DZ SIENNA User manual

Page
DZKit
ASSEMBLY MANUAL
SIENNA
SIENNASIENNA
SIENNA
HF RECEIVER/Transceiver
HF RECEIVER/TransceiverHF RECEIVER/Transceiver
HF RECEIVER/Transceiver
Price $30.00
DZ CompanY • LOVELAND, COLORADO

Page 2
DZ COMPANY CONTACT INFO
Orders, parts, phone assistance.....................................................................[phone]
Email orders............................................................................................... [e-mail]
Email technical support .........................................................................[email protected]
Web site.......................................................................................................www.dzkit.com
Mail:
DZKit
4321 W. Eisenhower Blvd.
Loveland, CO 80537
During your first ninety (90) days of ownership, DZ Company will replace or repair free of charge—as soon as
practical—any parts which are defective, either in materials or workmanship 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
We warrant that during the first ninety (90) days of ownership, our products, when correctly assembled,
calibrated, adjusted and used in accordance with our printed instructions, will meet published specifications
You will receive free consultation (except for the cost of your long distance phone call) on any problem you may
encounter in the assembly or use of your DZKit product Just drop us a line, email us, give us a call, or visit our
website and click on “Support” That will give you access to free on-line support and a discussion group Sorry,
we cannot accept collect calls
Our warranty, both expressed and implied, does not cover damage caused by the use of corrosive solder,
defective tools, incorrect assembly, misuse, fire, customer-made modifications, floods or acts of God, nor does it
include reimbursement for customer assembly or setup time The warranty covers only DZKit products and is
not extended to non-DZ allied equipment or components used in conjunction with our products or uses of our
products for purposes other than as advertised
If you are ever dissatisfied with our service—warranty or otherwise– or our products, please write or email the
president, Brian Wood, W0DZ, and he will make certain your problems receive prompt, personal attention
THE DZ COMPANY, LLC
LOVELAND, CO 80537
YOUR DZKIT 90-DAY FULLWARRANTY

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Assembly
Of the
Sienna HF Receiver/Transceiver
DZ COMPANY
LOVELAND, COLORADO
Copyright © 2011
The DZ Company, LLC
All rights reserved
11-30-11 Sienna
TABLE OF CONTENTS
Introduction .......................................4
General assembly/safety notes ..........6
Step-By-Step Assembly
Chassis, DC power, PC, Tuner...14
Initial tests...................................34
Front Panel integration...............36
Front Panel tests..........................48
Receiver Integration ...................50
Receiver alignment/test ..............59
Transmitter integration ...............68
Transmitter resistance/voltage....70
Transmitter alignment/tests ........72
100W PA Integration ..................78
100W PA alignment/tests............81
Final assembly............................84
Appendix A: PC Power Wiring .......86
Appendix B: RS232 Board..............90
Appendix C1: DCD: Power ............92
Appendix C2: DCD: SWR ...........100
Appendix C3: DCD: Tuner............102
Appendix D1: Blank Front Panel..106
Appendix D2: Full Front Panel .....108
Appendix E: IF Filter Board..........112
Appendix F: RXBPF Board...........118
Appendix G: Receiver Board ........126
Appendix H: Transmitter Board....134
Appendix I: TXBPF Board............145
Appendix J: 100W PA Board.........148
Appendix K: Installing Filters.......159
Appendix L: IF Test Procedure. ....163
Appendix M: RXBPF Test Proc....167

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The Sienna family of receivers/
transceivers represents a revolu-
tion in amateur radio. Now you
can start with a relatively inex-
pensive remote-control-only re-
ceiver, using either your own or
an internal “embedded PC to con-
trol it using your favorite soft-
ware, and then add a front panel,
transmitter, tuner and amplifier,
as well as numerous IF filters as
your desires or budget allow. Or
you can start with any combina-
tion of modules to create just
the right radio for your needs.
The time-tested triple-conversion
receiver design assures general
coverage receive with no dead
spots and excellent image rejec-
tion. It also has very good dy-
namic range by virtue of an op-
tional 5KHz roofing filter at the
70.455MHz first IF, and compati-
bility with a wide variety of
high performance crystal filters
and Collins mechanical filters at
the 2nd and third IF’s to provide
excellent selectivity. We’ve also
added innovations in AGC control,
bandpass filtering with GaAsFET
switches instead of PIN diodes,
and the ability to run full-
duplex and cross-band at HF fre-
quencies.
Sienna transceivers are also a
study in duality: dual preamps,
dual keying (manual and paddle
inputs available at the same
time), dual audio (headphones and
speakers available at the same
time), dual receive (front panel
access to the audio from an ex-
ternal secondary receiver), and
dual backlit analog meters, which
give the rig a nice glow that
harkens back to the early days of
radio when all radios glowed. Du-
al microprocessors are in total
control of the radio.
And now, for the first time, with
an optional internal PC, it is
INTRODUCTION
Microsoft and Windows are U.S. registered trademarks of Microsoft Corporation.

Page 5
possible to connect a keyboard,
mouse and display to your trans-
ceiver and add digital modes,
logging, rig control, file trans-
fer via LAN or USB and much more,
at a reasonable price, and with-
out adding any external rig in-
terface equipment. It accomplish-
es this by means of a tiny but
powerful personal computer that
runs a common operating system—
Microsoft® Windows® XP Embedded
or Linux. This “embedded PC is a
fully functional personal comput-
er with O/S stored on Compact
Flash. It also has on-board sound
card, Ethernet networking, COM
ports, VGA display, PS/2 key-
board/mouse, USB and more. And
it’s expandable, with plug-in MIO
boards that offer even more fea-
tures, such as dual display and 6
Watt stereo speaker outputs.
But unlike some “Software-defined
radios that are totally con-
trolled by PCs, the Sienna does
not need the PC unless you choose
to operate it without its option-
al front panel. Sienna is a full-
featured HF radio. The twin mi-
croprocessors in Sienna’s con-
troller run the radio. There’s no
waiting for the PC to boot when
you turn the radio on unless you
want to use the features added by
the PC.
The Sienna can be built in sever-
al stages and in several combina-
tions. This manual is thus a com-
plete assembly manual for the
fully loaded Sienna. As you up-
grade your Sienna, you can still
use this one manual as a complete
assembly reference.
Thanks for trusting in DZKit to
provide not only unique electron-
ic products, but to give you
hours of building fun too.

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1. Most screws in this kit are
Phillips Panhead Machine
Screws. For simplicity, we
refer to them simply as
“screws unless a different
style is used. These may be
stainless steel or zinc-
plated steel.
2. Almost all sheet metal parts
are attached to each other
using 6-32 x 1/4 screws that
are inserted into captive
fasteners that have been
pressed into the sheet metal
by the factory. You will not
need to use many nuts and
lockwashers.
3. Most PC boards attach to the
sheet metal using 6-32 x 1/4"
screws but there are some ex-
ceptions, which are explained
in the steps.
4. As you tighten a screw, it is
very important that you do
not strip the threads. All
screws should fasten smoothly
without resistance. If a
screw appears to be hard to
fasten, something else is
probably wrong—a cable could
be in the way, you are trying
to use the wrong size screw
or something else is wrong.
DO NOT FORCE SCREWS! Instead,
inspect the assembly careful-
ly and try to see why you are
having difficulty.
5. A PC within arms reach of
your workbench is useful in
helping you locate the parts
on the boards. Shipped with
your kit is a USB flash drive
containing the PCB layout
files for all boards (without
traces). To find the location
of a part, simply install and
run the “ExpressPCB program
(free download from
www.expresspcb.com) and open
the board you wish to work
on. Press “Ctrl-F to find a
part, and then enter it in
the box that pops up (e.g.,
“R1 , without the quotes).
The program will show you ex-
actly where that part is lo-
cated. If you do not have a
PC nearby but have ordered
the internal PC for the Sien-
na, you can run this program
on it once you have installed
the PC (which is done in an
early step). Take a few
minutes to familiarize your-
self with this program before
beginning construction. You
can also find parts manually
by just looking for the part
on the silkscreen, but on the
denser boards, this can take
a long time. We highly recom-
mend using ExpressPCB to lo-
cate parts.
6. There are three large sheet
metal brackets. Two are iden-
tical and are placed opposite
each other lengthwise from
front to back. These brackets
are referred to as "large
bracket LR" (for Left/Right).
The other large bracket runs
from side to side in the
General Assembly Notes

Page 7
Most kit builders find it helpful to sepa-
rate the parts into categories for quick
identification. Muffin tins and egg car-
tons serve this purpose admirably.
front, attaching to the other
brackets. It is called the
"front bracket".
7. All references to left and
right, front and back are with
the chassis in an orientation
such that the front of the ra-
dio faces you. The large open-
ings on the bottom of the
chassis are to the right, with
the folded sides pointed up.
8. Each circuit part has its own
component number (R1, L4, Q3,
etc.). R1 on one assembly will
not be the same as R1 on a
different assembly, so be sure
you are looking at the right
set of parts when comparing
part numbers with the printed
parts list. Check off each
part at the beginning of each
section to make sure all the
parts are there. If you find
any missing, give us a call or
email us and we will rush a
replacement to you.
9. Most electronic kits that are
returned for service have poor
soldering jobs. Please take a
moment to familiarize yourself
with proper soldering tech-
nique. And do not, under ANY
circumstances, use corrosive
(“acid-core ) solder! That
will void your warranty and
render your kit inoperative.
Also be sure to avoid the use
of products that may be called
solder but are really glue
(e.g., LePage's Liquid Solder
(nothing more than metallic-
grey colored airplane glue).
10.Soldering should only be done
in an area with good ventila-
tion and with a properly heat-
ed soldering iron.
11.Resistors are identified by
their values in Ohms, Kilohms
(K) or Megohms (M) and by col-
or codes. Your kit uses resis-
tors of several types. Axial
leaded resistors have color
coded bands on them. For 5%
resistors, the first two bands
represent the numeric value
and the third band represents
a multiplier, which is a power
of 10. Thus, a 56 Ohm resistor
is Green-Blue-Black. A 10KOhm
resistor is Brown-Black-
Orange, and so on. The fourth
band is the tolerance — no
band represents 20%, a silver
band 10%, and a gold band 5%.
Your Sienna uses mostly one
percent or better resistors,
which have 4 bands for the
value. A 4.75K resistor is
Yellow-Violet-Green-Brown. We
have placed resistors of given
types in individual bags for
you, but should they get mixed
and you have trouble reading
the color code, we recommend
an inexpensive volt-ohmmeter
be used to check the values. A

Page 8
fluorescent light is also use-
ful to “bring out the colors,
and a magnifying glass is also
handy.
12.Capacitors are identified by
their type — disk, polysty-
rene, polypropylene, electro-
lytic, trimmer, etc.) and ca-
pacitance values are in micro-
farads (uF) or picoFarads
(pF). Polarized types have the
positive pin marked on the
silkscreen and also have a
square pad.
13.Inductors are represented ei-
ther by their inductance in
nanoHenries (nH), microHenries
(uH), milliHenries (mH) or by
the number of turns in the
coil if you are doing the
winding.
14.Diodes are marked with a band
on the cathode end. The PC
boards have a bar silkscreened
across one side of the compo-
nent outline and a square pad
which identifies the cathode.
15.Transistors have either a tab
or a flat side that you can
match to the silkscreened com-
ponent outline. Most transis-
tors will need to have their
leads “sprung a little to fit
in the holes. Do so carefully
to avoid breaking the leads
off.
16.ICs have a notch, beveled side
and/or a dot representing the
side containing pin 1. When
you hold an IC with the notch
pointing up or the beveled
side to your left, pin 1 is in
the upper left corner. The
silkscreened outlines on the
board all have notches and pin
1 also has a square pad.
It is CRITICAL that you mount po-
larized parts correctly! Double
chec your wor to be sure that
all such parts match the photos.
See Detail 1.
De- tail 1.
Identifying polarity of diodes,
transistors, ICs and polarized
capacitors.
Transistor — Flat side
Diode — band on cathode
IC — pin 1 (through-hole part)
IC—pin 1 (SMT part)
Electrolytic capacitors — negative side

Page 9
Abbreviations and definitions of terms used in this manual:
PC = Personal Computer
PCB = Printed Circuit Board
PH = Panhead
FH = Flathead
M/S = Machine Screw
PCB-mt = Printed Circuit Board mounting
AMP MTA = Tyco Electronics connector with .1 or .156 pin spacing
IDC = Insulation Displacement Connector (MTA connectors are IDC type)
Ribbon cable = Flat, gray cable with connectors on each end
Header = PCB-mounted connector
CA = Cable Assembly
A word about what lies ahead…
This manual is designed to allow you to build confidence in your kit-
building ability as you go along. You start by building the DC power
distribution circuitry, which is the simplest of all the circuitry.
You then install this board on the chassis. You will then be able to
turn on the power and measure some voltages. If you purchased the PC,
you will then install it, build and attach its DC power supply, power
it up and see it boot. This will give you confidence that the kit-
building is progressing normally. You will also be able to use the PC
to help you locate parts on the rest of the boards using the PCB lay-
out files that we have included. The project continues with building
of the front panel circuit board (if you purchased a front panel) and
integration with the pre-assembled controller board. At that point,
you will be able to experiment with the front panel controls and/or
the remote control functions. Once all that works, you will build and
install the receiver’s IF and bandpass filter boards. Next you will
finish building the partially pre-assembled receiver. At this point,
you will be able to test and align the receiver and use the built-in
keyer. 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. The transmitter and receiver boards
are the most complex, which is why they have been saved for last. But
once you get to them, you will have great confidence that you have
built the radio correctly to that point. So let’s get started!
NOTE: If you would prefer to build all the boards first, you may go
directly to the Appendices and do so.

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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). Check off each part to be sure you are not missing any-
thing. Our method of bagging parts is different from all other kit
vendors and will make the task much faster and less error prone.
But despite our valiant efforts, mistakes can happen. If you are
missing any parts, call or email us and we’ll rush replacements to
you immediately.
2. Do not remove parts from the bags until called for, to avoid mixing
parts up (especially resistors).
3. Pay attention to soldering techniques. Keep your soldering iron
clean by using a wet sponge, use appropriate heat and maintain heat
long enough to make good solder joints. Solder problems are the
number one cause of problems when building electronic products (not
just kits!), so try extra hard to do it right.
4. Some boards have been pre-loaded with surface mount parts. Be care-
ful not to flex these boards to avoid having parts snap off.
5. ake your time! We know you want to get it done and start using it,
but doing it wrong will only delay that moment. Before you start,
set up a ventilated, static-free work area with enough room to
build the kit. Prepare parts bins and get the tools you will need
(needle-nose pliers, wire-cutter, wire stripper, Phillips head
screw drivers, wrenches, soldering iron, solder, insulated tool,
awl or other sharp-ended tool, scissors, magnifying glass, etc.)
Open bags only when they are called for so parts don’t get inter-
mixed. If you’re tired, take a break. Enjoy building your kit!
6. Make sure that you are loading the part that’s called for in the
right holes. Once loaded, it can be hard to find a misloaded part.
Be especially careful to load polarized parts (ICs, diodes, elec-
trolytic capacitors) the right direction. If you are not sure about
any step, call or email us!
7. Once you’ve done a step, put a checkmark inside the parentheses.
8. After you have assembled a circuit board, take a moment (just one)
to marvel at your handiwork, then spend a few more minutes critiqu-
ing it! Check for solder bridges, unsoldered or insufficiently sol-
dered connections, solder blobs (especially on insulated magnet
wire used on toroids), loose screws and electronic parts, reversed
polarized components, etc. Sometimes it helps to have a friend
check your work.
KIT-BUILDING PROCEDURES