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

Page 3
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

Page 4
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.

Page 6
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.

Page 10
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

Page 11
Your safety is of utmost importance to us. Please read this infor-
mation before you get started, and remember these rules as you contin-
ue building and testing your 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. Set the output
current only as high as necessary for a given step.
2. When measuring voltages inside electronic equipment, it is general-
ly a good idea to use only one hand, wear rubber-soled shoes and
avoid areas with standing water. However, remember that slightly
humid environments can prevent static electricity that could damage
the electronic parts! Use a humidifier in dry climates.
3. Do not work on powered electronics by yourself if at all possible.
Have a parent, spouse or friend nearby. If you must work alone,
keep a telephone handy in the event you run into problems.
4. Soldering irons are hot. They can burn your skin and cause damage
to workbenches and carpets. We recommend you use one with an auto-
matic shutoff in case you forget to turn it off when you are done.
5. Do not work on electronic projects when you are tired. We know you
want to finish it, but accidents are more likely when you are
tired. Take breaks! Be careful!
6. Use proper ventilation in your work area. Solder contains tin and
lead (or tin and silver), and solder fumes should not be allowed to
“hover near your work. Open a door or window, use a fan, and be
cognizant of the potential dangers.
7. When clipping leads, use eye protection and/or be sure to direct
the flying leads down into a nearby trash can. As you gain experi-
ence clipping component leads, you will learn how to clip them so
that they fall harmlessly away from the board.
8. Be careful not to cut yourself when handling sharp objects such as
connectors and sheet metal. Keep some tissues, bandages and antibi-
otic ointment nearby in the event of an injury.
9. This may sound obvious, but do not insert any parts in any portion
of your body.
10. Use common sense in dealing with unfamiliar things. If you don’t
understand something, call us or ask a friend for help.
Safety First!

Page 12
SOLDERING INSTRUCTIONS
Poor soldering accounts for almost 90% of all it 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. Study this
section carefully before you start building your kit.
Use a good quality, variable tem-
perature soldering iron with a
conical, narrow tip, and set the
temperature to 750 degrees F. Use
thin, non-corrosive, rosin core
solder to assemble your kit. Keep
the sponge damp and wipe the tip
on the sponge after each solder
step.
Solder blob. In this example,
solder flowed onto a lead, but
the heat was not maintained long
enough for it to flow onto the
circuit board pad. Solution: re-
heat the connection, touching the
iron to both the component lead
and the pad at the same time.
Solder bridge. Solder that
stretches from one trace or pad
to another creates a short cir-
cuit. Solution: Hold the board
upside down and reheat the area.
The excess solder will flow down
the soldering iron. Another so-
lution is to use a “solder suck-
er or solder wick to remove ex-
cess solder. Solder suckers work
well one or two times on a given
connection. If used too much,
they can pull pads and traces off
of PC boards.
Good solder connections. A good
solder connection looks like
this. Solder flows evenly onto
both the part and the PC board or
chassis component. It is shiny
and even, not lumpy and dull.
Component leads that are properly
soldered can not be moved in the
hole. The component lies flat on
the board.

Page 13
STATIC PRECAUTIONS
Many of the components in your
kit can be damaged by exposure to
static electricity. Please read
this page to familiarize yourself
with the causes of and solutions
to this problem.
When the climate is dry, you can
generate thousands of volts simp-
ly by walking across a carpet.
When you then touch a metal ob-
ject you can feel the effects of
this as you draw a spark! That
same spark, often too small to
see or feel, can destroy sensi-
tive electronic components. You
MUST take precautions when work-
ing with electronics to prevent
damage.
The best solution is to outfit
your workbench with anti-static
devices — floormats, grounded
soldering irons, and workmats
with grounded wriststraps. If
these are not practical for you,
the very least you should do is
to discharge yourself to ground
after you sit down and before you
touch any electronic items, by
touching a grounded object such
as the corner of a wall.
In a dry environment, simply
standing up after sitting in a
non-grounded chair can also
charge you with electricity. If
you stand up to stretch, for ex-
ample, be sure to re-ground your-
self before getting back to work.
Don’t wear insulated sole shoes
and avoid nylon, wool or other
static-producing material in your
clothing.
If your work area floor is car-
peted, spray fabric softener on
it using a hand spray bottle.
Fabric softener is conductive and
will bleed away carpet static for
a few hours.
Don’t use a plastic table unless
you have a grounded workmat on
it. Use a metal table if possi-
ble.
Cats are notorious for inducing
static into your work area. Don’t
allow them anywhere near your
workbench!
All electronic components are
susceptible to static, but semi-
conductors and assembled boards
containing semiconductors are the
most prone to damage. These in-
clude diodes (including light-
emitting diodes [LEDs]), transis-
tors and integrated circuits
(ICs).
You are a wal ing lightning
bolt! Be careful!

Page 14
Chassis Parts
2
65
16
7
15
13
18
3
4
14
11: various lengths
17
19 20
9
8
1
22
Item Description Qty Bag Nr
1 SO-239 RF chassis-mt connector 2 1
2 Phono connector, chassis mount, red 1 1
3 BNC connector, chassis mount 1 1
4 Gas discharge tube 3 1
5 Anderson Powerpole mounting clamp 1 1
6 Foot - front SCREW-ON BLK 1.00 X .75" 2 1
7 Foot - rear SCREW-ON BLK .28 X .625" 2 1
8 Plastic Board Guide - 6" 1 1
9 Screw - 6-32 x 1/4" PH Phillips thread-cutting
self-tapping 4 1
10 Screw - 6-32 x 1/4" FH Phillips Black M/S 11 1
11 Screw - 6-32 x 1/4" PH Phillips M/S 55 1
11 Screw - 6-32 x 1/2" PH Phillips M/S 17 1
11 Screw - 6-32 x 1" PH Phillips M/S 2 1
12 Screw - 10-32 x 5/8" PH Phillips M/S 1 1
13 Jackscrew - 4-40 x 3/16" x 3/16" x Male
thread = 5/16" 2 1
14 Hex M/F spacer - 6-32 x 1/2" 2 1
14 Hex M/F spacer - 6-32 x 5/8" 12 1
15 Hex F/F spacer - 6-32 x 2" 1 1
16 Washer, flat - #10 2 1
17 Nut - 6-32 KEPS 20 1
17 Nut - 10-32 KEPS 1 1
18 Nut - 10-32 Wingnut 1 1
19 #10 solder lug 1 1
20 Washer - #6 x .050" flat Plastic 1 1
21 Hole plug - .5" nylon 1 1
22 Angle bracket 6-32 threads 5 1
10
12
21

Page 15
24
23
25
Item Description Qty Bag Nr
Bare wire 18AWG (inches) 6 1
Hookup wire - white 24# (inches) 12 1
Heat shrink tubing, 3/32" x 6" 1 1
Heat shrink tubing, 1/8” x 4” 1 1
23 Sienna serial number sticker 1 2
24 Fan - 12V 60x60x25 2
25 Bottom cover plate 1
26 Chassis bottom 1
27 Speaker 2
28 Finger guard—metal 2 1
29 Finger guard—plastic 2 1
30 EMI shield—metal 2 1
26
27 28 29
30

Page 16
32
35 36
31
Item Description Qty
31 Large Bracket Front 1
32 Large Bracket LR 2
33 Small Bracket 1
34 Exhaust plate 1
35 Rear Panel 1
36 Rear Panel Tray 1
37 PC cover plate 1
38 Top cover 1
33 34
37 38

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
Cables
DCDIS -ONOFF
CON -RPKEY
RX-RPLINEIN
RX-RPLINEOU
CON -PCRS232
CA-APP DC power input
CON DA A- UNER
CON DA A-RX-BPF

Page 19
DCDIS -CON
CON -RXVOXS
DCDIS -RX
RX-BPFDC
RX-IFFIL
RF CABLES
AMP M A—M A Cables
SPKR1, SPKR2
Use:
15”
10”
6.5”
10”
2.5”
6”
RX-HP
CON -MIC
CA33 RXBPFMAIN-TX/AMP
CA34 RXANT
CA35 RF1 (RXBPF to RX)
CA36 RXLO1
CA37 RXLO4
CA39 RXLO2
CA40 RXLO3
CA41 IF1
CA42 IFOUT
CA43 IF4
CA44 TXVFO
CA45 IF2
CA46 IF3
CA38 TXBFO
CON - XVM
16”

Page 20
Refer to Pictorial 1 for the fol-
lowing steps.
( ) Place the chassis bottom on a
hard surface. Push the 6"
plastic board guide into the
holes in the center transmit-
ter compartment until the
guide is firmly seated.
( ) If the fans in your kit have
connectors attached, skip
this step. Locate a CA15 2-
pin cable with MTA connect-
ors. Cut one end to a length
of 6 . Strip the leads to
1/4 and tin them. Cut the
wires on one fan 3 from the
body of the fan. Strip the
leads to 1/4 and tin them.
Place 1/2 of heatshrink tub-
ing over the ends. Solder the
red wire from CA15 to the red
wire of the fan. Solder the
black wire of CA15 to the
other wire on the fan (some
fans use black wires, some
blue). Place the heatshrink
tubing over the solder joints
and apply heat until the tub-
ing shrinks.
( ) Examine the revision code on
your DCD/Tuner board (see the
PC Board kit box). If your
DCD/Tuner Board is rev B1 or
greater, skip this step. Clip
the wires at the end of the
other fan cable, removing the
connector. Using the direc-
tions in the previous step,
using another CA15 cable cut
so that the total length of
the fan cable from the fan
body to the MTA connector is
18 .
( ) Position the front bracket
with the top and bottom fold-
ed sides facing you and the
fan mounting holes toward
your left. Attach the fans to
the back side of this bracket
with four 6-32 x 1/2" screws,
a metal finger guard and four
6-32 KEPS nuts. (Hint: use a
5/16 socket wrench on 6-32
KEPS nuts.) Make sure the
airflow arrow on the fans
points toward the back, with
the power cable on the bot-
tom. Holding the front brack-
et as described, the KEPS
nuts should be visible to you
and the screw heads should
touch the fans. See Photo 1.
( ) Attach the front bracket to
the chassis bottom using one
6-32 x 1/4" screw in the mid-
dle hole.
( ) Attach the two large rubber
feet to the bottom of the
chassis and into the outer
two holes on the front brack-
et using two 6-32 x 1"
screws. See Photo 2.
( ) Attach the two small rubber
STEP-BY-STEPASSEMBLY: Chassis, DC Power, PC