Figured you guys would be interested in this...
So I have a v28 hammer drill, and had not used it in a while. Seemed like the battery would not take a charge correctly using the milwaukee charger, and the little "fuel gauge" was acting funny too. Pulled the pack apart and found that it has some sort of lvc/cell monitor as well as the fuel gauge, and it must have some sort of power interrupt as well. I measure the cell voltage before this apparatus and found the pack to be close to full,however measuring after the lvc it was about 5 volts lower without load. So i decided to can the internal lvc, and wire the pack straight to the output terminals. Now at the same time i decided that it would now be important to be able to balance charge the pack, using my hyperion 1210i and the 2 networked lba10 balancers. This posed an issue, as the lba balancers are designed to only handle 2 separate packs, up to 6s each, not 1 7 cell pack (the v28 has 7 emoli cells, std lipo voltage and 3000mah).
So I tried a few things, including wiring a 3 and 4s balance harness to the pack, and making a series adapter for the 2 lba outputs. No dice. So i had to physically split the 7 cell pack into a 3s and a 4s, wire them independently and figure a method to run them in series for drill use and split them back in the 3 and 4s to charge.
I ended up using some powerpole (first time using them and i really like them) connectors, cutting a square hole in the front of the case and gluing them in place. I made a small jumper to run the pos of the 4s pack to the neg of the 3s pack, and left the neg of the 4s pack and the pos of the 3s pack hooked to the main outputs that plug into the drill. I also ran wires off those main outputs to another set of powerpoles, so that I could plug directly into them to charge the cells. In the pic the small jumper (just 2 powerpole plus with a short wire to connect them) is plugged into the lower black and red powerpole plugs to bridge the wires necessary to run all 7 cells in series.
I also had to make some plugs to allow the balancer wires to exit, as I did not want pigtails hanging out of the pack. Used some 6 pin mpx? plugs i bought a while back from hobby city. One has 4 of the pins used for the 3s balance tap, and the other has 5 pins used for the 4s.
So after a bunch of soldering I got it all back together and gave it a try, works like a charm!
Pictures will be alot clearer than the explanation... And yes, there is a bunch of wire inside that poor casing. I could not be bothered to make all of the wires perfect length, so they are all the same length, all 9 of the balancer wires, and 6 14 gauge wires are in there as well.