Assembly Guide

Assembly Guide

This guide assumes you have all parts from the Parts List & Overview page and have already flashed MeshCore Repeater firmware onto the node.

Step 1: Test Before Sealing

Before putting anything in the enclosure, bench-test the complete power chain:

1. Connect the charge controller to a bench power supply set to 6V (simulating the solar panel).
2. Connect a battery to the charge controller output.
3. Power the node from the battery via the appropriate connector (JST or 18650 contacts).
4. Verify the node boots, joins the mesh, and can be configured. Fix any issues now before sealing.

Step 2: Prepare the Enclosure

1. Drill or punch holes for cable glands. Typical layout: one PG9 gland for the antenna pigtail, one PG7 gland for the solar wires. Place glands on the bottom or sides of the enclosure - never on top where water can pool.
2. Thread cable glands into holes. Tighten finger-tight plus a quarter turn with a wrench. Do not overtighten or you will crack the enclosure.
3. Route the antenna coax pigtail through a PG9 gland. Leave enough slack inside to connect to the node. Tighten the gland around the cable until it grips firmly.
4. Route solar panel wires through a PG7 gland.

Step 3: Wire the Power System

Wiring order: Solar panel → Charge controller input → Charge controller battery output → Battery → Charge controller load output → Node.

1. Connect the solar panel positive and negative wires to the IN+ and IN - terminals of the CN3791 or TP4056 charge controller.
2. Connect the battery to the BAT+ and BAT - terminals.
3. The node is powered from the charge controller load output (OUT+ / OUT - ). If using the Heltec V4 with its built-in solar input, connect the solar panel directly to the solar input and skip the external charge controller - the V4 handles charging internally.
4. Use appropriately rated wire. 24 AWG is adequate for the current levels involved (under 500mA).
5. Insulate all connections with heat shrink. Exposed connections inside an enclosure can still short against the metal walls of a die-cast box.

Step 4: Mount Components Inside the Enclosure

1. Use double-sided foam tape or small cable ties through holes in the enclosure wall to secure the charge controller and node. Hot glue is acceptable but makes future servicing harder.
2. Place the desiccant pack in a corner of the enclosure where it will not interfere with components or lid closure.
3. Ensure the node's USB port is accessible from the enclosure lid or a gland - you may need to access it for firmware updates.

Step 5: Seal and Close

1. Apply a thin bead of silicone sealant around the inside edge of each cable gland nut where the cable exits. This is belt-and-suspenders weatherproofing on top of the gland's O-ring.
2. Verify the enclosure lid gasket is seated properly. Close and latch the lid.
3. Check that no wires are pinched by the lid.

Step 6: Mount the Enclosure

1. Mount at the highest practical point with clear line of sight to the mesh coverage area. For most community nodes: rooftop, eave, fence post, or tree mount.
2. Orient the antenna vertically. A vertical antenna radiates horizontally in all directions; tilting it reduces coverage.
3. Mount the solar panel facing south (northern hemisphere) at an angle of 55 - 60° from horizontal for year-round performance in northern US/Canada. A shallower angle (30 - 45°) favours summer production; steeper favours winter.
4. Route solar panel wires so water cannot follow them into the enclosure. A drip loop - a downward U in the wire before it enters the gland - prevents capillary wicking.

Step 7: Verify Operation

1. In the MeshCore app, confirm the repeater appears in the node list and is relaying messages.
2. Check battery voltage via the app or CLI. A full 18650 reads ~4.2V; the CN3791/TP4056 will stop charging at 4.2V.
3. During daylight, verify solar charging is active (charge controller LED or app telemetry).