RADR Wireless Remote Assembly Guide

Purpose

This work instruction documents the current RADR wireless remote assembly process from prepared PCB and printed parts through final device test.

Use these instructions with the active PCB, printed parts, and BOM release for the build.

Read Safety first before you start. Warnings appear at the steps where each hazard occurs.

Required Parts and Consumables

1. Gather the required parts before starting assembly.

2. Confirm the assembly set includes:

   • RADR-PCB-assembly
   • screen
   • battery
   • front-housing
   • back-housing
   • battery-flap
   • 2x side-button
   • middle-button
   • power-slider-button
   • knob
   • weather-stripping
   • 5x BC-0408LTFB tri-lobe screws
   • hot-glue

3. If all required parts are present, continue onward.

Tools

• Rasp
• T8 bit for tri-lobe screws
• Electric screwdriver or hand driver
• Isopropyl alcohol
• Microfiber cloth
• Razor blade
• Hot glue gun
• Small screwdriver

Prepare the PCBA

1. Deburr the edges of the RADR-PCB-assembly with a rasp until the board edge is smooth.

   

   Board dust and static

   Deburr before the battery is connected. Circuit-board dust contains glass fibre: avoid breathing it, wipe it up with a damp cloth, and wash your hands afterwards. The PCBA is static-sensitive, so touch grounded metal before you handle it and hold it by its edges.

2. Wipe the marked weather-strip area on the PCBA with isopropyl-alcohol and a microfiber-cloth.

   

   Flammable solvent

   isopropyl-alcohol is flammable. Use a small amount on the cloth, let it evaporate fully, and keep it away from the hot glue gun.

3. Attach a 2.5 cm piece of weather-stripping to the center of the cleaned area.

   

4. Fit the printed power-slider-button over the PCBA on/off switch.

   

5. Connect the 800 mAh LiPo battery to the PCBA.

   Keep the PCBA switched off after connecting the battery. The PCBA produces a green light when powered on and does not produce that light when switched off.

   

   LiPo battery

   Do not use a battery that is swollen, dented, punctured, or has damaged wires, and do not bend, pierce, or crush it. The battery stays connected from here on: keep the PCBA switched off, keep the board and battery away from the razor blade and hot glue gun, and do not let metal tools bridge the battery leads or board components.

6. Confirm the PCBA is deburred, padded, fitted with the power switch cover, connected to the battery, and switched off before continuing.

Prepare the Front Housing

1. Use a razor-blade to cut a small triangle off both bumpers on the front-housing.

   These cuts stop the bumpers from catching on the PCBA during installation.

   Razor blade

   Hold the housing on a stable surface and cut away from your fingers with light, controlled strokes. Cover or retract the blade as soon as you finish.

   

   

2. Remove the protective film from the screen.

   

3. Install the screen into the front-housing.

   Insert the screen into the bottom lip of the interior front housing first. Gently flex the housing outward while pressing the screen into the upper screen lip. Confirm the screen is flush against the housing.

   

   

4. Run a thin, low-profile bead of hot-glue along the screen edges.

   Keep the glue bead in contact with both the screen edge and the plastic housing. The housing plastic should melt slightly into the glue.

   Hot glue

   The glue gun nozzle and fresh glue can burn skin. Rest the gun on its stand between uses and let the bead cool before you touch it.

   

5. Drop the printed buttons into the front-housing.

   

6. Confirm the bumpers are trimmed, the screen is glued in place, and the buttons move freely before continuing.

Install the PCBA

1. Feed the screen ribbon through the cutout in the PCBA, then press the PCBA flush into the front-housing.

   

2. Open the screen ribbon connector on the PCBA with a small screwdriver.

   

3. Insert the screen ribbon into the connector and close the connector.

   

4. Tuck the screen ribbon into the housing.

   

5. Confirm the PCBA sits flush, the ribbon connector is closed, and the ribbon is tucked away from pinch points before continuing.

Close the Housing

1. Place the back-housing over the front-housing by inserting the on/off switch into its cutout.

   

2. Pull the battery through the open space in the back housing that will become the battery compartment.

   

   

3. Using a medium torque setting, fasten the front and back housings together with tri-lobe screws.

   The screw is deep enough when the screwdriver ratchets.

   Check for pinched wires

   Before you drive the screws, check that the battery wires and screen ribbon are clear of the housing seam and screw holes. The battery is connected, so a pinched or cut battery wire can short it.

   

4. Fasten the front-housing screw holes with the same tri-lobe screws.

   

5. Place the battery inside the battery compartment.

   

6. Place the battery-flap over the battery and screw it shut with tri-lobe screws.

   

   Battery placement

   Seat the battery flat and route its wires so the flap and screws do not press into the battery or pinch the wires. A crushed or punctured LiPo can catch fire.

7. Confirm the housing is fully closed, all screws are seated, and the battery cover is secured before continuing.

Install Knob and Test

1. Use a small screwdriver to clean any excess filament from the interior knob circle.

   

2. Align the encoder shape with the interior knob circle shape and press the knob onto the encoder until it softly clicks.

   

3. Turn on the device and test as per protocol.

   

Final Assembly

1. Confirm the PCBA edges are smooth and do not catch on the housing.
2. Confirm the weather stripping is centered and adhered to the PCBA.
3. Confirm the power switch cover moves the on/off switch cleanly.
4. Confirm the front-housing bumpers are trimmed.
5. Confirm the screen is flush and glued with a low-profile bead.
6. Confirm the buttons are installed and move freely.
7. Confirm the PCBA sits flush in the front housing.
8. Confirm the screen ribbon is fully inserted and the connector is closed.
9. Confirm the screen ribbon and battery wires are routed away from pinch points.
10. Confirm the housings and battery cover are fastened with tri-lobe screws.
11. Confirm the knob is seated on the encoder.
12. Confirm the device powers on and passes the current functional test protocol.

QC Checklist

• PCBA edges were deburred until smooth.
• Weather-strip area was cleaned with isopropyl alcohol.
• 2.5 cm weather-strip piece was installed on the PCBA.
• Printed power switch cover was installed.
• Battery was connected with the PCBA switched off.
• Front-housing bumpers were trimmed.
• Screen film was removed.
• Screen was installed flush in the front housing.
• Screen was secured with a thin, low-profile hot glue bead.
• Buttons were dropped into the front housing.
• Screen ribbon was fed through the PCBA cutout.
• PCBA was pressed flush into the housing.
• Screen ribbon connector was opened, seated, and closed.
• Screen ribbon was tucked into the housing.
• Back housing was aligned around the on/off switch.
• Battery was pulled through the battery compartment opening.
• Front and back housings were fastened with tri-lobe screws.
• Battery was placed inside the battery compartment.
• Battery cover was installed and screwed shut.
• Knob bore was cleaned of excess filament.
• Knob was pressed onto the encoder until it clicked.
• Device was powered on and tested as per protocol.