Page 1 Price: $30.00 Page DZKit ASSEMBLY MANUAL SIENNA SIENNA SIENNA SIENNA HF RECEIVER/Transceiver HF RECEIVER/Transceiver HF RECEIVER/Transceiver HF RECEIVER/Transceiver...
Page 2 You can obtain parts directly from DZ Company by writing us, emailing us or telephoning us. And we’ll pay shipping charges to get those parts to you—anywhere in the world.
Page 3: Table Of Contents
Chassis, DC power, PC, Tuner ... 14 Initial tests ........34 Front Panel integration ....36 Front Panel tests......48 Receiver Integration ....50 Sienna HF Receiver/Transceiver Receiver alignment/test ....59 Transmitter integration ....68 Transmitter resistance/voltage ..70 Transmitter alignment/tests ..72 100W PA Integration ....
Page 4: Introduction
Page 4 INTRODUCTION The Sienna family of receivers/ the 2nd and third IF’s to provide transceivers represents a revolu- excellent selectivity. We’ve also tion in amateur radio. Now you added innovations in AGC control, can start with a relatively inex-...
Page 5 Sienna is a full- fer via LAN or USB and much more, featured HF radio. The twin mi- at a reasonable price, and with- croprocessors Sienna’s...
Page 6: General Assembly/Safety Notes
Page 6 General Assembly Notes 1. Most screws in this kit are your kit is a USB flash drive Phillips Panhead Machine containing the PCB layout Screws. For simplicity, we files for all boards (without refer to them simply as traces).
Page 7 20%, a silver replacement to you. band 10%, and a gold band 5%. 9. Most electronic kits that are Your Sienna uses mostly one returned for service have poor percent or better resistors, soldering jobs. Please take a...
Page 8 Page 8 fluorescent light is also use- board all have notches and pin ful to “bring out” the colors, 1 also has a square pad. and a magnifying glass is also It is CRITICAL that you mount po- handy. larized parts correctly! Double 12.Capacitors are identified by check your work to be sure that their type —...
Page 9 If you purchased the base Sienna model, which is a receiver, you’re done! Otherwise, you might want to take a break and spend a few hours using the receiver before continuing! Next, you will finish the partially assembled transmitter.
Page 10 Page 10 KIT-BUILDING PROCEDURES The steps involved in building a kit are listed below. Be sure to fol- low them and you will have a lot of fun building, aligning, testing and using your kit. 1. Do a parts inventory. At each major section and in the Appendices, there’s a list of parts used in that section (or that will be used shortly).
Page 11 Sienna. 1. Always have a healthy respect for electricity. While the voltages present inside the Sienna are not lethal, high currents are availa- ble (up to 30 Amps when the 100 Watt amplifier is used). Use a pow- er supply with overcurrent foldback or crowbar protection so that in case of high currents the supply will shut down.
Page 12 Page 12 SOLDERING INSTRUCTIONS Poor soldering accounts for almost 90% of all kit building problems. The photographs below show examples of the most common types of bad solder connections and a good one. If you locate any of these bad sol- der connections in your kit, correct them as described.
Page 13 Page 13 STATIC PRECAUTIONS Many of the components in your static-producing material in your kit can be damaged by exposure to clothing. static electricity. Please read this page to familiarize yourself If your work area floor is car- with the causes of and solutions peted, spray fabric softener on to this problem.
Page 14: Chassis, Dc Power, Pc, Tuner
Page 14 Chassis Parts Item Description Bag Nr SO-239 RF chassis-mt connector Phono connector, chassis mount, red BNC connector, chassis mount Gas discharge tube Anderson Powerpole mounting clamp Foot - front SCREW-ON BLK 1.00 X .75" Foot - rear SCREW-ON BLK .28 X .625" Plastic Board Guide - 6"...
Page 15 Bag Nr Bare wire 18AWG (inches) Hookup wire - white 24# (inches) Heat shrink tubing, 3/32" x 6" Heat shrink tubing, 1/8” x 4” Sienna serial number sticker Fan - 12V 60x60x25 Bottom cover plate Chassis bottom Speaker Finger guard—metal Finger guard—plastic...
Page 16 Page 16 Item Description Large Bracket Front Large Bracket LR Small Bracket Exhaust plate Rear Panel Rear Panel Tray PC cover plate Top cover...
Page 17 Page 17 Boards: Controller (assembled) DCD/Tuner IF Filter RXBPF Receiver (partially assembled) RS-232 Options: Front Panel Transmitter & SWR Meter (partially assembled) TXBPF (partially assembled) 100W amplifier Antenna Tuner PC (assembled)
Page 18 Page 18 Cables DCDIST-ONOFF CA-APP DC power input CONT-PCRS232 CONTDATA-RX-BPF CONTDATA-TUNER CONT-RPKEY RX-RPLINEIN RX-RPLINEOUT...
Page 19 Page 19 CONT-MIC RX-HP AMP MTA—MTA Cables Use: SPKR1, SPKR2 15” 10” DCDIST-CONT 6.5” CONT-RXVOXST 10” DCDIST-RX 2.5” RX-BPFDC 6” RX-IFFILT CONT-TXVM 16” RF CABLES CA33 RXBPFMAIN-TX/AMP CA34 RXANT CA35 RF1 (RXBPF to RX) CA36 RXLO1 CA37 RXLO4 CA38 TXBFO CA39 RXLO2 CA40 RXLO3 CA41 IF1...
Page 20 Page 20 STEP-BY-STEP ASSEMBLY: Chassis, DC Power, PC Refer to Pictorial 1 for the fol- tions in the previous step, lowing steps. using another CA15 cable cut so that the total length of ( ) Place the chassis bottom on a the fan cable from the fan hard surface.
Page 21 Page 21 DCD/Tuner Tray Large bracket left Large bracket right Power compartment Back panel PC compartment Small bracket Front bracket Large fan Attach 6” board guide in center of transmitter compartment Pictorial 1 Photo 1. Fan mounting...
Page 22 Page 22 feet to the two holes on the inch if they are not already back, directly opposite the twisted. Place a 1/2" length front feet, using two 6-32 x of 1/8” heatshrink tubing 1/4" screws. See Photo 2. over each wire. Using the 10” length of cable, solder the red wire to + and the black wire to - on one loudspeaker.
Page 23 Page 23 Photo 3. Fans, speakers and PCPS cable routing Detail 1. Right side speaker mounting...
Page 24 Page 24 If you have purchased the inter- right of the front bracket nal PC (Option 105): and leave the 6-pin IDC con- nector in the front control- ( ) Locate CA6, the PC power ca- ler compartment. ble. Set the end with the 2 quick disconnect connectors, ( ) Pass the other end of CA12 white unterminated wire and...
Page 25 Page 25 This page left intentionally mostly blank, but we promise to put something here one day.
Page 26 Page 26 ( ) Make sure that jumpers If you purchased the PC: J3/J4/J5 on the PC are set so that J3’s jumper is on, and ( ) Attach the 12-pin power cable J4 and J5’s jumpers are off. to the PC power connector. ( ) Align the board(s) so that the row of I/O connectors is toward the back.
Page 27 Page 27 CA32 Triangle = pin 1 Connector tab PC without MIO board attached Attach 1 screw to PC/MIO here Attach 4 brass spacers, nuts and screws to PC/MIO Do not install a nut here PC with MIO board attached (small bracket removed for clarity) Remove J7 when adding MIO board and do not install CA32...
Page 28 Page 28 the CF tray to the back panel cover (with holes and silk- using two #1 x 1/4” self- screening) to the back panel tapping screws. using two #6 x 1/4” self- tapping screws. If you did NOT install the MIO card, break the PC/MIO ( ) Fasten the PC/MIO cover cover apart at the breakaway...
Page 29 Page 29 PC/MIO cover. If you have the PC but not the MIO, snap the Exhaust plate bottom half of this bracket off at the breakaway tabs. Back panel CF tray MIO-6254 cover Jackscrews Pictorial 3...
Page 30 Page 30 Refer to Pictorial 3 for the fol- DCD/Tuner board. Parts are lowing steps. provided in the transmitter kit. See Appendix C2. ( ) Attach the back panel to the back of the chassis bottom ( ) If you have purchased the using two 6-32 x 1/4"...
Page 31 Page 31 ( ) Repeat the previous two steps ( ) Attach the front left corner for transistor Q1. of the DCD/Tuner tray to the chassis bottom as shown in ( ) Using an ohmmeter, verify the inset drawing in Pictori- that the resistance from each al 3, using a 6-32 x 2”...
Page 32 Page 32 ( ) Attach the plastic finger If you purchased the 100W PA: guards and metal EMI shields to the outside of the Exhaust ( ) Attach a fuseholder (provided Plate using four 6-32 x 1/2” with the amplifier kit) screws and four 6-32 KEPS the Fan mounting plate using nuts for each guard.
Page 33 Page 33...
Page 34: Initial Tests
Page 34 STEP-BY-STEP ASSEMBLY - Initial Tests ( ) Locate CA1, the on/off switch the higher noise level when with attached cable. Attach the fan is connected to J6, the 5-pin connector to J4 on leave it there to provide the DCD/Tuner board.
Page 35 Page 35 Measurement point Voltage J10 pin 1 5.0V +/-.15V J10 pin 2 -9.5V +/-.5V J10 pins 3 and 5 0.0V +/-.05V (ground) J10 pin 4 Applied voltage (11-15V) Anode (unbanded side) of D7 0.25 * applied voltage Cathode (banded side) of D9 and D5 2.7V Junction of R24 and R25 0.17 * applied voltage...
Page 36: Front Panel Integration
Page 36 STEP-BY-STEP ASSEMBLY: Front Panel Integration Models without controls If you have purchased a Sienna with front panel controls, (SF-100 models), go to page 38. If you are upgrading an existing from the DCD/Tuner board and Sienna by adding a full front...
Page 37 Page 37 Controller board 6-32 x 1/4” screw Pictorial 4...
Page 38 Page 38 STEP-BY-STEP ASSEMBLY - Front Panel Integration Models with controls ( ) Build the Front Panel board four 6-32 x 7/16" hex (See Appendix D). male/female spacers, and six 6-32 x 1/4" screws. Refer to Pictorial 5 for the fol- lowing steps.
Page 39 Page 39 Front Panel Board Controller Board S Meter White LEDs Tx Meter 6-32 x 1/2” Hex M/F Spacer 6-32 x 7/16” Hex M/F Spacer 6-32 x 7/16” Hex M/F Spacer Six 6-32 x 1/4” screws secure front panel board to sheet metal Eight 6-32 x 1/4”...
Page 40 Page 40 from its anti-static bag. a tissue or clean, dry towel. ( ) Solder the four white LEDs ( ) Remove the backing from the the back side of the control- front panel Lexan® overlay ler board with the flat side and attach it to the front facing up.
Page 41 Page 41...
Page 42 Page 42...
Page 43 Page 43 STEP-BY-STEP ASSEMBLY - Connect Controller Cables Make sure that no DC power is applied to the DC input connectors on the back panel while you connect internal cables. Do not simply rely on the on/off switch being off, because you could accidentally bump it to the ON position while working on the cables.
Page 44 Page 44 ( ) Locate the 8-pin microphone under the left bracket and connector to 6-pin IDC and 2- into the Power compartment. pin stereo cable (CONT-MIC — If you have DCD board revi- CA16). Remove the nut and sion B1 or greater, connect lockwasher.
Page 45 Page 45 Pictorial 6. Completed unit showing cable dress from controller...
Page 46 Page 46 a red wire and the other has J24 (RXLO1) on the Controller white and green wires. Insert board. Dress the cable the one with the black wire through the large rectangular into the hole labeled Keypad. hole on the right side of the Insert the one with the red front bracket.
Page 47 Page 47 a small piece of heatshrink three 16-pin connectors, J15, tubing over the end and heat on the Controller board. Fold it, so that the connector the cable at a right angle does not touch the chassis. and dress the cable along the underside of the top fold in the front bracket.
Page 48: Front Panel Tests
Page 48 STEP-BY-STEP ASSEMBLY-Front Panel/Controller Tests Units with full front panels ( ) Turn on the radio by applying time and note the response. DC power to the APP connect- The LEDs inside the buttons ors on the back panel and should light when you push pushing the on/off switch.
Page 49 If you want to experiment with ors on the back panel and other commands to observe the re- pushing the on/off switch. sponses, consult the Sienna Oper- ator’s Guide. ( ) You should again hear the PC boot if it is installed.
Page 50: Receiver Integration
Page 50 STEP-BY-STEP ASSEMBLY-Receiver Integration Refer to Pictorial 7 for the fol- Filter Board and insert it lowing steps. into J2. ( ) Build the IF Filter board ( ) Remove IF2 from J19 on the IF (See Appendix E). Filter Board and insert it into J3.
Page 51 Page 51 Insert IF4 here Insert IF1 here Insert IF2 here Insert IF3 here Mount test board here Pictorial 7. IF Filter Board Mounting...
Page 52 Page 52 al ends to the chassis. ( ) Connect the Receiver power cable from J10 (“Rx”) on the ( ) Attach the phono connector to DCD Board to J17 (“From DCD the back panel at the hole (test)”) on the RXBPF Board. marked IF OUT with the solder lug positioned to the right ( ) Connect the bottom of the two...
Page 53 Page 53 board in the transmitter com- connector labeled J4 (To partment and connect cables Rcvr) on the RXBPF board. as follows: ( ) Build the Receiver board (See ( ) Fan to J7 Appendix G). ( ) CONT-TXVM — CA18 to J6 ( ) CA4 (5-pin) to J5 ( ) Remove the 4-pin power con- ( ) CA4 (3-pin) to J4...
Page 54 Page 54 Refer to Pictorial 8 for the fol- ( ) Locate the 10" 3-pin IDC ca- lowing steps. ble labeled RX-TXLINE (CA29). Attach one end to J23 If you have installed the full (Line/VOX) on the receiver front panel: board.
Page 55 Page 55 Insert IF1 here Insert IF4 here Insert IF3 here Insert IF2 here Insert IFOUT here Insert RF1 here Pictorial 8...
Page 56 Page 56 board. This cable makes a PC compartment in an earlier tight turn as it comes up step. Insert the free end in- from the RXBPF board. to J26 (IFOut) on the receiv- er board. ( ) Insert RF cable IF1 into J17 (IF1-To9M) on the Receiver ( ) Connect the top connector on board.
Page 57 Page 57 ( ) If you have installed the PC option and NOT the MIO board, locate the cable assembly that you attached to the PC earlier that has three cables attached to a 2mm rectangular connector (PC-RX/TX — CA32). Pass the cable with the 2-pin MTA connector on the other end through the hole in the right bracket and into the transmitter compartment.
Page 58 Page 58 3 trimmers 7 trimmers L9:FM Peak Jumpers JP1-2-3 L5 (IF3 peak) S-meter zero pot Jumper JP4 AGC Threshold pot TP3—HRcvEn TP1—AGC TP2—BAGC (buffered AGC) Pictorial 9...
Page 59: Receiver Alignment/Test
Page 59 STEP-BY-STEP ASSEMBLY - Receiver Alignment/Tests Using full front panel If you have a blank front panel, go to page 64 When so instructed, connect a of the Service Manual. voltmeter to the test points described below (red to the ( ) Disconnect any antennas from noted test point, black to any the antenna jacks on the Back...
Page 60 Page 60 ing the internal IFOut-to-IF4 you see a selection called connection. An RFSpace SDR-IQ “FM/IF Test”. Select it with receiver is recommended for the large tuning knob . (If this, but any spectrum ana- it is the first item in the lyzer capable of displaying menu, rotate the large knob frequencies around 455kHz can...
Page 61 Page 61 put to the receiver (J14 on Threshold pot on the receiver the receiver board). board to get a voltage read- ing of 4.0V. ( ) Set the RF Gain control to the maximum clockwise posi- ( ) Rotate the RF Gain control to tion.
Page 62 Page 62 reading on the S-meter. it into J8 on the IF Test board (if present) in the ( ) Adjust variable inductor L5 transmitter compartment. (IF Peak) for a maximum read- ing on the S-meter. Typical- ( ) Set the Rcv/Cal switch to Rcv ly, the slug will extend out on the RXBPF board.
Page 63: Step-By-Step Assembly
Page 63 STEP-BY-STEP ASSEMBLY Receiver Voltage checks Voltage (+/-5%) J5 pin 1 +5.0V J5 pin 2 -9.5V J5 pin 4 +11 to +15V J13 pin 4 9.0V >4.0V U14 pin 1 -5.0V U13 pin 3 +5.0V U18 pin 14 +11 to +15V U19 pin 14 +11 to +15V U4 pin 8...
Page 64 Page 64 STEP-BY-STEP ASSEMBLY - Receiver Alignment/Tests Using remote control Skip this section if you have a full front panel ( ) Temporarily disconnect the 5- to the RXBPF board’s antenna pin power cable from the DCD/ input. Tuner board (J10) that goes to the 4-pin connector J5 on ( ) Flip switch S1 on the RXBPF the Receiver board (DCDIST-RX...
Page 65 { AGC Fast } RG255; { RF Gain max } ( ) Send the commands: ( ) Touch the red voltmeter lead { Sienna responds to TP1 and then send the com- with “ID710;” } mand “CRnnn000;”, where “nnn MD4;...
Page 66 Page 66 The above steps set the Re- peak”, “IF1 peak” and “IF2 ceiver’s Automatic Gain Con- peak” to achieve a maximum trol (AGC) threshold voltage. reading on the voltmeter. ( ) Touch the red voltmeter probe ( ) Adjust variable inductor L5 to TP4 (S Cal) [use the junc- (IF Peak) for a maximum read- tion of R181 and R187 on Rev...
Page 67 Page 67 ( ) Send the command: ( ) Connect an antenna to the back panel Receive Antenna CAxxx; input. Select the receive an- tenna, AM mode and enter the repeatedly until the station frequency of a local AM sta- is at a comfortable listening tion in your area using the level.
Page 68: Transmitter Integration
Page 68 STEP-BY-STEP ASSEMBLY-Transmitter Integration ( ) If installed, remove the Test tender plate to the large board from the transmitter right bracket using a 4-40 x compartment and disconnect 3/8” screw and a 4-40 KEPS all cables from it. nut.
Page 69 Page 69 neatly so that it lays flat that is connected between the against the large bracket, Main Antenna jack on the then fold it again at right RXBPF board and J11 (“To Tx”) angles to get it into the DCD on the DCD board.
Page 70: Transmitter Resistance/Voltage
Page 70 STEP-BY-STEP ASSEMBLY Transmitter Resistance and Voltage checks ( ) Temporarily remove J5 and Place JP8 on the left two J18, the two DC power cables pins. going to the transmitter. Us- ing an ohmmeter, verify the ( ) Turn on power. If you have a following resistances: full front panel, use the...
Page 71 Page 71 Volt- Mode Mode Commands Menu setting JP3 (top) 2.5V md2; md1; ESSB off JP4 (top) USB, LSB, DIGUSB, DIGLSB 2.5V md6; md9; (es0;) 2.5- md2; md1; ESSB off U20 pin 1 USB, LSB, DIGUSB, DIGLSB 3.5V md6; md9; (es0;) U20 pin 2 3.0V...
Page 72: Transmitter Alignment/Tests
Page 72 STEP-BY-STEP ASSEMBLY Transmitter, SWR Alignment/Tests—Models with front panels ( ) If all voltage and resistance tests. tests passed, install all jumpers and move JP8 to the ( ) Enable Power calibration by right two pins. selecting “Tx ALC” in the menu and then selecting ( ) Connect a dummy load and an “Off”.
Page 73 Page 73 ( ) Set the frequency to 14.0 MHz ( ) Key the transmitter by se- and adjust the RF Power con- lecting MOX or pushing the trol so that the external PTT switch on the microphone. wattmeter reads 10.0 Watts The S-meter should go to full when you press the key.
Page 74 Page 74 10.1, 14.2, 18.068, 21.3, you plan to use 4 or 5kHz, 24.89 and 29.0 MHz. change it to this in the ap- propriate menu. Keep the pow- Note: Although the menu setting er level less than 3W (30W shows only one setting for with 100W amp) on FM.
Page 75 Page 75 STEP-BY-STEP ASSEMBLY Transmitter, SWR Alignment/Tests—Models without front panels ( ) Connect a dummy load to the measurement function (in this antenna A jack via an RF pow- case, Forward Power). Voltag- er or SWR meter. Connect a es on this pin are never key to the front panel (if greater than 2V so choose a present) or back panel MANUAL...
Page 76 If one is no higher than 1.6V (12dB) not available, send the com- and the signal sounds clean mand “FD;” to put your Sienna and readable with little dis- into Full Duplex mode, allow- tortion. ing you to hear your trans- mitted signal.
Page 77 Page 77 change it to this in the ap- propriate menu. Keep the pow- er level below 3W when using FM (30W with the 100W amp en- abled). ( ) Enable TXALC by sending the command “AL1;”. Now the RF Power command (“PCxxx;”) should allow you to accurate- ly set the power level.
Page 78: Pa Integration
Connect the (See Appendix J). fan cable to J6 (marked “Fan”) on the 100W PA assem- ( ) Remove power from the Sienna. bly. ( ) Remove the two screws holding ( ) Locate one 12” 14AWG red wire...
Page 79 Page 79 Pictorial 10. 100W PA Mounting Detail 8. Photos of vertical tray mounting...
Page 80 Page 80 side of the 100W PA Board in- left side of the front brack- to the pad marked W1 (“From et and connect the end to J1 Fuse”). Solder the other end (“PA Curr”) on the PA board. to the end lug on the fuse- Dress this cable between the holder.
Page 81: 100W Pa Alignment/Tests
(right). reads “Int 100W”. Press MENU again to exit MENU mode. ( ) Connect power to the Sienna DC input terminals and turn ( ) Press the BAND button and on the unit. If you smell...
Page 82 ( ) Short TP2 to ground using a version (S-100xx) of Sienna: clip lead or insulated wire. Measure the voltage at TP1 ( ) Connect to Sienna using Hy- (“100V Back Bias”). It should perterm or other RS-232 con- read 100V +/-5V. Remove the trol program.
Page 83 Page 83 Transmitter board. Pass it 32 x 1/4” screws. through the rectangular hole in the back of the large left ( ) Insert the 6-32 x 1 1/2” bracket and connect it to J5 screw into the left front (“To RxBPF”) on the 100W amp corner of the DCD/Tuner board.
Page 84: Final Assembly
Use the provided tween the LINE OUT and IF OUT 1/20” (.050”) hex key to connectors. tighten the small knobs, the 1/16” (.063”) hex key to This completes assembly and test tighten the large tuning of the Sienna transceiver.
Page 85 Page 85...
Page 86: Appendix A: Pc Power Wiring
100W amp installed, as there is no place to put a backup battery. The UPS board mounts directly on the Sienna chassis in the compart- ment in front of the DCD board (rev C chassis) or on a small daughter board that mounts to the chassis (rev B chassis).
Page 87 Page 87 Parts provided with PC Power adapter Steel RFI shield (Supplied with (2 pieces) 2 jack screws 2 4-40 x 1/4” screws CF Mounting tray 2 #1 screws 6 6-32 x 1/4” screws #6 solder lug Mini-ATX Power Supply...
Page 88 Page 88 PC Power Supply Integration ( ) Insert the 20-pin white con- black lead toward the back of nector on the power adapter the radio. into the small sheet metal bracket (Shown in blue or ( ) Plug the white 12-pin con- darker color on previous nector into the PC mother- page).
Page 89 Page 89 connected to the red Anderson in the front left corner of Powerpole connector at J12 on the DCD board and insert the the DCD board. (Note: Rev B solder lug, then re-tighten DCD boards have a pad for the screw.
Page 90: Appendix B: Rs232 Board
Page 90 Appendix B: RS232 Board PARTS LIST Item Part Description 14-pin 2mm connector DB-9 PC-mt right-angle connector (male and female R1,R2,R3,R4,R5 100 ohm 1/8W resistor C1,C2,C3,C4,C5 150pF monolithic capacitor RS232 Board blank Notch RS232 Board, blank RS232 Board, assembled...
Page 91 RS-232 board and in- This completes assembly of the RS stall the board with compo- -232 Board. This board is only nents facing up. If you do used when no PC is installed in this, you will most likely the Sienna.
Page 92: Appendix C1: Dcd: Power
Page 92 Appendix C1: DCD/Tuner Board [DCD Section] PARTS LIST Item Part Description Qty Bag Nr .1uF 50V monolithic X7R 5% 100uF/25V 20% aluminum electrolytic 22uF/25V tant "D" 1 ohm ESR 165K ohm 1/8W 1% 1N4007B 1000V rectifier diode 1N5223B-2.7V Zener diode 1N5711 Schottky diode 1N5818 Schottky diode 1N5404 power rectifier...
Page 93 Page 93 Item Part Description Qty Bag Nr 1M ohm 1/8W 1% 16-pin 2-row .1" centers shrouded male header 2-pin .1" centers male keyed header 3-pin .1" centers male keyed header 4-pin .1" centers male keyed header 5-pin .1" centers male keyed header 8-pin .1"...
Page 94 Page 94 Item Part Description Qty Bag Nr 4-40 shoulder washer TO-220 insulator Magnet wire, red 24AWG (inches) TIP41C power transistor TO-220 2N7000 MOSFET MAX765 8-pin DIP 74HC273 octal D flip-flop 20-pin DIP ULN2803 relay driver 18-pin DIP LM339 quad comparator 14-pin DIP LM393 dual comparator 8-pin DIP AP1084-5 5V regulator TO-220 (“84-50”) LM2940CS-9 9V regulator TO-263...
Page 95 Page 95...
Page 96 Page 96 STEP-BY-STEP ASSEMBLY-DCD Board Highlight or check off each part Note that D6, the large on the parts list that came in- 1N5404, mounts vertically; side the bag as you install it place it with the band down on the board. Unless otherwise and bend the lead over and instructed, load all parts of into the round pad:...
Page 97 Page 97 into the red and black bod- sembly of this board, skip ies: the next step. ( ) Cut a 4” length of magnet wire. Insert one end into the bottom pad of L7 with about 1/2” extending out the bottom of the board.
Page 98 Page 98 Integrated Circuits except with the thick silkscreened U8, one bag at a time. Make bar. Be sure the connectors absolutely sure that the ICs are flush with the board. are inserted with pin 1 ori- ( ) Clip the pins of 8-pin con- ented correctly.
Page 99 Page 99 DCD Board, front, tuner section not installed, SWR meter installed DCD Board, back, tuner section not installed, SWR meter installed...
Page 100: Appendix C2: Dcd: Swr
Page 100 Appendix C2: DCD/Tuner Board [SWR Section] PARTS LIST Note: These parts are included with the transmitter board Item Part Description D1, D2 1N5711 Schottky diode (blue) D3, D4 1N4733A 5.1V 1W Zener diode (red) FT50-43 toroid .1uF monolithic capacitor C13, C14 1000pF ceramic disk capacitor 100pF silver mica capacitor...
Page 101 Page 101 ( ) Load and solder all capaci- per inch. Wrap twelve turns tors, including C17, the 30pF of the finished wires around trimmer capacitor. The trim- toroid T1. Insert the toroid mer can be installed either into the board with the un- direction.
Page 102: Appendix C3: Dcd: Tuner
Page 102 Appendix C3: DCD/Tuner Board [Tuner Section] (Option 102) PARTS LIST Item Part Description K1-K16 SPST 12V relay, 8A 10pF silver mica (sm) 20pF sm 39pF sm 82pF sm 150pF sm 330pF sm 560pF sm L1-L7 T80-2 Toroid 20# magnet wire 10’...
Page 103 ( ) If you are installing this around toroid L2. Solder the option after you finished toroid in place. wiring your Sienna, first disconnect power, remove all ( ) Wind 15 turns of magnet wire cables and screws from this around toroid L3.
Page 104 Page 104 If any do not read correctly, re-heat the connections mak- ing sure that all enamel is removed. ( ) Check your work. ( ) If this is an upgrade, rein- stall the board and reconnect cables. This completes assembly of the Tuner section of the DCD/Tuner board.
Page 105 Page 105 DCD Board, tuner and SWR meter installed, on tray...
Page 106: Appendix D1: Blank Front Panel
Page 106 Appendix D1-Front Panel without controls PARTS LIST Item Description Screw - 6-32 x 1/4" PH Phillips M/S Front Panel—no controls sheet metal Front panel– no controls polycarbonate overlay Controller Board...
Page 107 Page 107 There are no assembly steps here. See the integration pages (pp 36-37) for front panel assembly for information regarding assembly of this module.
Page 108: Appendix D2: Full Front Panel
Page 108 Appendix D2-Front Panel with controls PARTS LIST—PC Board Note: These parts comprise bag #1 for the front panel option Item Part Description C1, C2 .1uF monolithic capacitor 100uF/25V axial leaded electrolytic capacitor RV1,RV3, 10K 9mm snap-in pot RV5-RV12 J2,J4 8-pin 2-row male header J3, J5...
Page 109 Page 109 PARTS LIST—Hardware Item Part Description Knob-small RIT Knob Tuning knob 1/20” (.050”) Hex key 1/16” (.063’) Hex key 5/64” (.078”) Hex Key Screw - 6-32 x 1/4" PH Phillips M/S Hole plug—.25” Nylon Nut - 2-56 Hex M/F spacer - 6-32 x 7/16" Hex M/F spacer - 6-32 x 1/2"...
Page 110 Page 110 STEP-BY-STEP ASSEMBLY-Front Panel Board ( ) Load and solder the two mono- ( ) Mount all connectors (Bag 2) lithic capacitors (Bag 1) at to the back of the board - C1 and C2. the non-silkscreened side; i.e., solder them on the top ( ) Load and solder the 100uF side.
Page 111 Page 111 S1 RPG/PB S2 Rotary P9 S11 P1 P8 P10 S3 S5 P11 S4 S6 P12 S9 ( ) Measure resistances to ground on connector pins as shown below. Values shown are +/-20%. Values of 0 can read 0 to 1 ohm. Use any mounting hole as a ground point.
Page 112: Appendix E: If Filter Board
Page 112 Appendix E: IF Filter Board PARTS LIST Item Ref Desig Description Qty Stock Bin Bag Nr C30-47 10pF 50V ceramic disk NP0 5% 68 ohm 1/4W 1% 27pF 50V ceramic disk NP0 5% C3, C4 C7-29 .1uF 50V ceramic disk Y5U 5% C48-70 C1, C2 10uF/25V aluminum electrolytic 20%...
Page 113 Page 113 Item Ref Desig Description Qty Stock Bin Bag Nr D1-D36 1N914 signal diode Q1-Q10 2N7000 MOSFET R9, R12, R15 300 ohm 1/4W 1% 74HC139 dual 2-4 decoder 16-pin DIP 74HC240 octal buffer 20-pin DIP LTM455DU ceramic filter 8-pin .1" centers male keyed header J2, J3, J4, J5 Taiko-Denki RF jack PCB-mt J18, J19...
Page 114 Page 114 STEP-BY-STEP ASSEMBLY-IF Filter Board IMPORTANT! ALL parts are mounted Note: In the next three steps, on the top (silkscreened) side of you will load transformers. They the board EXCEPT: J1, all filters look exactly the same but there and the connectors that are are three different values.
Page 115 Page 115 Top view Bottom view IF Filter Photographs...
Page 116 Page 116 the heavy bar on the silk- threaded tabs and the two screen. pins. Push the sheet onto the filter, shiny side toward the ( ) If you have purchased a filter, and place the filter 5.8KHz Collins mechanical on the board at FL1 on the filter for 455KHz, install it...
Page 117 Page 117 Detail E1. Cutting 36-pin connector into 12 4-pin connectors...
Page 118: Appendix F: Rxbpf Board
Page 118 Appendix F: RXBPF Board Item Ref Desig Description Qty Stock Bin Bag Nr C45, C48, C50 10pF 50V monolithic C0G 5% 576A D1, D2 1N914 signal diode R12, R19, R30 4.75 ohm 1/8W 1% 15pF 50V monolithic C0G 5% 576B D3-D8 1N4007B 1000V rectifier...
Page 119 Page 119 Item Ref Desig Description Qty Stock Bin Bag Nr C16, C32-C40 .01uF 50V monolithic X7R 10% 575D C43, C44, C47 R7, R8 4.7K ohm 1/8W 1% C30, C31 .047uF monolithic X7R 10% 576H R1, R2 10K ohm 1/8W 1% C3-C8 C12-C15 C17, C19...
Page 120 Page 120 Item Ref Desig Description Qty Stock Bin Bag Nr 74HC138 3-to-8 decoder 16-pin DIP U2, U3 74HC174 hex flip-flop 16-pin DIP 74HC374 octal flip-flop 20-pin DIP 4-pin .1” centers male keyed header Filter pin socket Hex M/F spacer - 4-40 x 3/16" Nut - 4-40 KEPS nut 1-pin male tall pins 397B...
Page 121 Page 121 RXBPF board before loading Slot Frequency range 500 kHz — 1.8 MHz 1.8 MHz — 3.0 MHz 3.0 MHz — 4.0 MHz 4.0 MHz — 6.3 MHz 6.3 MHz — 8.4 MHz 8.4 MHz — 11 MHz 11 MHz — 16 MHz 16 MHz —...
Page 122 Page 122 STEP-BY-STEP ASSEMBLY-RXBPF Board Highlight or check off each loaded with the long (+) part on the bag label as you leads in the holes with install it on the board. Unless square pads and marked on the otherwise instructed, load all silkscreen with a ‘+’.
Page 123 Page 123 same pad. When one side is soldered, solder the other ( ) Load relays K1-K3. These are side. Note that there are al- surface mount relays. To load so transistors and/or ICs in a part, apply a small amount the same bags.
Page 124 Page 124 the other FT37-43 toroid. See is on the square pad. When photo. you are absolutely certain that the ICs are correctly ( ) For each toroid, insert the loaded, solder all pins. red wires into the holes marked 1 and 2, and the green ( ) Load all connectors.
Page 125 Page 125 Edge view of BPF RXBPF board after loading, prior to after installation insertion of BPF’s Cut to 1/4” RXBPF board after loading and inser- tion of BPF’s hex standoff. Tighten the ( ) Check your work carefully for board using a 4-40 x 3/16”...
Page 126: Appendix G: Receiver Board
Page 126 Appendix G: Receiver Board PARTS LIST Item Ref Desig Description Bag Nr C123 C124 6-70pF trimmer C125 C136 C137 C138 C158 22uF/16V bi-polar aluminum electrolytic 20% C106 C110 C132 100uF/25V 20% aluminum electrolytic C170 330uF/16V 20% aluminum electrolytic C103 470uF/10V 20% aluminum electrolytic C104...
Page 127 Page 127 Item Ref Desig Description Bag Nr 1N5711 Schottky diode 1N914 signal diode LTM455DU ceramic filter 16-pin 2-row .1" centers r/a shrouded male head- 2-pin .1" centers male keyed header 3-pin .1" centers male keyed header 4-pin .1" centers male keyed header 8-pin .1"...
Page 128 Page 128 Item Ref Desig Description Bag Nr 3-pin .1" centers header 2-pin .1” centers header 2-pin female shorting bar Taiko-Denki RF jack FT50-61 toroid Magnet wire, red 24AWG (inches) Magnet wire, green 24AWG (inches) 100uH variable inductor Resistor network, .1" SIP, 10-pin 10K T4-1 4:1 transformer 6-pin DIP 10K trimpot 500 ohm trimpot...
Page 129 Page 129...
Page 130 Page 130 STEP-BY-STEP ASSEMBLY-Receiver Board There are a lot of parts on finger if you are touching the this board. It can take quite a lead you are tacking down. Be while for you to locate the sure to touch other pins or the parts visually.
Page 131 Page 131 ( ) Load U31 (Bag 5), a 9V regu- square pad. lator, on the bottom of the board. This is an SMT device. ( ) Load and solder trimpot RV1 To load, place the part on (Bag 3). The value of this the pads and solder one pin pot is marked on the side while holding the device in...
Page 132 Page 132 that pin 1 goes into the hole with the square pad. ( ) Clip excess leads from the toroid wires. ( ) Load and solder U9, U12, and U32 (Bag 5), the MC1350 ( ) Using an ohmmeter, verify (NTE746) IF amplifier ICs.
Page 133 Page 133 thicker leads together board onto the 4 pins slightly so the connector such that the text reads will not fall out while you upside down compared to solder it. Solder one lead, text on the Receiver then push the connector down board.
Page 134: Appendix H: Transmitter Board
Page 134 Appendix H: Transmitter Board PARTS LIST: PC Board Item Part Description C108 18pF silver mica (sm) 20pF sm C103 27pF sm C112 33pF sm C110 47pF sm C105 56pF sm C95, C107 68pF sm 82pF sm C40, C89 100pF sm C106 120pF sm...
Page 135 Page 135 Item Part Description Qty Bag 16-pin 2-row .1" centers shrouded male header J3, J4, J15 2-pin AMP MTA male keyed header J6, J18 3-pin AMP MTA male keyed header 4-pin AMP MTA male keyed header 5-pin AMP MTA male keyed header J13, J17 4-pin 2-row female bd mt socket J12, J16...
Page 136 Page 136 Item Part Description Qty Bag L1-L4 T50-2 toroid (red) L5-L12 T50-10 toroid (black) L13, L14 Ferrite Bead RG-178/U coaxial cable (inches) #24 red magnet wire (inches) 180” #24 green magnet wire (inches) 36” D7-10, 14 1N5231B 5.1V Zener diode 2N5109 NPN low-noise RF transistor Power N-channel MOSFET (SMT) Q4, Q5...
Page 137 Page 137 PARTS LIST: Mounting Hardware Item Description SWR Meter Kit (parts added to DCD board—see App. C2) TXBPF Kit (see Appendix I) Screw - 4-40 x 3/8" PH Phillips M/S Screw - 2-56 x 5/8” PH Phillips M/S Nut—4/40 KEPS nut Nut - 2-56 Hex F/F spacer, 4-40 x 1 1/4"...
Page 138 Page 138 STEP-BY-STEP ASSEMBLY-Transmitter Board Remove the transmitter board nally, solder around the edg- from its antistatic bag. Handle es of the metal tab, applying this partially assembled board enough heat to cause the sol- carefully and observe antistatic der to “wick” under the part. precautions to avoid damaging the board.
Page 139 Page 139 with the band goes into the of the crystals (Y1-Y19, Bag hole with a square pad. Clip 8). Insert the crystal on the the leads. board and solder one pin while pushing on each crystal ( ) Load and solder diodes D7, to be sure it lies flat D8, D9, D10 and D14 (Bag 5).
Page 140 Page 140 angle when inserted into the counterclockwise, the others board. J12, J13, J16 and J17 clockwise. Solder the leads, mount on the back side of the keeping the soldering iron board. Be sure these lie flat (set to 750 degrees F) on the against the board.
Page 141 Page 141 the resulting inductor fits ( ) Cut 13” of red 24# magnet in the holes for L13. Load wire and wrap 12 turns com- and solder this part and clip pletely around an FT37-43 to- the leads. roid (the smaller ones in Bag 7).
Page 142 Page 142 Figure H1. Transverter coax cable wiring red wire goes in 2. The other R39). Solder and clip the green wire goes in 4. Clip leads. the leads. ( ) Cut two 2” lengths of red magnet wire and feed one through one hole in the core and one through the other.
Page 143 Page 143 Thermalsil insulators (4) ( ) Load and solder power resistor R39 (Bag 6). ( ) Load and solder relays K12 and K13 (Bag 3). ( ) Strip and tin the 8” RG-178/U coaxial cable (Bag 4) as shown in Figure H1 above.
Page 144 ( ) If you are adding the trans- shown using a fiber shoulder mitter later to an already washer and a 4-40 x 3/8” built Sienna, remove the DCD screw through each mounting board and add the SWR meter hole and into the threaded components to it.
Page 145: Appendix I: Txbpf Board
Page 145 Appendix I: TXBPF Board PARTS LIST Item Part Description J1, J3 8-pin 2-row male header J2, J14 4-pin 2-row male header BPF TF1 BPF TF2 BPF TF3 BPF TF4 BPF TF5 BPF TF6 BPF TF7 BPF TF8 BPF TF9 BPF TF10 Filter pin socket 4-40 x 7/16”...
Page 146 Page 146 STEP-BY-STEP ASSEMBLY-TXBPF Board Remove the TXBPF board care- are mounted as straight as fully from its antistatic possible. bag. Observe static control precautions while loading ( ) Push one filter pin socket this partially-loaded board. onto the end of each of the The GaAsFET switches that 20 filter pins.
Page 147 Page 147 TXBPF with BPF’s installed TX10 Cut to 1/4” Detail I1. BPF Assy...
Page 148: Appendix J: 100W Pa Board
Page 148 Appendix J: Option 104: 100W PA PARTS LIST Item Part Description Qty Bag 18pF silver mica capacitor (sm) 20pF sm 27pF sm 33pF sm 47pF sm 56pF sm C50, C57 68pF sm 82pF sm C38, C47 100pF sm 120pF sm C52, C59, C61 150pF sm...
Page 149 Page 149 Item Part Description Qty Bag 1N5818 diode (solid, black) D7, D8, D9, D10 1N914 diode (glass) D2, D4, D5, D12 1N4007B rectifier 100V 1A DO-41 1N5231B 5.1V Zener diode DO-35 1N5239B 9.1V Zener diode DO-35 1N5404 diode (large) 16-pin 2-row shrouded connector, right angle J1, J6 2-pin AMP MTA connector...
Page 150 Page 150 Item Part Description R13, R14 1.6 ohm 2W metal film resistor R11, R12 68 ohm 2W metal oxide resistor R15, R16 10 ohm 2W metal oxide resistor 15 ohm 3W metal oxide resistor R32, R35 47 ohm 1W metal oxide resistor 300 ohm 2W metal oxide resistor 120 ohm 2W metal oxide resistor RFC1(A,B)
Page 151 Page 151...
Page 152 Page 152 STEP-BY-STEP ASSEMBLY-100W PA Board When loading the following (Bag 3). Note that these are parts, locate the appropriate not all the same value capac- bag and remove only the speci- itors. The long lead is posi- fied parts, one value at a tive and must be mounted in time.
Page 153 Page 153 ends of the wire down so that nectors J2, J4 and J5 (Bag the resulting inductor fits 6). Clip the leads. in the holes for RFC1. Load and solder this part and clip ( ) Cut the leads on small trans- the leads.
Page 154 Page 154 ( ) Load and solder all silver ers into the four mounting mica capacitors (Bag 1). Clip holes on the heatsink as the leads. The component val- shown in Detail J2. ue in picoFarads is printed on the body of the cap. For ( ) Affix three Thermalsil insu- example, a 330pF capacitor is lators to the heatsink as...
Page 155 Page 155 are fully attached to the ( ) In the next few steps you pads. Re-heat the pad you will attach the heatsink, af- tacked earlier, applying more ter which the bottom of the solder if necessary. PC board will no longer be accessible, so take a few ( ) Line up the other three tran- minutes to check every solder...
Page 156 Page 156 ( ) Gently wiggle Q3, Q6 and Q7 ( ) Solder the pins on Q3, Q6 and so that their mounting holes Q7 and clip their leads. line up perfectly with the corresponding threaded hole ( ) Insert four 6-32 x 1 1/4” hex in the heatsink.
Page 157 Page 157 Detail J4.
Page 158 Page 158...
Page 159: Appendix K: Installing Filters
Inrad crystal soldered into the bottom of filters. A 4-pole SSB filter the board at Slot 1 instead is shipped with all Sienna of the ceramic filter noted radios standard, and mounted above. Other mechanical fil- on a Yaesu-style snap-in “C”...
Page 160 Page 160 Once filters are installed, the 455kHz IF: 20kHz ceram- control firmware in the Sienna ic filter in slot 1 main microprocessor must be told which filter is located in which slot. If you have a front panel, press the menu button and rotate the small tuning knob until the IF filter choices show up.
Page 161 Page 161 If you have a front panel-less 9MHz filters: model of the Sienna, you must en- “IYn;” n = 0,1,2,3,4,5,6,7,8 ter the filter information by where: sending commands in the following 0 = 6000, 1=2800, 2=2400, form: 3=2100, 4=1800, 5=1000,...
Page 162 Page 162 Photo not available at time of printing Photo L1. Test Board connections to IF Filter Board...
Page 163: Appendix L: If Test Procedure
Board. It should be the same as your DC input voltage to ( ) Locate the RF cable that has Sienna’s back panel (11-15V). been inserted into the Tx Call this voltage “VDD”. compartment, labeled “TXVFO”.
Page 164 Hyperterm or any RS-232 Set the display frequency of remote control program (9600 Sienna and the monitor re- baud, 1 stop bit, no parity, ceiver to 455.00 kHz. Use the no handshake): FAST button and the small FT0;...
Page 165 Page 165 same way you verified the 9MHz slots. ( ) Remove JP3 on the Test Board. This forces the IF Filters to be disabled, and the input and output connections are simply terminated in 50 ohms. It does not matter whether JP1 and JP2 are installed or not.
Page 166 Page 166...
Page 167: Appendix M: Rxbpf Test Proc
J5 on the RXBPF board. ( ) Make certain that all cables ( ) If your Sienna has Antenna A that are not in use are not or B connectors on the back shorting to the chassis or to...
Page 168 Page 168 you can hear with an antenna when Sienna is tuned to a connected to your monitor re- frequency between 3 and 4 ceiver should still come MHz. through fine as long as Sien- na is set to the same fre- ( ) You can make signals stronger quency.
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Page 172 Page 172 DZ COMPANY LOVELAND, COLORADO UNIQUE electronic equipment in kit form UNIQUE electronic equipment in kit form UNIQUE electronic equipment in kit form UNIQUE electronic equipment in kit form...

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