Holoseat

h1. Assembly Instructions

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h2. Introduction

Below are the assembly instructions for the v0.3 *Holoseat* controller.  This version is built using an "AdaFruit Feather 32u4 Basic Proto":https://www.adafruit.com/product/2771.  It also includes a remotely mountable sensor board. You will need to use your soldering skills on this build. 

h2. Sensor Board Assembly

h3. Tools

* Diagonal Cutters

* Wire Strippers

* Needle Nose Pliers

* Soldering Iron

* Utility Knife

* Punch Down Tool

* Heat Gun

h3. Materials

* (1) HS001 - Double-Side Prototype PCB

* (1) HS002 - Category 5e Jack

* (2) HS003 - 750 OHM 1/2W 1% Axial Resistor

* (2) HS004 - OH090U Hall Effect Sensor

* (2) HS005 - Diffused Blue 3mm LED

* Hook up wire

* CAT5 internal wire

* Solder

h3. Safety Issues

* Care must be taken when using sharp hand tools to avoid cuts

* Care must be taken when using the soldering iron, the tip is very hot

* Always wear safety glasses while working with soldering irons

* Avoid breathing in the soldering fumes, use a vent or hood if needed to provide adequate ventilation

h3. Product

(1) Holoseat Sensor Board

h3. Procedure

# Prepare Sensor/LED sub-assemblies

Repeat this procedure twice to assemble (2) *Sensor/LED sub-assemblies*

## Take (1) *HS004 - OH090U Hall Effect Sensor* and (1) *HS005 - Diffused Blue 3mm LED* from your supplies

!0h090u1-400x302.png!

## Solder the LED's anode (long leg) to pin 3 of the sensor (the data pin) and solder the LED's cathode (short leg) to pin 2 of the sensor (the ground pin) using the following steps

!led-plus-sensor.png!

### Align the LED to it sits on top of the sensor with the long leg next to pin 3 and the short leg next to pin 2

### Wrap the LED's long leg around pin 3 to create a secure physical connection

### Wrap the LED's short leg around pin 2 to create a secure physical connection

### Apply solder to the two joints formed in the steps above to secure the connections between the LED and the sensor

## Cut approximately 40 cm lengths of black, red, and green hook up wire

## Strip both ends of the (3) lengths of hookup wire

## Solder the hookup wire to the ends of the sensor pins (red to pin 1, black to pin 2, and green to pin 3) using the following steps

!led-plus-sensor-and-leads.png!

### Wrap one end of the red hook up wire around pin 1 to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connections between the red hookup wire and pin 1

### Wrap one end of the black hook up wire around pin 2 to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connections between the black hookup wire and pin 2

### Wrap one end of the green hook up wire around pin 3 to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connections between the green hookup wire and pin 3

## Apply sufficient heat shrink to the red and green joints to cover them completely

## Apply sufficient heat shrink to assembly to completely cover the solder joints of all three leads, leaving some overlapping the LED to give it strain releaf

## Apply larger heat shrink to the three leads made from the hookup wire to complete the *Sensor/LED sub-assembly*

# Prepare the *HS002 - Category 5e Jack*

## Cut approximately 15 cm each of the following colors of Cat5 internal wire: Blue/White, Green, Brown, Brown/White

## Strip one end of each length of Cat5 internal wire to allow for soldering

## Cut approximately 20 cm each of the following colors of hookup wire: (2) green, (1) red, (1) black

## Strip one end of each length of hookup wire

## Solder the hookup wire to the Cat5 internal wire using the following steps

### Wrap the stripped end of the Brown Cat5 internal wire around the stripped end of the red hookup wire to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connections between the Brown Cat5 internal wire and the red hookup wire

### Wrap the stripped end of the Brown/White Cat5 internal wire around the stripped end of the black hookup wire to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connections between the Brown/White Cat5 internal wire and the black hookup wire

### Wrap the stripped end of the Green Cat5 internal wire around the stripped end of a green hookup wire to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connections between the Green Cat5 internal wire and the green hookup wire

### Wrap the stripped end of the Blue/White Cat5 internal wire around the stripped end of the other green hookup wire to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connections between the Blue/White Cat5 internal wire and the other green hookup wire

## Use a punch down tool to connect the Cat5 internal wires to their corresponding positions on the *HS002 - Category 5e Jack* for pinout option A

!cat5e-jack-with-leads.png!

# Finish Assembling the Sensor Board

Reference the image below for the following steps

!sensor-board.png!

## Connect the black leads

### Test fit the black leads from both *Sensor/LED sub-assemblies* and the *HS002 - Category 5e Jack*, cutting the wires to length as necessary (remember to leave room for the stripped wire)

### Strip the three black wires from the step above

### Position the three black wires above in the correct holes of the *HS001 - Double-Side Prototype PCB* and bend them over to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connection among the three black leads

## Connect the red leads

### Take the (2) *HS003 - 750 OHM 1/2W 1% Axial Resistors* and position them according to the diagram (making sure to bend their leads to secure them in place

### Test fit the red leads from both *Sensor/LED sub-assemblies* and the *HS002 - Category 5e Jack*, cutting the wires to length as necessary (remember to leave room for the stripped wire)

### Strip the three red wires from the step above

### Position the three red wires above in the correct holes of the *HS001 - Double-Side Prototype PCB* and bend them over to create a secure physical connection

### Cut a short length of red hookup wire to bridge the red leads according to the diagram

### Strip both ends of this additional length of red wire and place it according to the diagram, bending its ends over to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connection among the three red leads

## Connect each of the green leads

Repeat these steps for each of the sensors' green leads according to the diagram

### Test fit the green leads from one of the *Sensor/LED sub-assemblies* and the *HS002 - Category 5e Jack*, cutting the wires to length as necessary (remember to leave room for the stripped wire)

### Strip the two green wires from the step above

### Position the two green wires above in the correct holes of the *HS001 - Double-Side Prototype PCB* and bend them over to create a secure physical connection

### Apply solder to the joint formed in the step above to secure the connection among the two green leads

The Sensor Board is now complete.