Align governor sensor adaptor mount for TSA 700E helicopter
Description
This is a mount for the Align magnetic governor sensor for the TSA Infusion 700e helicopter. It has provision for a governor sensor using magnets on the auto rotation gear however the existing mounting holes on the frame are for a TSA sensor that no longer seems to be available, so I made this mount for an Align sensor. It mounts using the unused holes for the rudder lead retaining clip on the side opposite where the rudder servo is usually mounted. With the Align sensor you must swap the red and black wires in the plug because red is ground and black is positive. Additionally you must NOT use the 4x1.5mm magnets that come with the sensor, they are not strong enough to trigger it where it is mounted to the frame (there is about 2mm of separation between the sensor and the magnet.) Instead obtain some 4x2mm neodymium magnets from ebay or wherever (the sockets for the magnets are 2mm deep). "instant" CA glue sets too fast to install the magnets, they are a close fit and may glue in place before fully seated. I used JB weld for this, I also found it necessary to use a press due to trapped air under the magnets. A small hobby vice would also work for this. Only apply enough pressure to seat the magnets (they will make an audible "pop" as the air is pushed out around the magnet). DO NOT test fit the magnets before gluing they are almost impossible to get out. I recommend installing both magnets facing the direction that will trigger the sensor rather than opposite directions as is typical with clutch bell magnets. This is because unlike with a clutch bell you would only be getting one pulse per revolution of the head. By facing both magnets to trigger the sensor you double the resolution of the RPM signal.The number of pulses per revolution should be set to the actual number of magnets that trigger the sensor (2 if you've installed both to trigger the sensor) rather than divided by two as you would with a brushless motor sensor and the gear ratio should be set to 1:1. You will need two m2x6mm machine screws to attach the sensor to the mount and an m3x8mm screw to attach the mount to the frame. I found self tapping m2.5 screws were slightly too large for the holes in the sensor so I used machine screws. For the M3 screw I used a self tapping screw though a machine screw could also be used (take care to not over tighten machine screws in plastic). the sensor mount needs to seat fully against the side of the frame. If the post is too big you may need to resize it a little. I found that if it is only slightly oversize near the bottom you can press the mount into an M3 screw hole in a piece of CF with a vice or arbor press to correct it.
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