VAL AVIONICS LTD
AWOS 2000
VHF Transmitter
Maintenance and Repair
Manual
Revision 1
April 2012
P/N 172211
VAL AVIONICS LTD
VAL AVIONICS LTD
VAL AVIONICS LTDVAL AVIONICS LTD
AWOS 2000
AWOS 2000 –––– VHF TRANSMITTER
AWOS 2000 AWOS 2000
MAINTENCE AND REPAIR MANUAL
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MAINTENCE AND REPAIR MANUALMAINTENCE AND REPAIR MANUAL
VHF TRANSMITTER
VHF TRANSMITTER VHF TRANSMITTER
Table of Contents
1 Introduction .............................................................................................................................3
1.1 General Description .........................................................................................................3
1.2 Detailed Description.....................................................................................................3
1.2.1
Main Board Assembly ..............................................................................................4
1.2.1.1 Microcontroller ........................................................................................................4
1.2.1.2 Power Supply Circuits ..............................................................................................5
1.2.1.3 Modulation Control..................................................................................................5
1.2.1.4 RF TX Generator .......................................................................................................6
1.2.2
Transmitter Board....................................................................................................7
2 Troubleshooting.......................................................................................................................8
2.1 Troubleshooting Equipment Required.............................................................................8
2.2 Initial Troubleshooting Operations..................................................................................8
2.3 Power Supply Check.........................................................................................................8
3 Disassembly Instructions .........................................................................................................9
3.1 Removal of the Covers.....................................................................................................9
3.2 Board and Module Disassembly ......................................................................................9
3.2.1 Main Board Removal........................................................................................................9
3.2.4 Transmitter Board Removal.............................................................................................9
3.3 Reassembling the Unit ...................................................................................................10
4 Service and Testing ................................................................................................................10
4.1 Initial Alignment / Return to Service..............................................................................10
4.1.1
Test Equipment Required ......................................................................................10
4.1.2
Setup ......................................................................................................................10
5 Appendix ................................................................................................................................13
5.1 Table of Parts .................................................................................................................13
5.2 Specifications .................................................................................................................13
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AWOS 2000
AWOS 2000 –––– VHF TRANSMITTER
AWOS 2000 AWOS 2000
MAINTENCE AND REPAIR MANUAL
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MAINTENCE AND REPAIR MANUALMAINTENCE AND REPAIR MANUAL
VHF TRANSMITTER
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1 Introduction
This manual is intended to provide instructions and guidelines for the
maintenance and repair of the VAL AWOS 2000.
WARNING: This unit contains static sensitive devices. Service personnel must
ensure that proper precautions are taken to prevent damage to this equipment
from electrostatic discharge (ESD). Disassembly and repair should only be
accomplished in an approved ESD workstation, and performed by properly
trained and grounded personnel.
1.1 General Description
The AWOS 2000 is a full-featured VHF transmitter designed for fixed remote
installation. The AWOS 2000 uses a two-stage transmitter. The user interface
consists of DIP-switches to control the active frequency and three adjustments
for controlling power, modulation and frequency. The unit case is constructed
from milled aluminum; the boards are constructed using high quality materials
and use the latest techniques in manufacturing technology.
In order to achieve the desired reliability, size, and power requirements, surface
mounted components are used extensively. Specialized equipment and
procedures are required to repair circuit boards having surface mounted
components. Val Avionics LTD. does not authorize the repair of AWOS 2000
circuit boards. All circuit boards and assemblies from the AWOS 2000 can be
economically replaced if necessary.
The following modules and printed circuit board assemblies are available for
replacement:
Main Board:
Printed circuit board, which contains the microcontroller, power supply circuitry,
and audio components.
Transmitter Board:
Contains the two-stage transmitter.
1.2 Detailed Description
Internally the AWOS 2000 is divided into two printed circuit boards: the main
board and transmitter. The block diagram in Figure 1 below shows the
relationships between the major circuits and modules within the AWOS 2000.
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1.2.1 Main Board
Assembly
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The main board assembly
contains the microcontroller,
power supply, audio circuitry
and RF TX generator.
1.2.1.1 Microcontroller
This board contains a microchip
PIC16F818 microcontroller
featuring 1kB of EEPROM
memory running at 8MHz.
Other circuits on the board are
used for input/output functions
such as controlling the
frequency and controlling the
transmitter boards.
The block diagram in Figure 2
below shows the interaction
between the various main
board circuits.
J4 – DB9 Connector
RF Connector
MainTransmitter J3 / X1 / X3 / X5
XMIT LO
Figure 1: AWOS 2000 Block Diagram
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AGC Sense
From TX
To Transmitter
J3/X1/X3/X5
Synthesizer
To J4
Audio
Input
Modulation
Control
Modulation
XMIT
Power
VCO Enable
TX
To J4
XMIT
Key
XMIT Enable
MAIN CPU
Internal frequency
– 8MHz
5V DC
5V Power
Supply
(0Hz)
12V DC
12V Power
Supply
(300kHz)
To Transmitter
XMIT LO
118 – 137MHz
Figure 2: AWOS2000 Mainboard Block Diagram
1.2.1.2 Power Supply Circuits
The power supply section of the main board supplies 12V for the transmitter and
5V for the microcontroller and audio circuitry. The unit is turned on and off by a
digital circuit operated by the left rotary encoder push button. The 12V power
supply is a self-contained module that outputs 12V ±10%. The 5V power supply
is also a linear regulator that outputs 5V ±5%.
1.2.1.3 Modulation Control
The audio section of the main board receives the audio input and regulates the
output to the transmitter board.
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1.2.1.4 RF TX Generator
The RF TX generator consists of a frequency synthesizer and high-precision
crystal oscillator. The frequency synthesizer uses the high-precision oscillator as
a reference frequency for the phase detector in the synthesizer. The resulting
frequency is used to drive the transmitter board. The RF TX generator is
contained within a shielding fence/cover and connection to the transmitter board
is made via a RG-174 cable.
The block diagram in Figure 3 shows the interaction between components in the
RF TX generator.
12MHz Crystal
Reference
LMX1601
Synthesizer
Vtune
FB
IF1 VCO
XMIT LO
Figure 3: TX LO Generator Block Diagram
118.000MHz -
136.975MHz
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1.2.2 Transmitter Board
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The transmitter receives RF signals from
the main board to the first stage of the
transmitter. The signal is amplified
through the first stage to drive the gate of
the final. The RF signal from the second
stage is mixed with the microphone audio
signal from the main board to drive the
final and produce the amplitudemodulated signal. The resulting signal is
then monitored by a diode demodulator to
provide a DC signal back to the
mainboard to control the power output
across the temperature range of the unit.
RF Connector
137MHz
Filter
TX AGC
137MHz
Filter
X5
Modulation
IN
AGC Out
J3 / X1 /
X3 / X5
-3dB
+20dB
-3dB
118-137MHz
Figure 4: AWOS 2000 Transmitter Block
Diagram
XMIT LO
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2 Troubleshooting
2.1 Troubleshooting Equipment Required
• 0 to 30V DC/5 amp power supply
• Digital multimeter
• 20MHz oscilloscope
2.2
Initial Troubleshooting Operations
The first step in troubleshooting the AWOS 2000 is to remove the cover
assembly (see Section 3.1) and verify the unit as being properly powered.
2.3 Power Supply Check
1. Check the DC voltage between U119 pin 3 and ground. The voltage
should be between 4.5 and 5.5V. If the voltage is out of limit specified
replace the main board.
2. Check the DC voltage between L107 and ground. The voltage should be
between 11 and 13V. If the voltage is out of limit specified replace the
main board.
2.4
PROBLEM RECOMMENDED ACTION
Unit will not power on
Weak or garbled transmit
Troubleshooting Chart
Check external power connection
Send unit for Service
Replace antenna and/or antenna cable
Send unit for Service
Weak or no modulation
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Adjust modulation setting
Replace antenna and/or antenna cable
Send unit for Service
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3 Disassembly Instructions
To avoid damaging the AWOS 2000’s circuit boards and assemblies the
following procedures should be carefully followed. Assembly drawings are
included in Section 5 for reference.
3.1 Removal of the Covers
1. Remove all external power and sources before disassembly.
2. From the top the unit remove the 21 4-40 x ¼” (p/n 5010xx) screws
retaining the top heatsink.
3. Remove the top cover by lifting it upwards.
3.2 Board and Module Disassembly
3.2.1 Main Board Removal
1. Remove the covers as described in Section 3.1.
2. Remove the 2 4-40 x ¼” nuts retaining J104 on the rear of the unit
3. Remove the 6 2-56 x ¼” panhead screws from the main board.
4. De-solder the coax cable from J105
5. Carefully slide the main board upward, pulling it away from the transmitter
boards.
3.2.4 Transmitter Board Removal
1. Due to the complexity of removing the transmitter board, if the transmitter
board is found to require servicing, it is recommended that the entire unit
be sent to Val Avionics for service.
2. Remove the covers as described in Section 3.1.
3. Remove the main board as described in Section 3.2.2.
4. De-solder J302.
5. De-solder and remove J304.
6. Remove the 12 2-56 x ¼” pan head screws from the transmitter board.
7. Remove the 2 4-40 x ¼” roundhead screws from Q304.
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8. Lift the transmitter board from the unit.
3.3 Reassembling the Unit
1. Reverse the disassembly instructions for the modules that have been
disassembled.
4 Service and Testing
4.1 Initial Alignment / Return to Service
After completing all necessary maintenance and/or service, the following test
procedure is provided to ensure that all AWOS 2000 functions are operating
properly.
4.1.1 Test Equipment Required
• A 0 to 30V DC/ 5 amp power supply
• AWOS 2000 installation/mounting harness
• Digital multimeter
• Oscilloscope 20 MHz minimum
• Radio service monitor (IFR 1200S recommended)
• Standard radio headset
4.1.2 Setup
• Pre-set the power supply to +13.75V DC.
• Connect the positive output of the power supply to the red power-in wire
on the harness.
• Connect the negative output of the power supply to the black wire on the
harness.
• Connect the wiring harness to J101.
• Connect the headset to the microphone and headphone jacks.
• Connect the RF input to the service monitor.
• Apply power to the system.
• Monitor the power and voltage with the digital multimeter and set the
power supply to +13.75V DC.
• If unit is not already on set the power switch to turn the unit on.
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4.1.3 Transmitter Alignment and Test
• Set the DIP-switches to 118.900 MHz.
• Adjust R427 (Power Adj.) to midpoint.
• Reduce R308 to minimum by turning the flathead screws attached
counter-clockwise until you hear a click.
• While monitoring with the digital multimeter with the unit transmitting,
increase R308 to 2V by turning the flathead screws clockwise.
• Verify that the current supplied by the external power supply is less than 2
amps.
• Increase R308 until the output power is 2.5 watts at 118.900 MHz. If the
voltage from R308 is greater than 4 Volts unit needs service.
• Adjust R423 (Mod %) to 30% with the supplied audio.
• Verify that there are no spurs across the band using a spectrum analyzer.
• When reinstalling at a site, please follow the AWOS 2000 Owners /
Operators Manual for final calibration instructions.
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Table 1: Rear Connector Pin Functions
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PIN
TERMINAL
1
2
3
4
5
6
7
8
9
FUNCTION
GROUND (AUDIO RETURN)
POWER INPUT (+13.75 Vdc)
POWER INPUT (+13.75 Vdc)
TRANSMITTER KEY
GROUND
GROUND (KEY RETURN)
GROUND
No Connection
AUDIO IN
Figure 5: AWOS 2000 Controls
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5 Appendix
5.1 Table of Parts
The AWOS 2000 contains no field serviceable parts. Please contact Val Avionics for
repair.
5.2 Specifications
Physical Dimensions: Width: 5.9 inches
Height: 2.3 inches
Length: 7.45 inches
Weight 3.0 Lbs.
Voltage: 13.75 ± 0.5 Vdc
Current: Standby 250 mA; Transmit 2.0 A
Frequency Range: 118.000 to 136.975 MHz
Channel Spacing 25 kHz
Frequency Stability: . 001%
Spurious Emissions Greater Than 80 dB down from carrier
Modulation Adjustable (50 to 90% Typical)
Temperature Range -35 to +55 Celsius
Transmit Power: 2.5 watts
Emission 6K 00A3E
Duty Cycle 100%
Design All Solid State. Printed Circuit Board & Point to Point Wiring.
Mounting Rigid Mounting, No Shock Mounting Required.
FCC ID EZN5PRAWOS2000
Unit Part Number 0800202
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