoxy Glue. For some really badly damaged ones where 4 out of 5 pins were exposed, I still managed to fix them this way. Of course this is not recommended, I only do it to keep me going for a few more charges before the delivery of my new plugs.
Repair LiPo Balance Plug using Epoxy Glue
The Epoxy I used is the 15-minute one. Mixi them well, and leave it for 5 to 10 mins to get a bit more sticky. It’s harder to work with when it’s runny.
I have lots of these spare jumper wire pins laying around which I saved from previous projects. Before applying the glue, I plug a jumper pin in where the glue is going to go. This stops the glue from going into the pin hole and affects conductivity later. Be aware to make sure there is no way the metal part of your your jumper pins can touch each other, which could cause short circuit and even fire!
Once applied the Epoxy, leave it to solidify. Just before it’s completely dried, you should still be able to modify the shape of the glue with your finger tip.
And it’s working for another day! Of course I would not recommend this method as it’s quite risky, so do it at your own risk!
Replace Balance Plug
Whenever you can, always replace the broken balance plug.
It’s very straight forward, the key is to replace ONLY 1 WIRE at a time. This prevents the wires from touching each other and causing shorts.
And she’s as good as new :D Always buy spare balance plugs with new LiPo batteries !