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  1. #1
    Sooo...how much for the 780? stimpsonjcat's Avatar
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    Dead gas level sender and don't want to rip the tank out to replace? My alternative

    So I have TWO skis where the sending unit in the gas tank has died.

    Mind you, I have plenty of spare senders.

    But I do not relish the idea of getting the tanks out just so I can replace the sender, and on the SLTs you can't swap the sender without yanking the tank.

    What's a tinkering owner to do?

    At work we sell lots of industrial control components. Among them capacitive proximity sensors. These devices can sense liquid level through a plastic tank. So I got a few and tested them and decided on a small plastic unit.

    https://www.automationdirect.com/adc...tion/cr1-00-2a

    Next I need a way to use the signal from the sensor to send two different reisistances to the MFD, so I got a Hermetically sealed 12V relay. I really only needed a single pole relay, but the 4-pole was the cheapest sealed relay.

    https://www.automationdirect.com/adc...)/h782-4c3-12d

    Now I need to find an approximately 50 Ohm resistor and an approximately 200 Ohm resistor. Since the sensor detects fluid, it sends an ON signal when the gas is above it's level, so we want the normally closed output from the relay to connect the 220 Ohm resistor to tell the MFD the tank is empty. Any time the gas is above the sensor, it shows a full tank.



    Shrink wrap and then hot-glue all the exposed connections after soldering.

    I just added a new 12V feed from downstream of the battery disconnect switch, you could steal power from the MFD feed but the relay might pop the 0.5A fuse, inrush was easily an amp when I tested it.

    Lastly I JB-welded the sensor to the tank where I figured it had a gallon or so left in it.

    I'll test this for a while and then do the same to the other ski if I don't have any issues.

    I'll probably try to do all the wiring inside the Ebox for that one.


  2. #2
    Click avatar for tech links/info K447's Avatar
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    Quote Originally Posted by stimpsonjcat View Post
    ... capacitive proximity sensors. These devices can sense liquid level through a plastic tank. ... decided on a small plastic unit.

    https://www.automationdirect.com/adc...tion/cr1-00-2a

    Next I need a way to use the signal from the sensor

    ... the relay might pop the 0.5A fuse, inrush was easily an amp when I tested it.

    ...
    What output does the sensor actually provide?
    Switched voltage, contact closure to ground or power rail?

    There may be a simpler way to wire it in, possibly without any relay (especially a huge relay that needs a full amp of coil current)

  3. #3
    Sooo...how much for the 780? stimpsonjcat's Avatar
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    The relay pulls about 60mA of current steady state. It's only the inrush that is a waste.

    The sensor can be wired PNP or NPN.

  4. #4
    Click avatar for tech links/info K447's Avatar
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    Quote Originally Posted by stimpsonjcat View Post
    ...

    The sensor can be wired PNP or NPN.
    Where can I find some info on how the sensor is supposed to be configured/wired?

  5. #5
    Sooo...how much for the 780? stimpsonjcat's Avatar
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    Quote Originally Posted by K447 View Post
    Where can I find some info on how the sensor is supposed to be configured/wired?
    Wiring diagrams are on the spec page:
    https://cdn.automationdirect.com/sta...prectangle.pdf

    The 'load', in this case the relay coil, can be between +12V and the signal wire or it can be between the signal wire and the common. It's shown as a small rectangle on the schematic.

    On the second ski, I will only run a new ground wire up front for the common and use the existing pink wire to source +12V from the Ebox and the existing black wire as the signal lead from the sensor. Then I can locate the relay/resistors inside the ebox, much cleaner than the mess I have in this ski right now.

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