VAL Avionics COM 2KR Setup guide

VAL AVIONICS LTD
COM 2KR
Remote VHF Transceiver
Installation and Operator’s
Manual
Revision 3
March 2013
P/N 172201-3

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Revision History:
September 2012 – Initial Printing
December 2012 – Updated Appendix B wiring diagram to show RS-232 connection.
Added dimensional drawings of COM 2KR case.
Figure 1 updated to current design.
Figure 3 & 4 Removed, as they are no longer accurate.
March 2013- corrected typographical errors.
Corrected Table 4
Corrected Figure 3

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Table of Contents
1 SECTION I - GENERAL INFORMATION .....................................................................................................4
1.1 INTRODUCTION...........................................................................................................................................4
1.2 SCOPE ............................................................................................................................................................4
1.3 EQUIPMENT DESCRIPTION.......................................................................................................................4
1.4 FCC .................................................................................................................................................................5
1.5 SPECIFICATIONS .........................................................................................................................................6
1.6 EQUIPMENT SUPPLIED ..............................................................................................................................7
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED .......................................................................................7
1.8 LICENSE REQUIREMENTS.........................................................................................................................7
2 SECTION II - INSTALLATION .......................................................................................................................8
2.1 GENERAL INFORMATION .........................................................................................................................8
2.1.1 Scope .....................................................................................................................................................8
2.2 UNPACKING AND INSPECTION................................................................................................................8
2.3 EQUIPMENT INSTALLATION PROCEDURES .........................................................................................8
2.3.1 Cooling Requirements ...........................................................................................................................8
2.3.2 Mounting Requirements ........................................................................................................................8
2.3.3 Wire Harness Fabrication ......................................................................................................................8
2.3.4 COM 2KR Installation...........................................................................................................................9
2.4 POST INSTALLATION CHECK...................................................................................................................9
2.4.1 Operational Check .................................................................................................................................9
2.4.2 Final Inspection .....................................................................................................................................9
2.5 LIMITATIONS ...............................................................................................................................................9
3 SECTION III - OPERATION ..........................................................................................................................10
3.1 GENERAL INFORMATION .......................................................................................................................10
3.1.1 Scope ...................................................................................................................................................10
4 SECTION IV - WARRANTY AND SERVICE ..............................................................................................11
4.1 LIMITED WARRANTY ..............................................................................................................................11
4.2 SERVICE ......................................................................................................................................................11
5 Appendix A – INSTALLATION DRAWINGS AND CONNECTOR LAYOUT.........................................12
6 Appendix B – WIRING DIAGRAMS ..............................................................................................................14
7 Appendix C – Certifications .............................................................................................................................15
7.1 FAA Acceptability: .......................................................................................................................................15
8 Appendix D – INSTRUCTIONS FOR CONTINUED AIRWORTHINESS ................................................16
8.1 MAINTENANCE INSTRUCTIONS............................................................................................................16
9 Appendix E – RS-232 Command Interface .....................................................................................................17
9.1 Input Commands ...........................................................................................................................................17
9.2 Output Messages ...........................................................................................................................................17
9.3 Data Format...................................................................................................................................................17
9.4 Default Message Output................................................................................................................................17
9.5 Message Formats...........................................................................................................................................18
9.6 Message Definitions......................................................................................................................................19
9.6.1 Input Messages ....................................................................................................................................19
9.6.2 OUTPUT MESSAGES........................................................................................................................23
Table 1: Specifications .................................................................................................................................................6
Table 2: Equipment Supplied .......................................................................................................................................7
Table 3: Equipment Not Supplied ................................................................................................................................7
Table 4: Rear Connector Pin Functions......................................................................................................................13
Table 5 - Data Output Requests...................................................................................................................................19
Figure 1: Physical Dimensions ...................................................................................................................................12
Figure 2: P1 Connector Pin Out..................................................................................................................................12
Figure 3: COM 2K Basic Wiring Diagram..................................................................................................................14

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1 SECTION I - GENERAL INFORMATION
1.1 INTRODUCTION
Thank you for purchasing our COM 2KR – Remote VHF Transceiver. Here at Val Avionics Ltd., our core design
philosophy is based on the ease of installation and use. The COM 2KR represents 20 years of refinement in that
process, based on the feedback of customers that have used the COM 760. The COM 2KR takes the original idea of
the COM 760: a simple-to-use, reliable unit without the frills of other radios, and overhauls that idea with new and
exciting features.
That design philosophy translates into ease of installation and integration that makes the COM 2KR – VHF
Transceiver a communication solution specialized for operating with the latest EFIS system technology. The COM
2KR satisfies the need for compact, fully integrated, quality radio that can be counted on to provide years of
maintenance-free, reliable service.
Before installing and/or using your new COM 2KR please read this manual completely. This will ensure proper
installation and familiarize you with all of the features your COM has to offer.
1.2 SCOPE
This manual will provide detailed information about the installation and operation of the COM 2KR – Remote VHF
Transceiver. It will also provide equipment limitation information and instructions for continued airworthiness.
1.3 EQUIPMENT DESCRIPTION
The COM 2KR has been designed for integration with most major EFIS systems. Using the NEMA-0187
communications standard, the interface is compatible with the Garmin SL-30 command stack. Using state-of-the-art
technology Val Avionics Ltd. has created a radio that will provide the pilot with seamless and easy-to-operate
communications.
The COM 2KR simplifies installation into an aircraft by allowing installation anywhere. Using a standard RS-232
serial connection, the COM 2KR can connect to many available EFIS systems available today.
The COM 2KR has one internal receiver. The internal receiver operates from 118.00 MHz to 137.975 MHz. This
receiver is capable of receiving down to 2µV with a 6dB signal-to-noise ratio.
The COM 2KR has many audio inputs and outputs to facilitate any installation. The unit has two capacitively
coupled audio inputs for adding a Nav receiver audio output or other such audio device. The COM also has a 5W
speaker output and 50mW headphone output.

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1.4 FCC
The COM 2KR transceiver is a voice-modulated communications device utilizing amplitude modulation,
with a maximum power of 10W, operating in the 6K00A3E emission designator, with a 25kHz channel spacing.
This unit has been tested and found to comply with the limits for a Class B receiver, pursuant to Part 15 of
the FCC rules, as well as the emission requirements set forth in Part 87 of the FCC rules. These limits are designed
to provide reasonable protection against harmful interference when it is operated in an aircraft environment. The unit
generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the
instructions manual, may cause harmful interference to radio communications. Operation of the unit in a residential
area is likely to cause harmful interference in which case the user will be required to correct the interference at his
own expense.
FCC ID: EZN5PRCOM2KR

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1.5 SPECIFICATIONS
Table 1: Specifications
SPECIFICATIONS CHARACTERISTICS
Environmental: (RTCA/DO160D)
Minimum Performance Standard (RTCA/DO-186B)
Physical Dimensions:
Height .86 inches (2.54 cm)
Width 5.9 inches (15.88 cm)
Depth 10.1 inches (22.86 cm)
Weight: 2.0 pounds (1.5 kg)
Mounting: Ridged mounting, no shock mounting required
Temperature Range: -30 to +55 Celsius with short time operations at
+70 Celsius
Power Requirements:
Voltage 11.0 to 30.0 VDC
Current 0.5 Amp Rec. 3 Amp max transmit
Receiver:
VHF Frequency 118.00 to 136.975 MHz
Sensitivity 2 µV to provide a 6dB S+N:N
Channel Spacing 25 kHz
Stability ±.002%
Selectivity ≥60dB
Audio output 5W to 4ΩSpk 50mW to 600ΩPhone
AGC Characteristics From 10 µV to 200 µV the audio level will not
vary more than 3db.
Transmitter:
Carrier Power 8W nom. RMS
Duty Cycle 50%
Interface: RS-232
Baud Rate 9600
Manufacturer’s Model Number COM 2KR
Part Number VPN 0800106

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1.6 EQUIPMENT SUPPLIED
Table 2: Equipment Supplied
QTY DESCRIPTION PART NUMBER
1 COM 2KR – 760 Channel Radio 0800106
1 INSTALLATION KIT 651008
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED
Table 3: Equipment Not Supplied
QTY DESCRIPTION PART NUMBER
1 Circuit Breaker 5 amp Potter & Brumsfield PB W23
1 Aircraft Cabin Speaker Ref aircraft parts manual for
specific part number
1 Contact Crimping Tool w/
Positioning Tool
AMP P/N 601966-1
AMP P/N 601699-5
1.8 LICENSE REQUIREMENTS
There is no licensing requirement to operate the COM 2KR when installed and operated in accordance with this
manual.

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2 SECTION II - INSTALLATION
2.1 GENERAL INFORMATION
2.1.1 Scope
This section of the manual will provide the needed information to successfully complete the installation of your new
COM 2KR – Remote VHF Transceiver. Please read this section completely before proceeding with the installation
process. Although the COM 2KR installation procedures are designed with the do-it-yourselfer in mind, we at Val
Avionics Ltd. strongly suggest that you seek the advice of a qualified avionics installation facility before beginning
this or any other installation project. Qualified avionics installation technicians can offer good advice as to time-
tested installation practices and techniques that can save you many hours of time and frustration.
2.2 UNPACKING AND INSPECTION
Use care when unpacking the equipment. Inspect the unit and supplied parts for visual signs of damage during
shipment. Examine the unit for loose screws, dents, broken buttons and other signs of damage that may have
occurred during shipment. Verify the contents of the container with the list in section 1.5. If any damaged or missing
parts are discovered during the inspection save the shipping material and contact the freight carrier to file a claim. If
it is suspected that parts were omitted from the container please feel free to contact Val Avionics Ltd., to acquire the
missing items.
2.3 EQUIPMENT INSTALLATION PROCEDURES
2.3.1 Cooling Requirements
Forced air-cooling is not required for the COM 2K – VHF Transceiver. However, when planning the location for
mounting, ensure adequate spacing from heat producing sources such as heating or defrosting ducts.
2.3.2 Mounting Requirements
The COM 2KR should be rigidly mounted in the aircraft cabin using the hardware provided in the installation kit.
Ensure that the mounting location will provide easy access for future maintenance. Ensure that the mounting
position will provide adequate clearance between the unit and the associated wire harness and the aircraft controls.
Consult FAA Advisory Circular AC 43.13-2B for acceptable practices and techniques.
2.3.3 Wire Harness Fabrication
Val Avionics Ltd. Strongly recommends the use of a factory fabricated wire harness (VPN 751028) with your new
COM 2KR – Remote VHF Transceiver. Use of the factory fabricated wire harness will ensure proper operation of
the COM 2KR, reduction in the occurrence of interfering signals and ground loops, greatly reduced installation time,
and provide prolonged trouble-free performance of your new equipment.
Although strongly recommended, it is not required to use the factory fabricated wire harness when installing the
COM 2KR. A wiring harness can be fabricated in the field. Refer to appendix B of this manual for a complete
wiring diagram. The COM 2KR is connected to the aircrafts avionics bus via a 5 AMP circuit breaker. All wires
must be 22 AWG MIL-SPEC, unless otherwise noted in accordance with current regulations. Two and three

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conductor shielded MIL-C-27500 or equivalent wire must be used where indicated. Use AMP Contact Crimping
Tool (AMP P/N 601966-1) with Positioning Tool (AMP P/N 601699-5) or equivalent to ensure good quality
contacts. Refer to FAA Advisory Circular AC 43.13-2A for acceptable practices and techniques.
2.3.4 COM 2KR Installation
2.3.4.1 Mounting
The COM 2KR is rigidly mounted in the aircraft cabin or avionics bay. Once a location has been selected, a visual
inspection should be made of the area, which will be occupied by the COM 2KR and harness assembly for obvious
obstructions such as heater ducts, control cables, fuel and oil lines or any other obstruction. Pay particular attention
to any control systems. They should be moved to the full limit of travel and verified that sufficient clearance exists
prior to beginning installation. Mark and drill the mounting holes as required.
With the unit held in place, insert the four supplied 6-32 X 3/8” screws from the front and tighten as appropriate.
2.3.4.2 Antennas
One antenna is required for the COM 2KR installation. A standard COM antenna can be used with the unit such as a
COMANT CI-121 or equivalent. Follow the antenna manufacture’s installation Manual to ensure proper installation
of the antenna.
2.3.4.3 Audio
The COM 2KR has two auxiliary audio inputs and two audio outputs, Speaker audio and Headset audio. In
installations with two radio and/or more audio devices, it is strongly recommended that these audios be coupled to a
quality audio selector panel.
2.4 POST INSTALLATION CHECK
2.4.1 Operational Check
Refer to section three of this manual. Check all functions of the COM 2KR for proper operation. Check the
operational functions of other equipment installed in the aircraft in accordance with the individual manufacture’s
operation manuals to insure that no cross interference exists as a result of this installation.
2.4.2 Final Inspection
Verify that the wiring is bundled away from all controls and that no part of the installation interferes with the
movement of the aircraft controls. Move all of the aircraft controls through their full range of movement while
visually verifying that the installation does not mechanically interfere with the control movement. Verify that the
wiring harnesses are properly secured to the aircraft structure in accordance with accepted practices as described in
AC 43.13 and that adequate strain relief and service loops have been provided. Ensure that there are no kinks or
sharp bends in the wire harnesses. Verify that the wire bundles are not exposed to any sharp or abrasive surfaces.
Complete log book entries, weight and balance computations and other documentations as required.
2.5 LIMITATIONS
There are no known limitations to the operation of the COM 2KR. Instructions for Continued Airworthiness and
Return to Service Instructions can be found in Appendix C.

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3 SECTION III - OPERATION
3.1 GENERAL INFORMATION
3.1.1 Scope
This section will provide detailed operating instructions for your new COM 2KR – Remote VHF Transceiver.
All user interface functions are controlled by an external EFIS system over RS-232. Refer to your EFIS Systems
manufacture’s installation and operations manuals for complete installation and operation information.

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4 SECTION IV - WARRANTY AND SERVICE
4.1 LIMITED WARRANTY
The equipment delivered with this Standard Factory Warranty is manufactured by Val Avionics, Ltd. and is
guaranteed against defective materials and workmanship for two years from date of original retail purchase. Any
unit found to be defective due to material and workmanship during the warranty period will be repaired or replaced
at the sole discretion of Val Avionics Ltd.
Val Avionics, LTD liability under this warranty is limited to servicing, repairing or adjusting any equipment
returned prepaid to the Val Avionics’ factory by express written or verbal authorization for that purpose and to
repair or replace defective parts thereof.
If, upon examination, it is determined that a malfunction has been caused by misuse of the equipment, installation or
operation not in accordance with factory instructions, accident or negligent damage, alterations of any manner, and
repair by other than the factory, the repairs will not be covered under the warranty. In such cases, an estimate will be
submitted for approval before repair is initiated. In most cases, Val avionics, Ltd. will provide one week turn around
on its warranty and repair service. We recommend that contact be made with the FACTORY CUSTOMER
SERVICE DEPARTMENT prior to any unit return and obtain RETURN AUTHORIZATION AND
INSTRUCTIONS. This will provide proper control and expedite service.
Val Avionics, Ltd. reserves the right of continuous product development without obligation to install changes in
previously manufactured products.
Installation of Val Avionics, Ltd. products must conform to methods acceptable by the Federal Aviation
Administration as described in the appropriate Federal Aviation Regulations (FAR’s) and Advisory Circulars
(AC’s).
4.2 SERVICE
Repair service for the COM 2KR – Remote VHF Transceiver is available at our manufacturing facility. Units in
need of servicing should be returned prepaid to Val Avionics Ltd at the following address.
Val Avionics
2950 Pringle Roasd SE
Salem, OR 97302

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5 Appendix A – INSTALLATION DRAWINGS AND
CONNECTOR LAYOUT
Figure 1: Physical Dimensions
Figure 2: P1 Connector Pin Out

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Table 4: Rear Connector Pin Functions
Pin
Functoin
I/O
1 RS-232 In Input
2 Aux In 2 Input
3 Speaker Ground
4 Headphone Ground
5 Mic Ground
6 Key Input
7 Main Ground Input
8 Main Power Input
9 RS-232 Out Output
10 Aux In 1 Input
11 Speaker Output
12 Headphone Output
13 Mic Audio Input
14 NC
15 NC

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6 Appendix B – WIRING DIAGRAMS
Figure 3: COM 2K Basic Wiring Diagram

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7 Appendix C – Certifications
7.1 FAA Acceptability:
This device has been tested and found to meet the specification of TSO-C169a (RTCA; DO-186B, DO-160E, DO-
178B DO-254).

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8 Appendix D – INSTRUCTIONS FOR CONTINUED
AIRWORTHINESS
8.1 MAINTENANCE INSTRUCTIONS
Maintenance of the COM 2KR – Remote VHF Transceiver is on condition only. No periodic maintenance is
required. If unit is found to be out of calibration, send unit in for service. If unit is removed for service, upon re-
installation perform Post Installation check as described in section 2.4 of this manual.

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9 Appendix E – RS-232 Command Interface
This appendix includes the interface specifications for the RS-232 serial port. The RS-232 port can be used
to input active and standby frequencies as well as using an external serial resolver such as an EFIS system.
The interface format conforms to NMEA 0183 message format specifications. For improved compatibility,
the COM 2000 / COM 2KR accepts all commands for the INS 429 / NAV 2000 / NAV 2KR
9.1 Input Commands
The following input command messages are supported:
• Request data output
• Set active COM frequency data from a remote source
• Set standby COM frequency data from a remote source
• Set COM Volume and Squelch Level
• Set COM Mic Gain and Sidetone
9.2 Output Messages
The COM 2000 / COM 2KR output messages include:
• Reset status
• Communications Error
• COM Receiver status
• COM audio mode
• COM microcontroller software version
• COM Volume and Squelch Level
• COM Mic Gain and Sidetone
9.3 Data Format
The data format for serial communication is:
• Baud rate 9600
• Data bits 8
• Stop bits 1
• Parity none
9.4 Default Message Output
At system start when the COM 2000 / COM 2KR is configured to operate in normal mode, the following
messages will be configured for output and the specified rates:
• COM Receiver status at 1 Hz (low rate)
These default rates can be changed by using the Request Data Output message.

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9.5 Message Formats
All messages will conform to the NMEA 0183 proprietary message format as follows. All characters will
be standard ASCII characters. No binary data characters will be used.
“$”.....................................Start of message character, ASCII “$” (024h)
“P”.....................................Proprietary message identifier
“MRR” ..............................II Morrow company identifier
c.........................................Message class identifier. Used to identify a message as either a
COMM of VHF NAV message. Those message types, which are also
supported by the VAL COM 2000 VHF Transceiver, will use the “C”
identifier to allow the INS 429 to accept COMM radio commands from
existing products. All other messages will use the “V” identifier to
indicate that they relate to a VHF NAV receiver.
nn ......................................Message identifier, two-digit number in ASCII characters.
d…d ..................................Message data characters defined for each message.
chksum ..............................Message checksum, including message identifier through data
characters. The two-digit checksum is generated by adding all values
of valid characters together, ignoring carry (if any). This value is
converted into two encoded hex
1
characters (30h-3Fh).
<CR>.................................ASCII carriage return (0Dh)
<LF> .................................ASCII line feed (0Ah)
The maximum message length, including the start of message character (“$”) and the end of message
<CR><LF> sequence, is 25 bytes.
This message format is the same as is used in the INS 429 / NAV 2000 / NAV 2KR. The COM 2000 /
COM 2KR will be able to accept all messages intended for a INS 429 / NAV 2000 / NAV 2KR without
generating a serial communications error. It will ignore all of those messages. Those messages have been
included for completeness.
1
Encoded Hex: each character consists of 4 bits of data placed in the low order nibble +30h. For example, the 8-bit
value of 5Fh would be encoded as two characters with values of 35h and 3Fh, which map to the ASCII characters
“5” and “?” respectively.

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9.6 Message Definitions
9.6.1 Input Messages
REQUEST DATA OUTPUT
This input is used to request an output message to be sent by the INS 429 / COM 2000.
Message format:
“V” ...............................Message class. This is a VHF NAV message.
“24” ..............................Message identifier.
ii ....................................Output identifier of requested message, two ASCII characters.
dd...................................Message data, two encoded hex
2
characters (30h-3Fh), used for specific output
request. Set to “00” if not needed. These characters are used for such items as
selecting a specific EEPROM address to output.
A....................................Request type: (ASCII) “0”= output repeatedly at low speed (1 Hz); “H” = output
repeatedly at high speed (10 Hz).
ii Output Dd Data Description a
“20” Reset Status “00” “0”
“21” CDI, GSI, and Flags “00” “0”, “L”, “H”
“22” Decoded OBS Setting “00” “0”, “L”, “H”
“23” Radial from Active VOR “00” “0”, “L”
“28” Receiver Status “00” “0”
“30” NAV Microntroller Software Version “00” “0”
“32” ADC Data Output cc ADC channel: “00”
to “08”
“0”
“35” Comm Transceiver Status “00” “0”
“36” Comm Software Version “00” “0”
“71” Comm Volume and Squelch “00” “0”, “L”
“72” Comm Mic Gain and Sidetone “00” “0”
Table 5 - Data Output Requests
Example messages:
$PMRRV242100L<chksm><CR><LF>
Request periodic output of CDI, GSI, and related flags at low (1Hz) rate.
$PMRRV2432050<chksm><CR><LF>
Request a single output of ADC data from channel 5.
2
Encoded Hex: each character consists of 4 bits of data placed in the low order nibble +30h. For example, the 8-bit
value of 5Fh would be encoded as two characters with values of 35h and 3Fh, which map to the ASCII characters
“5” and “?” respectively.

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SET ACTIVE VOR/LOC FREQUENCY AND RECEIVER FUNCTION
This message is used to set the standby VOR or Localizer frequency as well as the receiver operating
function. The INS 429 can detect if the supplied frequency corresponds to a VOR or a Localizer channel,
so this command will work for both types of NAV aids.
Message format:
$PMRV27E4N<chksm><CR><CR><LF>
This example command would set the active VOR frequency to 117.100 MHz. This can be interpreted by
noting that the ASCII ‘E’ corresponds with 45h, + 30h = 75h, converted to decimal equals 117 for the MHz
portion of the command. The kHz portion converts ASCII ‘4’ to 34h, - 30h = 4h, x 25 kHz steps = 100
kHz. This command would also set the receiver function to normal, leaving the standby channel inactive.
Note: The INS 429 will check input frequencies for validity. An RS-232 serial error message output will be
generated if the frequency is invalid.
SET STANDBY VOR/LOC FREQUENCY AND RECEIVER FUNCTION
This message is used to set the standby VOR or Localizer frequency as well as the receiver operating
function. The INS 429 can detect if the supplied frequency corresponds to a VOR or a Localizer channel,
so this command will work for both types of NAV aids.
Message format:
“V”………..Message class. This is a VHF NAV message.
“28”………Message identifier.
mk………..Standby VOR/LOC frequency:
m = desired frequency in MHz in hexadecimal, where m = desired frequency – 30h,
with desired frequency in range of 108 to 117 MHz.
k= desired frequency in kHz, where k = (desired frequency / 25 kHz) + 30h,
desired frequency in range of 000 to 975 kHz in 50 kHz steps, or the even numbers
from 30h to 56h.
a………….Receiver function: N = normal, 0 = unchanged.
Example message:
$PMRRV28?PN<chksm><CR><LF>
This example command would set the standby VOR frequency to 111.800 MHz. This is interpreted by
noting that the ASCII ‘?’ corresponds with 3Fh, + 30h = 7Bh, converted to decimal equals 111 for the
MHz portion. The kHz portion converts ASCII ‘P’ to 50h, -30h, -30h yields 20h, x 25 kHz steps = 800 kHz
portion. This command would also set the receiver function to normal, so the receiver would receive only
the active VOR channel.
Note: The INS 429 will check input frequencies for validity. An RS-232 serial message output will be
generated if the frequency is invalid.