CEB Press/Manufacturing Instructions/Sensor Unit

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Tools

• Soldering Iron

• Soldering Stand

• Solder

• Wet sponge or wet paper towel

• Heat Gun

• 22AWG-compatible Wire Stripper

Materials

• Hall Effect Sensor

• PVC Pipe with 1/2" Thickness, 5/8" Outer Diameter, 3.5" Length

• 1m of Underground telephone cable (4 wire)

• 2-part Potting Compound

• Disposable Mixing Cups

• Shrink Wrap

• Electrical Tape

Steps

• Cut the sleeve 5cm at one end of the underground telephone wire and 20cm at the other end.

• Cut the orange-white wire at both ends of the telephone wire.

• Strip the blue, blue-white, and orange wires by 2cm at both ends of the telephone wire.

• Insert shrinkwrap into the 5cm blue, blue-white, and orange wires.

• Solder the hall-effect sensor prongs to the 5cm blue, blue-white, and orange wires. The orientation of the soldering connections is such that, when you can see the sensor text and its prongs pointing downward, from left to right the colour of the wires to be soldered are: blue (5V+), orange (GND), blue-white (Signal).

• Cover the exposed prong-solder-wire connections with the shrinkwrap and apply heat to the now-covered connections. The shrinkwrap should shrink, forming a tight isolating seal for each of the prong-to-wire connections.

• Insert the wired hall-effect sensor into the PVC tube leaving 3cm of space at the non-insertion end of the tube. Tape the insertion end of the tube as to produce a seal between the tube and the telephone cable.

• Mix the 2-part potting compound together then pour the mixture into the tube from the non-insertion end.

• Tape the tube to a surface such that the non-insertion end is pointing upwards. Wait for the potting compound to cure.

Sensor Construction

A four wire telephone cable is used to connect to the hall effects sensor. Only three of the exposed wires are used; orange, blue/white, and blue. These wires are soldered to the three prongs of the hall effects sensor in order from left to right when the hall effect sensor orientation includes visible text and the prongs pointing downwards: blue, orange, blue-white. Small shrink wrap should be applied to the wires prior to soldering, and then slid into place to cover the leads to prevent short circuiting.

Slide the sensor into a small piece of pvc tube 3.5 inches long. The pvc will be filled with a potting compound to encapsulate the sensor. Tightly wrap electrical tape around the wire exiting the pvc tube, creating a seal to hold in the potting compound. Clamp the pvc vertically with the wire protruding from the bottom and fill the inside of the pvc with the potting compound.

1. cut telephone cable 70" long
2. strip shielding plastic 1.5" and 8" at either end
3. solder hall effects sensor

Step 1. Start with potting compound, 2 parts.

Step 2. Take one Hall Effect sensor.

Fabricate the Sensors

1. Cut three 3’ sections of Underground Telephone Cable.
2. Strip about 3” of the outer covering off each end of the three sections
3. Strip about ¼” off the orange, blue and blue-white wires at each end of each section.
4. Tin the ends of the all of the wires on all of the sections
5. Splice, with Solder, about 6” of the inner strands of some Cat-5 Cable (E17) to the wires at one end of each of the sections of Underground Telephone Cable
6. Thread shrink-wrap (E28) to the three wires on the other end of each of the three sections of Underground Telephone Cable.
7. Solder a Hall Effect Sensor (E20) to one endof the ther sections (pins numbered from left to right)
   1. Pin 1: Blue (5V)
   2. Pin 2:  Orange (GND)
   3. Pin 3: Blue-White (Signal)
8. Shrink the Shrink-Wrap around each of the solder joints
9. Cut three 3.5” sections of PVC Pipe (E15).
10. Place a section of Pipe around each of the three hall effect sensors and encase them in Potting Compound (E29) with the Pipe Caps (E16) in place.