Friday, December 28, 2018

How to install optical sensor from SuperPID and retain the power button

On converting my Dewalt WP611 to be controlled by superPID, I followed Adam David's instructions at However I didn't like the way the sensor wire was poking out , and had to be wrapped around to secure it to the AC wires. 
Hole drilling Location
Directly behind the power switch. Drill a 9.5 mm hole approximately 21 mm down from the top most part of the router. Then cut off a length of about 5mm off the 9.5 mm tube that came with your superPID. You only need enough tube to go through the plastic wall you just drilled a hole into. The picture above shows what it should look like with the tube inserted.

Heres a picture showing the tube pointing directly at the ring that you paint half white above the commutator.

Next cut off most of the blue shrink wrap covering the sensor. You can leave just enough so to where it covers just the sensor itself. This makes it easy to make a 90 degree bend where the exposed wires will now be.

So make a 90 degree bend in the wire directly behind the back of the sensor, stick the sensor in the tube. and put a dab of super glue to keep it from moving. I put lots of hot glue to keep the wire from wobbling around. The picture above shows the switch seated nicely were it was intended to.
Now you can just leave the button there disconnected, or if you like, you can solder on 2 small wires and run that to your superPID and hook up one end to the GND tab, and the other to "RUN" and you will have a functional switch.

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