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5. 14 or 28V Extensive damage may result from improper grounding and is not covered under warranty Back Lighting Models 610 1200 only The gas plasma display dims automatically with reductions in ambient light For models 610 and 1200 back lighting is provided by connection to any aircraft dimmable DC lighting source The instrument automatically configures itself for 14 or 28V dimming bus voltage Refer to Drawing No 1200 017 on Page 22 EGT Probe Wiring The temperature probes must be wired with the correct polarity The EGT probes connect to the harness wires with the yellow jacket The probe leads and harness wires are color coded red and yellow to facilitate correct polarity Each wire is marked with the cylinder number Slide the wire marker down the wire so it remains with the installation for trouble shooting Strip the wires according to Drawing No 8254 on Page 19 and terminate with the crimp on terminals provided Verify the quality of each crimp with a sharp pull on the wire The terminal should be almost impossible to pull off when crimped correctly Harness and probe wire colors should match as in Drawing No 8254 on Page 19 NOTE The ring terminals may be crimped with a service type tool however AMP part number 47386 is recommended Be sure to test each crimp by pulling on the wire to en sure it won t come out The most common installation problems are the result of poor qual ity termination Page 7
6. on top in some engines The Spark Plug Gasket Probe Part Number 2853 replaces the copper 18 mm diameter spark plug gasket The Bayonet Adapter Probe Part Number 2855 screws directly into the temperature well and replaces the standard bayonet adapter to allow simultaneous utilization of the factory installed Bayonet Probe The Threaded Adapter Probe Part Number 2856 is similar to the 2855 except it is thread ed on the inside to allow simultaneous utilization of the factory installed Threaded CHT Probe Page 3 series Installation Manual Drawing 8258 Version 3 0 1 Installing The Turbine Inlet Temperature Probes Models 603 610 1200 only There are three types of Turbine Inlet Temperature TIT probes which can be used with the GEM series systems Clamp Type TIT Probe Part number 2871 is identical to the EGT probe except that the clamp diameter is larger Threaded Type TIT Probe including a weld on boss Part Number 2872 Threaded Type 1 4 NPT TIT probe Part Number 2873 For aircraft with a threaded fitting boss already welded to the turbine inlet the two threaded type probes are used part number 2872 7 16 20 Thread and part number 2873 1 4 NPT Thread as applicable The 2872 Threaded fitting can be installed on any aircraft when a more permanent installation is desired or when space for the clamp type probe is limited Probe Type 2872 fits in a 1 2 inch hole and should be welded by an app
7. potting substance prior to tightening NOTE Be careful not to get potting substance on the connector Page 5 series Installation Manual Drawing 8258 Version 3 0 1 Wiring Considerations The GEM series system is supplied with a factory assembled wiring harness configured for the specified number of cylinders The harness edge connector contains a polarization pin which mates with a slot in the display s printed circuit board This prevents improper en gagement of the connector Before installing confirm that the factory fabricated harness connector matches wiring dia gram Drawing 8255 All the red thermocouple wires should be on one side of the connec tor The GEM series Display circuit boards are supported during shipment by small anti static shipping restraints Leave these restraints in place during the installation of the display and remove only prior to inserting the harness edge connectors Unlike most other EGT and CHT installations the probe wire length is not critical and may be trimmed to any length as required to fit each probe Note Plan your Installation to include a service loop in the GEM wiring harness to allow for future adjustments CAUTION Splicing of the thermocouple wire is not recommended Display Wiring Power Connections All models The GEM series Display automatically accommodates both 14 and 28 Volt electrical sys tems Connect the red power lead to a separate trip free re settable
8. v NOIL diai2 30 asa Page 24 GEM series Installation Manual Drawing 8258 Version 3 0 1 APPENDIX WEIGHT and BALANCE DATA Quantity Weight Display Unit GEM 602 or 603 Display Unit GEM 610 EGT Clamp Probes CHT Spring Probes 5 CHT Spring Probes CHT Gasket Probes 1 iN N o Adapter Probe 1 1 EN 24 Ft Wiring Harness 31 0 876 IAT OAT Probe 3 5 9 Page 25 GEM series Installation Manual Drawing 8258 Version 3 0 1 If you have difficulty installing or using a GEM system please read the GEM s documenta tion Every GEM system is shipped with complete instructions for installation and use The answers to many technical questions can be found in this booklet or the GEM Installation Manual Insight provides customer support free of charge for as long as you own the instru ment If you have any questions concerning GEM operation do not hesitate to call The Customer Service department accepts calls Monday through Friday between 9 am and 5 pm EST Be sure to have your instrument model number and serial number s ready when you call GEM Model No GEM Serial No Aircraft Type HPLX Technical Support Answers to questions about the use of the HPLX s built in applications FILER 123 Spread sheet etc are found in the HPLX User s Guide and HPLX Quick Start Guide Telephone numbers for Hewlett Packard are in the HPLX s
9. Air Temperature IAT probe must be mounted in a location in which there is free ambient air Avoid locating the probe adjacent to ventilation ducts near windows or near the windscreen Select an area of air circulation no direct sunlight and where the pilot wants to know cabin temperature Refer to Drawing No 1200 016 on Page 21 for the mounting dimensions and appropriate hole size for drilling purposes Mount the IAT probe in the prepared hole and secure the nylon nut being careful not to overtighten Installing The Outside Air Temperature Probe Models 610 and 1200 only The Outside Air Temperature OAT probe must be mounted in a location which is in free ambient air Avoid locating the probe adjacent to exhaust pipes in a confined area or on the top of the fuselage Refer to Drawing No 1200 016 on Page 21 for the mounting di mensions and appropriate hole size to drill Any location where the probe is exposed to direct sunlight or radiant heat from the runway pavement will cause increased temperature readings above ambient temperature Mount ing the probe near the engine induction air filter will often read well as soon as the engine is started Mount the OAT probe in the prepared hole and secure the nylon nut being careful not to over tighten If the OAT probe is installed on a pressurized aircraft where bulkhead penetration is neces sary and or potting of the OAT probe is required be certain to apply Proseal or equivalent
10. Monitor Display Carefully inspect the contents of this package for damage If damage is found save all packaging so that a claim can be made against the carrier Inspect the contents of the shipment to ensure that all component parts and materials have been supplied Visually inspect all components for proper identification or damage Immediately report any discrepancies to the Insight Customer Service Department Page 1 GEM series Installation Manual Drawing 8258 Version 3 0 1 Installation Planning Plan the location of the display such that it is not positioned near any source of high cur rent and is easily visible by the pilot The engine harnesses should be positioned away from sources of high energy such as ignition harnesses P leads alternator wiring and high frequency radio antennas Some thought about the process and steps needed may save hours of installation time and trouble shooting Tools and Materials Required Proper wire stripping and crimping tools Trip free resettable Circuit breaker amp SHY 1AMP 602 603 2AMP 610 1200 INSTALLING THE GRAPHIC ENGINE MONITOR Installing the Display Models 602 603 and 610 displays mount in a 2 25 inch diameter display cutout while Model 1200 mounts in a 3 125 inch diameter display cut out Care should be given to pro vide sufficient depth allowance for harness and cable routing at the rear of the display See Drawing 930309 on Page 24 for displa
11. at least 1 inch away from the ignition harness P leads and alter nator wiring Some aircraft produce electrical noise which will cause erratic indications Pagel GEM series Installation Manual Drawing 8258 Version 3 0 1 Warranty policy The Insight Instrument Corporation s Graphic Engine Monitor temperature display unit is war ranted against defects in materials and workmanship for two years from date of purchase Insight Instrument Corporation s temperature probes are warranted for one year from date of purchase or 1000 hours whichever comes first Insight will at its option repair or replace without charge those products that it finds defec tive Material returned for repair or replacement will be returned prepaid by second day freight Insight will not be responsible for repairs that result from improper installation unauthorized maintenance or abuse Insight is not liable for consequential damages or any labor costs either directly or indirectly No other warranty is expressed or implied Page ll GEM series Installation Manual Drawing 8258 Version 3 0 1 Table of Contents IF YOU READ NOTHING ELSE READ THIS MODELES G02 GOO 5 unan m sau a mia aa a MODELS 602 603 610 1200 ense ditte to uten isi se ede WARRANTY POLICY uu augu a a E Qy aasawa
12. completely before starting Insight Instrument Corporation s GEM Series of Graphic Engine Monitors provides simulta neous analog and on some displays digital display of engine temperatures for nearly all makes and models of piston powered aircraft These displays are designed for rugged use However since they are constructed of computer type components standard precautions for electronic equipment are required Do not expose to rain or water Handle with care DO NOT DROP Be sure that all electrical connections are correct and properly made Follow anti static procedures Temperatures are sensed through thermocouple type probes which are installed in the engine and other areas for temperature data gathering These probes are crucial to the proper and accurate operation of the GEM display Therefore utmost care must be exer cised during installation in the aircraft Models 602 and 603 configure themselves automatically for 4 or 6 cylinder engines The GEM Models 610 and 1200 displays are configured with the Hewlett Packard Palmtop Computer using Insight s GEMCOM software The configuration is easily transferred into the 610 1200 Series display using a wireless infrared interface contained within the display and the Palmtop computer Details about how to configure the 610 1200 are described later For a comprehensive description of functions and features consult the GEM GEMINI Pilot s Guide Unpacking the Graphic Engine
13. manuals Educational Video To assist our customers in installing and using GEMs Insight has produced an educational video CD entitled Modern Engine Management Our video is available free of charge Call or write to obtain your personal copy of this classic production Service Procedures Like many modern electronic devices the Graphic Engine Monitor is extremely reliable Other than configuration during installation the GEM requires no adjustment or routine maintenance Should you suspect a malfunction perform the self test described under Test Mode If the GEM fails this test it must be returned to the factory for service If the instru ment performs the self test successfully discuss the problem with your dealer or consult the troubleshooting section of the GEM Installation Instructions Keep in mind that in the vast majority of cases erratic or unusual GEM operation can be traced to an installation problem a problem with probes wiring harness or the aircraft s electrical system The instrument itself is the least likely source of trouble For this reason we encourage you to contact Insight Customer Service at one of the numbers listed below before returning an instrument to the factory or any time you have any questions concerning the operation of the Graphic Engine Monitor Technical Support Contact Phone Numbers 905 871 0733 Web www insightavionics com Page 26
14. the meter probes Symptom No CHT in one or more columns Cause Faulty probe Swap probes to isolate fault to probe Swap connections with a known good probe to isolate the fault to the harness terminal crimp or GEM series Display If an EGT probe is completely inoperative the CHT reading will appear as a single bright bar where the dark bar would normally appear Page 13 GEM series Installation Manual Drawing 8258 Version 3 0 1 Symptom No CHT in one or more columns Cause Faulty probe Swap probes to isolate fault to probe Transpose connections with known good probe to isolate the fault to the harness terminal crimp or Display Symptom Display goes out during engine start Cause Voltage transient or over voltage condition The Display should not be turned on during engine start An Avionics Master or separate power switch should be installed to ap ply power to the Display Symptom Display is unstable Cause Noisy or defective magneto or ignition harness Check operation on left and right magnetos The temperature should rise slowly and may stabilize slightly or completely on one or the other magneto Single magneto operation will pinpoint the problem to one igni tion harness unless both are faulty Verify that the probe wires and GEM series system har ness are isolated from the ignition harness If necessary repair or replace the faulty ignition harness to eliminate ignition related interference Symptom Displa
15. 3 15 p oVdecc 16 24 Pici Bp HERE 25 26 WEIGHT AND BALANCE DATA tin ni rita ict A ee RE v aan aii anne 25 TECHNICAL SUPPORT ua tege beat 26 HP PALM TOP COMPUTER TECHNICAL SUPPORT 3 26 EDUCATIONAL VIDEO rette tee E etg ete oed etai t ode mel dee bn geb adde pet dea 26 SERVICE aaa 26 Table of Drawings DRAWING 8252 GEM CONNECTIONS FOR CONTINENTAL ENGINES 17 DRAWING 8253 GEM CONNECTION FOR LYCOMING ENGINE 18 DRAWING 8254 GEM PROBE 19 DRAWING 8255 GEM WIRING 20 DRAWING 1200 016 GEM GEMINI IAT OAT PROBE MOUNTING DETAIL 21 DRAWING 1200 017 GEM GEMINI DB15 INTERCONNECT DIAGRAM 22 DRAWING 1200 018 GEM GEMINI WIRING DIAGRAM 2 23 DRAWING 930309 GEM GEMINI DISPLAY OUTLINES 2 2 ee 24 Page IV GEM series Installation Manual Drawing 8258 Version 3 0 1 INTRODUCTION This Installation Manual will acquaint you with the installation requirements operational functions and some of the powerful features of these advanced Graphic Engine Monitoring systems Please read it carefully and
16. 610 1200 with the alternator charging remove the GEM series ground and provide an extension directly to the engine block If this solution fixes the problem a ground fault exists between the engine and air frame which should be remedied Symptom Display indicates full scale or blanks out Cause This can be symptomatic of an intermittent ground fault between engine and air frame See All EGT readings too high Symptom Software version number ex 118 shown continuously on Display Cause Problems detected in GEM system during or after self test Contact Insight Product Support for service information or instruction Page 15 GEM series Installation Manual Drawing 8258 Version 3 0 1 Drawings Drawing No Revision Title Date E GEM CONNECTIONS FOR CONTINENTAL ENGINES 860331 E GEM CONNECTIONS FOR LYCOMING ENGINES 860331 GEM PROBE CONNECTIONS 860331 C GEM WIRING DIAGRAM 860331 C GEM GEMINI DB15 INTERCONNECT DIAGRAM 921201 C GEM GEMINI WIRING DIAGRAM 921204 930309 EN GEM GEMINI DISPLAY OUTLINES Appendix 031114 GEM GEMINI IAT OAT PROBE MOUNTING DETAIL 930601 Page 16 GEM series Installation Manual Drawing 8258 Version 3 0 1 2661 PEE daana ia GNNOYD NV OL 0001 ININ3D 019 W39 Jonuepyuco pub UonoodIeD iueurusul ASVOMNVYD ANIONS JHL Ol 09 209 W39 p 1u teu jo Ayedosd s sru 9WG
17. CHECK WIRING HARNESS BEFORE INSTALLATION It s easier cheaper to check and recheck all harness s and connections than repairing them later GEM SERIES INSTALLATION MANUAL Graphic Engine Monitors Models 602 603 610 1200 READ THESE INSTRUCTIONS COMPLETELY BEFORE PROCEEDING WITH INSTALLATION Insight Instrument Corporation Box 194 Buffalo NY 14205 0194 Tel 905 871 0733 Fax 905 871 5460 Web www insightavionics com Copyright 1992 1993 1996 Rights Reserved DRAWING 8258 VERSION 3 0 1 May 1996 E EB s B NN NN NND NND UN GEM series Installation Manual Drawing 8258 Version 3 0 1 If You Read Nothing Else Read This page Follow these recommendations to minimize installation related problems Models 602 603 BE SURE that the display mounting screws do not penetrate the display face by more than 1 8 inch or you will break the display Instrument panels come in different thicknesses so the supplied screws may need to be shortened Measure the portion of the screw which protrudes from the back side of the panel to be certain BE SURE that the display ground wire has a good low resistance connection to the en gine case Improper grounding can cause erratic readings or damage the instrument ALL Models USE CAUTION when crimping the terminals onto the end of the GEM harness Test each crimp by tugging on it sharply It is almost impossible to pull off a properly crimped terminal KEEP the GEM harness
18. GEM series Installation Manual Drawing 8258 Version 3 0 1 CHT Probe Wiring The CHT temperature probes must be wired with the correct polarity The CHT probes connect to the harness wires with the black jacket The probe leads and harness wires are color coded red and white to facilitate correct polarity Each wire is marked with the cylin der number Slide the wire marker down the wire so it remains with the installation for trouble shooting Strip the wires according to Drawing No 8254 on Page 19 Terminate with the crimp on ring terminals provided Verify the quality of each crimp with a sharp pull on the wire The terminal should be almost impossible to pull off when crimped correctly Harness and probe wire colors should match according to Drawing No 8254 on Page 19 Insulate and bundle as discussed below Routing the Wiring Harness It is essential to match the cylinder numbers on all the probes to display the proper infor mation to the pilot The probe harness connections should be insulated with the high tem perature fiber glass sleeves provided and routed away from high temperature areas e g exhaust stacks turbochargers etc The probe wires must not be tied in with ignition alternator or cabin heater ignition wires because of potential errors in temperature readings All wires should be bundled and tied with nylon wire ties or lacing cord and attached to the airframe to prevent damage from vibration and wind buffetin
19. MINI 1200 To perform this adjustment follow the instructions which are described in Section CON FIGURING THE GEM on Pages 10 11 The GEM series Display must be observed in all phases of flight for consistency in perfor mance If a problem is noted during the flight test discontinue the flight test and trouble shoot the system Observe the EGT function For normally aspirated non turbocharged engines the average peak indication after leaning for cruise should be around the Reference Asterisk when the aircraft is operated at typical altitudes and power settings It is also important that 12 or more bars indicate when the engine is leaned at the low end of the desired operational power range Turbocharged engines have little or no altitude sensitivity over most of their operational range so the highest EGT indication should be centered at the Reference Asterisk at nor mal power settings after leaning for cruise It is normal for the GEM series Display to indicate 1 3 EGT bars during idle 4 8 bars during takeoff and 12 16 bars when leaned for cruise Should you have any questions or problems during installation or trouble shooting of the GEM series don t hesitate to contact Insight Product Support Page 12 GEM series Installation Manual Drawing 8258 Version 3 0 1 Trouble shooting The following is a compilation of the common symptoms and causes of problems which may be experienced with the GEM Systems Close exami
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22. Y uu it ettet t tied ent hte 6 7 BACK LIGHTING MODELS 610 1200 7 Ixeuddieaud cw 7 CHT PROBE WIRING ES 8 ROUTING THE WIRING HARNES S 8 CONNECTING AND ROUTING THE IAT AND OAT HARNESSES MODELS 610 AND 1200 8 Page III GEM series Installation Manual Drawing 8258 Version 3 0 1 CHECKING THE p REA RSS 9 MODELS 610 1200 ONLY u 1 nde eaa teer eed aqu shua d cuv le 9 iei 9 CONFIGURING THE GEM MODELS 610 AND 1200 10 11 GEM SOFTWARE INSTALLATION oot rtg teret i beds 10 Automatic Start easda crece eot e ete dtc la adie Dor dd o Duda 10 MANUAL START OF 1215 0 000 nnn nennen ndn nennen 10 SELECTING FUNCTIONS a eet partae a tee hare Lon En Eee RR Rea 10 FUNCTION MENU SELECTION 20 0000266000 0000000 nennen en nennen nnn innert a ia tnr 11 FLIGHT TESTING AND CALIBRATING THE GEM MODELS 602 AND 603 ONLY 11 12 FLIGHT TESTING THE GEM MODELS 610 AND 1200 12 ER 1
23. aula 1 TABLE OF CONTENTS TABLE QF DRAWING S Er IV INTRODUCTION eR 1 2 UNPACKING THE GRAPHIC ENGINE MONITOR 1 INSTALLATION PLANNING iu ann he redet edet cene ues deter cede tn a aqu 2 TOOLS AND MATERIALS REQUIRED tte ett aote tr emt eet rea 2 INSTALLING THE GRAPHIC ENGINE 2 9 INSTALLING THE DISPLAY etant etr tenere tha e tee ae a nha de tua necu ma tu qr 2 INSTALLING THE EXHAUST GAS TEMPERATURE PROBES eene 2 3 INSTALLING THE CYLINDER HEAD TEMPERATURE PROBES 44er 3 INSTALLING THE TURBINE INLET TEMPERATURE PROBES MODELS 603 610 1200 4 PROBE CHARACTERISTICS iiia thao oraret tea ront arco nates 4 5 INSTALLING THE INSIDE AIR TEMPERATURE PROBE MODEL 1200 5 INSTALLING THE OUTSIDE AIR TEMPERATURE PROBE MODELS 610 AND 1200 5 WIRING CONSIDERATIONS l u S hias inasa 1 6 DISPLAY WIRING ici adnate 6 7 POWER CONNECTIONS ALLE MOPDBELS tee pnt denne ped 6 GROUNDING MODELS 602 603 ONLY node eek ei rte nd na 6 7 GROUNDING MODELS 610 1200 ONL
24. circuit breaker which re ceives power from the avionics or aircraft bus 1 amp models 602 603 2 amp models 610 1200 If an Avionics Master switch exists power will be removed from the GEM series Display during engine starts and shutdowns If the aircraft installation does not include an Avion ics Master switch circuit or bus we recommend that one be installed or a separate switch provided to remove power from the Display unit during engine starts Grounding Models 602 603 only Connect the ground wire directly and only to the engine case No airframe connections Grounding Models 610 1200 only Connect the ground wire s black to a common avionics ground bus airframe ground Page 6 series Installation Manual Drawing 8258 Version 3 0 1 CAUTION For upgrade installations GEM 602 603 to 610 and 1200 harness is grounded at the engine block disconnect the ground from the engine case and connect the ground wire to the ground bus airframe ground Do not connect to two ground points NOTE Double check the Display ground connection before applying power Many aircraft have terminal strips under the instrument panel that will appear to be connected to airframe ground and will even measure to ground with an ohmmeter The terminal strips may instead be connected to ground terminated loads such as landing lights or gear motors When these loads are activated the voltage on this supposed ground will rise to full bus voltage
25. de sensitivity over most of their operational range so the highest EGT indication should be centered at the asterisk at normal power settings The GEM 603 is calibrated similarly to the GEM 602 but has a different adjust ment mechanism It has a larger calibration hole above and to the left of the bezel ring A one tenth inch blade common screwdriver is required for adjustment The adjustment is actually a continuous rotation ten position rotary switch Each clockwise click of the calibra tion adjustment will increase the reading one bar at cruise power setting This adjustment effects the height of the EGT bars only The turbine inlet digital display is unaffected and is permanently calibrated at the factory for best accuracy Once the GEM 603 is set up for a given aircraft no further adjustment is ever required The adjustment hole is intentionally hidden by the panel and is accessed by removing the mounting screws and tilting the Dis play An access hole may be drilled to allow calibration from the panel if desired The pilot should consult the GEM Pilot s Guide for details on the use of the Display FLIGHT TESTING THE GEM Models 610 and 1200 only It is essential that the GEM series Display be flight tested The GEM series Display EGT BAR HEIGHT is pre adjusted at Insight Instrument Corp It may be necessary to readjust the EGT BAR HEIGHT while in flight The HP Palm Top computer will be required for this adjustment on the GEM 610 and GE
26. est temperature readings If the EGT probe must be located closer to the flange than recommended compensating for the resultant higher temperatures is accomplished using the BAR HEIGHT adjustment procedure If the probe must be positioned in a slip joint the inner tube must have a clearance hole of at least 1 4 diameter to prevent it from shearing the probe Be certain to locate all holes to allow straight in insertion of the probe without bending or stressing the probe tip See FLIGHT TESTING THE on Page 11 12 for details Before drilling ensure that nothing interferes with the probe clamp clamp screw or wire Center punch and pilot drill each hole in the exhaust stack with a No 28 or 9 64 drill bit Use caution while drilling perpendicular to the stack to prevent an elongated hole NOTE Tighten the clamp screw with hand torqued nut driver only A right angle drill extension may be necessary in some locations The probe will slip into carefully drilled hole and make a tight seal Installing The Cylinder Head Temperature Probes There are three types of Cylinder Head Temperature CHT probes Spring Probe Part Number 2852 Spark Plug Gasket Probe Part Number 2853 Adapter Probes Part Numbers 2855 Bayonet Adapter and 2856 Threaded Adapter The Spring Probe Part Number 2852 is equivalent to the old style Bayonet Probe and screws into threaded thermo wells in the cylinder head next to the lower spark plug
27. g The probe wiring harnesses are made of special alloy wire which must not be substituted or extended with copper wire The power and ground wires are copper and may be extended if necessary When the installation is complete all wires should be secured using wire ties and carefully checked for interference rubbing or chafing with flight control cables or other moving parts Connecting and Routing the IAT and OAT Harnesses Models 610 and 1200 only Refer to Drawings 1200 016 and 1200 017 on Pages 21 and 22 for wiring information Route the IAT and OAT harnesses factory terminated with probe connectors to the probes and secure Attach the harness connectors to the probes making certain that the connectors engage properly and that the male pins on the probes are undamaged Page 8 GEM series Installation Manual Drawing 8258 Version 3 0 1 Checking The Installation Verify the power and ground connections before applying aircraft power Pin 15 on the GEM series Display is aircraft ground and pin 5 is approximately 14V DC or 28V DC See Drawing No 1200 018 on Page 23 For Models 602 603 pin 15 must be connected to the engine case For Models 610 1200 pin 15 may be connected to the ground bus airframe ground When power is initially applied the GEM series Display will illuminate to full brightness Models 610 1200 only Immediately upon power application the version number of the operating system software will appear i
28. ibrated for average aircraft and may require slight adjustment The goal of cali bration is to center the average peak EGT indication around the asterisk when the aircraft is operated at typical altitudes and power settings It is also important that 12 or more bars indicate when the engine is leaned at the low end of the desired operational power range The instrument will thus indicate 1 3 EGT bars during idle 4 8 bars during takeoff and 12 16 bars when leaned for cruise Calibrating the GEM 602 For normally aspirated non turbocharged engines the average peak indication should be centered about 1 bar higher than the asterisk at 3 000 ft Altitude centered at the asterisk at 6 000 ft and would be a bar or two below the asterisk at 12 000 ft The Display may be calibrated with a jeweler s screwdriver through a small adjustment hole below the bezel ring on the front face of the Display The adjustment hole is intentionally hidden by the Display panel and is accessed by removing the mounting screws and tilting the Display An access hole may be drilled to allow calibration from the Display panel if desired Each clockwise turn of the calibration adjustment will increase the reading at cruise power setting about two bars At idle power settings each clockwise turn will increase the reading about one bar Page 11 GEM series Installation Manual Drawing 8258 Version 3 0 1 Calibrating the GEM 603 Turbocharged engines have little or no altitu
29. llow enough wire length to move the probe to the other plug if necessary The Spark Plug Gasket must be removed and replaced by the Gasket Probe Annealing of the Gasket Probe is not required or recommended and the Gasket Probe Does Not require replacement when the spark plugs are changed Page 4 GEM series Installation Manual Drawing 8258 Version 3 0 1 Alternatively an Adapter Probe may be used instead of a Gasket Probe An adapter probe will allow both displays to derive their CHT readings from the same thermo well For this reason use of the Adapter Probe is recommended instead of a Gasket Probe If the factory installed CHT display has a bayonet style probe the Insight Bayonet Adapter Probe 2855 may be used instead of the Gasket Probe The Bayonet Adapter Probe replaces the original bayonet adapter It has a screwdriver slot to facilitate tightening in place and placing a drop of non seizing lubricant on the threads before installation will ease installation and subsequent removal Once the Bayonet Adapter Probe has been installed the original bayonet probe maybe locked in place with a push and a twist If the factory installed CHT display has a threaded probe located in the thermo well the Insight Threaded Adapter Probe 2856 may be used The Threaded Adapter Probe is in stalled in the thermo well between the cylinder head and the original CHT probe Installing The Inside Air Temperature Probe Model 1200 only The Inside
30. n the Digital Display window for approximately two seconds After the version numbers extinguish the GEM series Display reverts to Monitor Mode operation Monitor Mode is the default power on operating mode EGT and CHT bar graph columns indicate their respective cylinder temperatures and the temperature currently displayed in the Digi tal Display windows are identified by the illuminated annunciator EGT CHT TIT OAT IAT The selected or CHT cylinder number is indicated by the blanked Highlight All models The GEM series Display brightness level automatically adjusts to match the ambient light level The automatic dimming may be tested in bright ambient light by covering the entire face of the Display with the palm of your hand for several seconds The Display will dim and then brighten when your hand is removed In low ambient light the auto dimming feature may be tested by shining a flashlight on the display for several seconds It changes brightness slowly in discrete steps to prevent annoying flicker in response to rapid ambient light level changes After the tests described above have been performed check for possible interference with existing avionics by listening for audio interference on Com Nav DME ADF etc Interfer ence is uncommon however these characteristics should be tested If interference is detected remove power from the Display unit to check if it is the emitter of the interference If
31. nation of these symptoms should assist in identifying the cause of the problem Symptom The GEM series Display does not illuminate Cause No ground return at Pin 15 of the LEFT ENGINE connector either from the engine blocks or from airframe ground Symptom The GEM series Display does not illuminate Cause Voltage is missing at Pin S of the LEFT ENGINE connector from the circuit break er or bus Symptom One or more columns or segments will not illuminate Cause Try recycling power to check the Display If all columns do not illuminate the GEM series Display has been damaged or is inoperative Symptom One or more columns or segments will not illuminate Cause Check the probe connections the display will blank columns with poor EGT and CHT connections Columns 5 and 6 shouldn t illuminate on a 4 cylinder engine Symptom No EGT in one or more columns Cause Errors in harness wiring Visually check probe connections and polarity Check for probe continuity at the display connector The resistance of the lead wire is approximately 1 ohm per foot Take extreme care to not damage the connector terminals with the meter probes Symptom No CHT in one or more columns Cause Errors in harness wiring Visually check probe connections and polarity Check for probe continuity at the display connector The resistance of the lead wire is approximately 1 ohm per foot Take extreme care to not damage the connector terminals with
32. osg 6uuds IHO 1ON G O 9A MOJA H j JepuiKo sad HD euo mi Peu TA 2 8 v ono m oro 0 rm o o Moll d pay MOJI A pay Z AO A MO 9A uonoauuo ON UOn29eUuO ON L Vv 8 3 3 3 H r 1 u s J pulIKo sad qojd 193 euo MOII A 40 02 Jequunu JepuuKo 109 5 YOLOSNNOO PayJOW 9JD SaJIM SS UJDH MIIA M3IA LIN3NNYLSNI 3O193NNOO 3993 101096 12 G3SIA33 20 uonpaod402 GEM series Installation Manual Drawing 8258 Version 3 0 1 101096 109086 210 0001 ON SMG 1 HOLO3NNOO 6189 33S 2661 wbukdoo EX 0906 pes IEEE uononpoJdey puo NI jonuepyuoo sumquoo uono queuwrujsuj T T g m Jo ein B 9S YZI 1203 71 xog lu Bisui W130 9NILNDON 380ud 34nivJ3dW31 3015 1 JYNLVYSdN3L 30151 0 H3TIVISNI AG Q3IJIGON 38 AVW HLONST LNG SI A18W3SSV 318 2 NOSN3S Z 380 4 YSHLIZ ONILVOO1 380438 SNOILONYLSNI OL 33333 SJIV13G ONIMIM NOLVM3dO 1234402 OL WOILIYD SI 38O0Md LVI 1 0 30 NOILVDO7 1 SS LON 91 LAN NOTAN 134Sv9 N3ggnwW 110 102 ONILNNOW Q3O0N3WNW
33. re running may result in loss of data files Return to the HP Palmtop s built in applications by quitting GEMCOM select from GEMCOM s main menu NOTE The reboot method of starting GEMCOM is enabled by use of the Palmtops au toexec bat and config sys operating system files Altering or removing these files will disable the automatic start of GEMCOM Consult the Palmtop Users Manual for detailed information Manual Start of GEMCOM GEMCOM can be manually started from within the FILER by highlighting the GEMCOM EXE file and pressing ENTER Selecting from the GEMCOM Main Menu returns control to the FILER Selecting Functions GEMCOM provides access to the advanced user functions through a standard screen menu system Functions are selected by pressing the Number Key NOT the F function key corresponding to the desired selection Page 10 series Installation Manual Drawing 8258 Version 3 0 1 Function Menu Selection 1 HELP 2 GEM CLOCK 3 GEM CONFIG 4 EGT BAR HEIGHT 5 N A 6 DATA TRANSFER 7 DATALOG CONFIG 8 EXPAND FILE 9 IR COMM TEST Q QUIT to SYSTEM MANAGER An explanation of each of these functions is available on line in the HP Palm Top computer by pressing F1 Help and selecting the topic FLIGHT TESTING AND CALIBRATING THE GEM Models 602 and 603 only It is essential that the installation be flight tested and calibrated The Graphic Engine Moni tor is pre cal
34. roved exhaust repair facility Locate and drill the probe hole as described in Section INSTALLING THE EXHAUST GAS TEMPERATURE PROBES on Page 2 and refer to Drawing No 8254 on Page 19 for the recommended location NOTE If you have questions as to the correct type or location of TIT probes call Insight Product Support for technical assistance Probe Characteristics The Spring Probe 2852 has a probe bushing with a screwdriver slot to facilitate tightening into place A drop of anti seizing lubricant on the threads before installation will ease instal lation and subsequent removal When installing Spring Probes be sure you have correctly identified the standard thermo well Some aircraft have fuel primer ports with the same thread size Many factory installed CHT displays utilize a single threaded or bayonet style resistive type probe that occupies one of the thermo wells This probe is not compatible with the thermo couple probes required for the Graphic Engine Monitor A Spark Plug Gasket Probe 2853 may be used on this cylinder for the GEM series Dis play so as to allow the factory installed display to remain functional The Spark Plug Gasket Probe replaces the standard copper spark plug gasket on one spark plug in the selected cylinder The spark plug chosen should be the one that provides the best correlation with the other temperature probes On common downdraft cooled engines the selected cylinder will be the upper plug A
35. the GEM series Display is the interference source re route the wiring harnesses away from affected equipment Contact Insight Product Support if needed further assistance Page 9 GEM series Installation Manual Drawing 8258 Version 3 0 1 CONFIGURING THE GEM Models 610 and 1200 only GEM Software Installation GEMCOM is Insight s program for communicating with the GEM 610 or GEMINI 1200 It is pre loaded on the Insight RAM card included with the Palmtop computer CAUTION Always switch off the HP Palmtop before inserting or removing the RAM card to protect the contents of the card To install GEMCOM into the HP Palmtop first install batteries and initialize the Palmtop according to the HP User s Manual Then switch off the HP insert the RAM card switch on and run the built in HP FILER program the first blue application key from the left From the FILER view the drive RAM card highlight the install bat file and press ENTER The install file will copy all necessary files from the RAM card to the Palmtop s memory All GEMCOM program and data files will be stored in a directory called GEM Remove the RAM card and store in a safe location for future use Automatic Start of GEMCOM To automatically start GEMCOM first exit any open applications Then simultaneously press and hold the CTRL ALT and DEL keys CAUTION This method of starting GEMCOM reboots the Palmtop computer Rebooting while application programs a
36. uring leaning Cause The EGT BAR HEIGHT is too low see Flight Testing on Page 11 12 for details Symptom EGT Annunciator will not stay blinking Cause Intermittent probe connections or interference Check for interference see Display is unstable Check for intermittent probe connections see No EGT and No CHT Symptom EGT indication is not uniform Cause The EGT indication for a fuel injected engine will typically vary a bar or two from perfectly uniform when leaned for cruise Clean the fuel injection nozzles Non uniformity is normal in carburetored engines All cylinders are measured by the same circuitry It is almost impossible to not have identical response on all channels of the GEM series Symptom A sudden or gradual reduction in the EGT indication 2 or more bars can be symptomatic of several engine faults Cause Exhaust leaks above the probe and poor compression due to bad rings valves or valve guides If a probe substitution does not reveal a faulty probe check for mechanical faults in the engine Consult the GEM series Pilot s Guide for more detailed engine diag nostic information Symptom All EGT readings too high Cause Readjust the BAR HEIGHT on the Display Use DVM a digital voltmeter to measure the difference between the Display ground and engine block ground with the engine running and the battery charging If the difference is greater than 2 V DC mod els 602 603 or 2 V DC models
37. y is unstable Cause Magneto ungrounded or defective P lead Check ignition harness for proper shield ing grounding and loose spark plug caps Check magnetos for proper grounding or evi dence of arcing Disconnect magneto P leads one at a time If this eliminates or reduces the problem replace the P lead A faulty ignition harness will typically cause all EGT read ings to dance up and down The GEM series Display will detect this type of fault long before standard test methods thus eliminating the potential of more serious problems Symptom Display is unstable Cause Noisy or defective alternator defective generator or faulty ground connection Try operation with alternator or generator off Alternator related interference may indicate faulty commutat Symptom Display is affected by radio transmissions Cause Proximity of probe and or display unit to the radio power wiring and away from radi os and antenna coax Check radio rack connector for missing 50 ohm matching device The 50 ohm matching device is a thick washer like component part that is installed underneath the connector end cap The end cap will have to be unsoldered to check for the matching device This seemingly unimportant component is supplied with all connectors and is re quired for proper operation of the connector Utilize shielded twisted pair for power leads Page 14 series Installation Manual Drawing 8258 Version 3 0 1 Symptom No Columns blink d
38. y outline and hole layout Connections to the GEM series displays shall be made in accordance with Drawing No s 1200 017 and 1200 018 on Pages 22 and 23 Do Not connect the GEM ground wires to both the engine and the airframe NOTE The possible existence of a double ground condition should be verified and cor rected particularly if the GEM is a replacement for a previously installed GEM display Installing The Exhaust Gas Temperature Probes The Exhaust Gas Temperature EGT probe is designed fit into a hole in each exhaust stack and be secured with an integral stainless steel clamp It is important that each probe is mounted a uniform distance from the exhaust stack flange For normally aspirated engines a nominal distance of 2 to 3 inches from the flange is rec ommended For turbo charged engines a nominal distance of 4 to 5 inches is recommended See Drawing No 8254 on Page 19 Page 2 series Installation Manual Drawing 8258 Version 3 0 1 If the recommended distance is impractical because of obstructions slip joints or bends in the exhaust system position all the probes a uniform distance from the flange as space permits It is more important that all probes be positioned at a uniform distance from the flange rather than meeting the preferred dimension Probe locations closer to the flange may result in slightly higher inconsequential temperature indications Careful matching of probe position will provide b

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