Boss Audio Systems 610C Installation manual

GEM INSTALLATION MANUAL
DOCUMENT No. 070906 REV. 1.3
CHECK WIRING HARNESS BEFORE INSTALLATION
INSTALLATION MANUAL
FOR INSIGHT GEM 610C-001
G4-001 AND G4-002
DOCUMENT No. 070906
READ THESE INSTRUCTIONS COMPLETELY
BEFORE PROCEEDING WITH INSTALLATION
Insight Instrument Corporation • Box 122 Fort Erie, ON L2A 5M6
Tel: 905-871-0733 • Fax: 905-871-5460 • Web: www.insightavionics.com
Copyright 2009
Instrument Corp.
INSIGHT INSTRUMENT CORP.
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GEM INSTALLATION MANUAL
DOCUMENT No. 070906 REV. 1.3
If You Read Nothing Else Read This page!
Follow these recommendations to minimize installation related problems.
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 at least 1 inch away from the ignition harness, P-leads, and alternator wiring.
Some aircraft produce electrical noise, which will cause erratic indications.
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.
·
Ensure that all electrical connections are correct and properly made.
·
Observe electro-static discharge precautions.
The GEM can only do its job of performing accurate engine monitoring if the engine and airframe have a
good, solid, low-resistance electrical connection between them. Check for this with a careful visual
inspection of the aircraft's ground connections. A measurement with an Ohmmeter will reveal a gross fault
but a better test is to measure between the engine case and the airframe with a voltmeter with the engine
running and the electrical system under normal load. The voltage difference should be very small (millivolts).
Overlooking this important step can lead to a lot of unnecessary troubleshooting later.
Insight Instrument Corp. supports GEM installations with Insight thermocouple probes and harness. GEM
installations with probes and harnesses from other manufacturers are not supported.
GEM Installation Location Cautionary Notice
The G-series GEM graphic engine monitors have EGT, CHT and TIT primary STC. The GEM display must
be mounted so as to be clearly visible to the pilot. The GEM display should be mounted within the pilot’s
subpanel or the center panel and not on the copilots subpanel unless the GEM can be canted towards the
pilot.
GEM Fuel Totalizer Cautionary Notice
Please note that not all GEM models provide fuel data. The Fuel Remaining display on the GEM is very useful
but is not without limitations. Understand first that the factory fuel quantity gauges are the only instruments in
the panel that physically measure fuel level. They are still the primary indication of fuel level in the airplane.
The GEM doesn’t measure level, but instead measures only fuel flow rate. The GEM totalizes the rate
information to account for fuel used. If you know how much fuel you started with and how much you have used
you can figure fuel remaining by simple subtraction. The pilot must supply an accurate starting fuel level for
this subtraction to produce the correct fuel remaining result. Should the pilot overstate the fuel quantity on
board, the GEM will dangerously overstate the fuel remaining and the endurance time as well. The pilot must
be careful and diligent when setting the fuel on board. (Cont'd)
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GEM Fuel Totalizer Cautionary Notice (Cont'd)
When the aircraft is filled prior to takeoff, the number is the total available on board. If partially filled to a
known configuration (ex. tips empty) then the total is easy to calculate.
However if tanks are partially filled on top of a poorly known original value - errors will abound. Unaccounted
fuel loss from leakage, fuel vent overflow or theft will of course produce erroneous results.
Be careful and the GEM will deliver safe, reliable, and convenient fuel information. But be sure to cross
reference the information on the primary fuel quantity gauges. Never trust a single source of fuel information
when you have two on board. Fuel exhaustion still ranks highly among accident causes.
Don’t let your engine stop until you’re parked.
Warranty policy
The Insight Instrument Corp.’s Graphic Engine Monitor temperature display unit is warranted against
defects in materials and workmanship for two years from date of purchase. Insight Instrument Corp.’s
temperature probes are warranted for one year from date of purchase or 100 hours whichever comes
first.
Insight will, at its option, repair or replace, without charge, those products that it finds defective. 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.
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Table of Contents
IF YOU READ NOTHING ELSE READ THIS PAGE! ............................................................... 2
GEM INSTALL LOCATION CAUTIONARY NOTICE .................................................................. 2
GEM FUEL TOTALIZER CAUTIONARY NOTICE ...................................................................... 2
WARRANTY POLICY ................................................................................................................. 3
TABLE OF CONTENTS........................................................................................................... 4, 5
TABLE OF DRAWINGS .............................................................................................................21
INTRODUCTION ......................................................................................................................... 6
INSTALLATION PLANNING......................................................................................................... 7
UPGRADING .......................................................................................................................... 7, 8
TOOLS AND MATERIALS REQUIRED ....................................................................................... 9
UNPACKING THE ENGINE MONITOR DISPLAY…………………………………………………
9
INSTALLING THE GRAPHIC ENGINE MONITOR DISPLAY...................................................... 9
INSTALLING THE EXHAUST GAS TEMPERATURE PROBES .........................................…....10
INSTALLING THE CYLINDER HEAD TEMPERATURE PROBES .............................................10
CHT PROBE CHARACTERISTICS.................................................................................…........ 11
INSTALLING THE CARBURETOR TEMPERATURE PROBE.…………………………………… 11
INSTALLING THE TURBINE INLET TEMPERATURE PROBES................................................ 12
INSTALLING THE MANIFOLD TEE ............................................................................................ 12
INSTALLING THE OIL TEMPERATURE PROBE.....................................................…................ 12
INSTALLING THE OIL PRESSURE SENSOR.................................................................…........ 12
INSTALLING THE TACHOMETER CABLE FOR RPM.......................................................…..... 12
INSTALLING THE VIBRATION SENSOR......................................................................….......... 13
INSTALLING THE OUTSIDE AIR TEMPERATURE PROBE...........................................…........ 13
INSTALLING THE FUEL FLOW SENSOR……………….……..........................................…........ 13
WIRING CONSIDERATIONS ..........................................................................................……...... 14
DISPLAY WIRING POWER AND GROUND CONNECTIONS..........................................…....... 14
EGT PROBE WIRING ........................................................................................................…...... 15
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Table of Contents
CHT PROBE WIRING ............................................................................................................... 15
ROUTING THE WIRING HARNESS..............................................................…......................... 15
CONNECTING AND ROUTING THE OAT HARNESSES ......................................................... 16
CHECKING THE INSTALLATION ............................................................................................. 16
UPDATE GEM SOFTWARE ...................................................................................................... 16
FLIGHT TESTING THE GEM ..................... .............................................................................. 17
WEIGHT AND BALANCE DATA………………………………………………………………………17
TROUBLE-SHOOTING........................................................................................................ 18-20
DRAWINGS ......................................................................................................................... 22-37
TECHNICAL SUPPORT ............................................................................................................ 38
SERVICE PROCEDURES................................................................................................…...... 38
Drawings
Table of DRAWINGS................................................................................................................... 21
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INTRODUCTION
This Installation Manual will acquaint you with the installation requirements, operational functions and some
of the powerful features of the Insight G-series Graphic Engine Monitors. Please read it carefully and
completely before starting.
Insight Instrument Corp.’s Graphic Engine Monitors provides simultaneous analog and digital display of engine
temperatures for nearly all makes and models of piston-powered aircraft.
The Insight G-series graphic engine monitors are manufactured with models ranging from basic EGT/CHT
monitor to full-featured with data-logging and advanced vibration measurement.
G-series GEMs and Available Features Table:
GEM Model Name
G4
G4
G3
G2
G1
Single
Twin
3.125
3.125
2.25
2.25
2.25
EGT
X
X
X
X
X
CHT
X
X
X
X
X
TIT
X
X
X
X
X
FUELFLOW
X
X
X
X
OAT
X
X
X
X
BUSS VOLTAGE
X
X
X
X
TACHOMETER
X
X
X
MANIFOLD PRESSURE
X
X
X
OIL TEMPERATURE
X
X
X
OIL PRESSURE
X
X
X
ACCELEROMETER
X
X
X
CARBURETOR TEMPERATURE
X
X
X
INSTRUMENT VACUUM
X
X
X
AUXILLIARY TEMPERATURE(S)
X
X
X
RS-232 INTERFACE(S)
X
X
X
VIBRATION
X
X
X
Bezel Size
X
X
For a comprehensive description of functions and features, consult the Operation Instructions and Pilot’s Guide.
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Installation Planning
Plan the location of the GEM display such that it is not positioned near any source of high
electrical current and is easily visible by the pilot.
The GEM's wiring harnesses should be positioned away from sources of high energy, such as
ignition harnesses, P-leads, alternator wiring and high frequency radio wiring and antennas.
Some thought about the steps needed may save hours of installation time and trouble-shooting.
Steps to a successful installation
1. Select which new G-series GEM model is to be installed. Check the GEM's STC Approved
Model List for aircraft model eligibility.
2. Review the features and requirements of the selected GEM to ensure compatibility with
existing and planned aircraft equipment. Read this manual completely.
3. Identify whether or not the installation is an upgrade from a legacy GEM system or a firsttime GEM installation. In the case of an upgrade, see the "Upgrade Installation" section.
4. GEM kits contain much of what is required for installation except for the materials listed in
the "Tools and Materials Required" section.
Upgrade Installations
GEM upgrade kits are designed to utilize existing Insight Instrument Corp. EGT/CHT/TIT/OAT
wiring and probes that are already installed in the aircraft. Prior to ordering an upgrade kit,
inspect the aircrafts existing GEM wiring and probes for condition, suitability, and length for
use with the new GEM. If an existing harness is not suitable for upgrade use, new
replacement harnesses are available from Insight.
Legacy GEMs were typically installed as supplemental (non-primary) EGT/CHT/TIT
instruments. New G-series GEMs may be used as primary EGT/CHT/TIT instruments. Check
the GEM STC for eligibility.
Check the GEM instrument hole location for compliance with the new GEMs location
requirements.
Upgrading from GEM 602 or 603
Many aircraft have been equipped with GEM 602 or GEM 603 systems. Model 602
systems supported four or six cylinder engines, and 603 systems supported four or six
cylinder engines with turbo-chargers. Any 602 or 603 equipped aircraft can be easily
upgraded to a G-series GEM system.
New G-series GEMs are plug-compatible with legacy wiring and EGT/CHT/TIT probes from
a GEM 602 or 603 system with one difference, the instrument ground wire (black) may
have been attached to the engine case and should be moved to an airframe or avionics
ground. See wiring drawing 1200-018. The new GEM housings are shorter than old GEM
housings; check that the harness length is sufficient to reach the new GEM housing.
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The G1, G2 and G3 models have a top control knob or push-button that requires a
clearance hole in the instrument panel, check GEM display drawing 610C-001 and outline
drawing #930309 for hole sizes and locations.
The G1 GEM is a functional direct replacement for a 602 or 603. Note that the G1 must be
configured at the Insight factory. Specify four or six cylinder, turbo-charged or non-turbo,
and carburetor or fuel-injected at time of ordering. The configuration determines how many
cylinders, and whether or not TIT (Turbo Inlet Temperature) and Carburetor Temperature
are measured and shown on the G1 display. The G1 GEM is not field-configurable and
must be returned to Insight if a configuration change is needed.
The G2, G3 and G4 models have an additional interface connector (P2) to provide
connections to supplemental features such as fuel flow sensors, tachometer, etc. Upgrade
kits contain much of the wiring and sensors to accomplish installation, contact Insight for
details. See the following sections of this manual for installation details of the new sensors
and wiring.
The G4 models are available in single engine and twin configurations. The G4 displays fit
into a standard 3.125 inch panel hole. See drawing #930309.
Upgrading from GEM 610 or GEMINI 1200
Upgrading from models 610 or 1200 is similar to upgrading from 602 or 603 with a few
differences.
Previous 610 installations will already have all holes drilled for panel mounting a G1, G2 or
G3. G4 models require a 3.125 inch hole.
Previous installations of 610 and 1200 models may already have an Insight OAT probe and
wiring that can be retained and connected to a G-series GEM. See wiring drawing 610C315.
Upgrading to G4 Single
The single engine G4 display (3.125 inch) is plug compatible with the G3 display (2.25
inch). Refer to 610C-315 and 1200-018 wiring diagrams.
Upgrading to G4 Twin
The twin engine G4 display is plug compatible with the EGT/CHT/TIT wiring harnesses
of legacy GEMINI 1200 installations. The G4 twin display has an additional interface
connector (P2) to provide connections to additional sensors such as fuel flow and
tachometer, etc. Refer to G4-315 and 1200-018 wiring diagrams.
Upgrading GEM installations in twin-engine aircraft
Twin engine aircraft may be equipped with two single-engine GEM displays or a twin
engine GEM display. Check the ground wire configuration if upgrading from older
GEMs. Wire the thermocouple harnesses according to wiring diagram #1200-018.
Install the supplementary feature wiring according to wiring diagram 610C-315 for 25pin D-sub connectors, and diagram G4-315 for 37-pin D-sub connectors.
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Tools and Materials Required (NOT included in GEM kit - Installer supplied)
·
Proper wire stripping tools.
·
Proper crimping tools, Insight recommends;
M22520/2-01Crimping tool and M22520/2-08 Positioner or equivalent.
·
Insertion/extraction tool for Amp pin #205089-1.
·
Trip-free, re-settable Circuit-breaker (1 AMP).
·
Hardware and plumbing for mounting and connection of the Oil Pressure Sensor, and
the Manifold Pressure connection.
Unpacking the Graphic Engine 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.
INSTALLING THE GRAPHIC ENGINE MONITOR DISPLAY
Models G1, G2 and G3 displays mount in a 2.25 inch diameter panel cutout. A new GEM installation will require
four mounting holes and two holes for the control knobs in addition to the 2.25 inch hole. See Drawing #610C001for a display outline. Insight can supply an adapter plate to allow mounting a 2.25 inch GEM in a 3.125 inch
hole.
The G1, G2 and G3 will fit directly into the holes from a previously installed GEM Model 610. Upgrading from
GEM 602 or 603 will require a single new hole for the upper control knob.
G4 models fit into a 3.125 inch diameter hole.
See Insight drawing 930309 for 2.25 and 3.125 inch panel mounting holes.
Connections to the GEM G-series displays shall be made in accordance with Drawing No’s. 610C-315 and
1200-018. Care should be given to provide sufficient depth allowance for harness and cable routing at the rear
of the display. Plan for service loops in all the wiring to ease service or adjustments after the installation.
NOTE: Check for the possible existence of a “double” ground, particularly if the GEM is a replacement for a
previously installed GEM display. The GEM must have only one ground connection.
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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 recommended.
For turbo-charged engines, a nominal distance of 4 to 5 inches is recommended. See Drawing No. 8254.
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 best temperature readings.)
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.
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-torque nut driver only.
A right angle drill extension may be necessary in some locations. The probe will slip into a 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 (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 threaded on the inside to
allow simultaneous utilization of the factory-installed Threaded CHT Probe.
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CHT 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 installation, 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 electrically compatible with the thermocouple probes
required for the Graphic Engine Monitor.
A Spark Plug Gasket Probe (2853) may be used on this cylinder for the GEM series Display, 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. Allow
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.
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 installed in the thermo-well between the
cylinder head and the original CHT probe.
Installing the Carburetor Temperature Probe
The GEM is supplementary for carburetor temperature. Install the Insight Carburetor Temperature probe
(Insight P/N 610C-021) into an existing tapped hole in the carburetor. Consult with the engine or carburetor
manufacturer to determine the probe-hole location and thread size. Ensure the probe does not interfere with any
internal carburetor components.
For G2, G3 and G4 GEMs refer to Drawing 610C-315 or G4-315 for electrical connections.
The G1 GEM uses pin numbers "A" and "1" on the P1 Edge-Connector. In the case of upgrading from an older
GEM system to a G1 GEM check for the possibility of existing wiring to the "A" or "1" pins on the P1 connector.
Remove any existing connections to these pins and only connect the Insight Carburetor Probe. See Wiring
Diagram Drawing 1200-018 Rev. E or later.
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Installing the Turbine Inlet Temperature Probes
There are three types of Turbine Inlet Temperature (TIT) probes which can be used with the GEM G- series
system.
·
Clamp-Type TIT Probe (Part number 2871) - is identical to the EGT probe except that
the clamp diameter is larger
·
Threaded-Type, (7/16-20) 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.
The Probe Type 2872 Boss fits in a 1/2” inch hole and should be welded by an approved exhaust repair facility.
Locate and drill the probe hole as described in Section “INSTALLING THE EXHAUST GAS TEMPERATURE
PROBES”, and refer to Drawing No. 8254 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.
Installing the Manifold Pressure Tee
The GEM is supplementary for manifold pressure. The GEM's manifold pressure sensor is located internally
inside the GEM display. Refer to Drawing 610C-001 or G4-001 for the location of the GEM's Manifold Pressure
port (5/16"-24 #2 Flare fitting). The installer must supply the tubing and a "Tee" fitting to connect the GEM to the
existing manifold pressure indicator.
Installing the Oil Temperature Probe
The GEM is supplementary for oil temperature. Install the Insight Oil Temperature probe into an existing tapped
hole in an oil gallery in the engine. Insight can supply Oil Temperature probes in a variety of thread sizes to
suite most engine types. Consult with the engine manufacturer to determine the probe-hole location and thread
size. Ensure the probe does not interfere with any internal engine components. Refer to Drawing 610C-315 or
G4-315 for electrical connections.
Installing the Oil Pressure Sensor
The GEM is supplementary for oil pressure. Install the Insight Oil Pressure Sensor (1/8 NPT) on a length of
flex-hose "Tee-ed" into the existing oil pressure sensor. The Installer must supply the "Tee" fitting, flexible hose
and mounting hardware. Refer to Drawing 610C-315 or G4-315 for electrical connections.
Installing the Tachometer Cable for RPM
The GEM is supplementary for Tachometer. Insight provides a shielded cable with included protection-resistor
(Insight P/N 610C-026) for connection to a magneto. Refer to Drawing 610C-315 or G4-315 for electrical
connections.
For aircraft equipped with electronic ignition systems with a tachometer signal output, use Insight Tachometer
Signal Adapter P/N 610C-027 instead of P/N 610C-026. Wire according to Insight wiring diagram #101123.
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Installing the Vibration Sensor
The GEM is supplementary for Vibration Measurement. Insight provides a shielded cable pre-terminated with a
mating 7-pin circular plastic connector (CPC) for connection to an Insight Vibration Sensor (Insight P/N 1000004V). Refer to Drawing 610C-315 or G4-315 for electrical connections. Wire as shown for option "A".
Aircraft with 24 Volt (28 Volt) electrical systems require a 750 Ohm resistor installed in series with the vibration
sensors power supply wire.
The sensor should be mounted to an engine case bolt on the top of the engine as close to the propeller as
practical. The sensor should be oriented with the nameplate up and the aircraft symbol pointing forward. The
sensor may be oriented otherwise if the preferred mounting is impractical, please consult Insight technical
support.
Installing the Outside Air Temperature Probe
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 for the mounting dimensions 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.
Insight recommends mounting 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 necessary and/or potting
of the OAT probe is required, be certain to apply “Proseal” or equivalent potting substance prior to tightening.
NOTE: Be careful not to get potting substance on the connector.
Installing the Fuel Flow Sensor
Aircraft without existing FF sensors should have one Insight supplied sensor installed per engine except
for engines equipped with pressure-carburetors, which require two sensors.
Insight manufactures a variety of fuel flow sensors for injected and carbureted engines. See drawing
1000-303 (3 pages) for sensor details and part numbers.
Existing FF sensors may be connected directly to the GEM but compatibility with other manufactures' fuel
flow sensors cannot be assured. To connect a GEM to an existing fuel flow sensor/fuel computer system
use Insight Fuel Flow Signal Adapter P/N 610C-025. Use Insight wiring diagram #101116. Compatibility
cannot be assured.
Wire new Insight FF sensors in accordance with Insight Drawing 610C-315 or G4-315, Option "C".
Wire new Insight combination FF/Vibration sensors in accordance with Insight Drawing 610C-315 or G4-315,
Option "B".
For all fuel flow sensor installations refer to AC 43.13-1B, Chapter 8 Section 2, 8-30, 8-31, 8-37, 8-38.
The Insight fuel flow sensor case must be connected to airframe ground.
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Wiring Considerations
The GEM is supplied with a factory-assembled EGT/CHT (TIT) wiring harness configured for the
specified number of cylinders and required length (for each engine). The harness edge connector
contains a polarization pin which mates with a slot in the display’s printed circuit board. This
prevents improper engagement of the connector.
Before installing, confirm that the factory fabricated harness connector matches wiring diagram,
drawing # 1200-018. All the red thermocouple wires should be on one side of the connector.
The GEM 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.
The EGT and CHT wire length is not critical and may be trimmed to any length as required to fit each
probe.
CAUTION: Splicing of the thermocouple wire is not recommended.
Note: Plan your Installation to include a service loop in the GEM wiring harness to allow for future
adjustments.
Wires for the supplemental features are supplied pre-terminated at the sensor end, but must be
terminated at the instrument end during installation. The D-sub connectors (25 and 37 pin) utilize
crimp pins; see the materials section for recommended tooling.
Some of the D-sub ground pins are shared by multiple wires use a "pig-tail" style connection inside the
connector shell to accommodate multiple wires in a single pin.
Display Wiring Power and Ground Connections
The GEM displays automatically accommodates both 14 and 28 Volt electrical systems. Connect
the “red” power lead to a separate trip-free, re-settable circuit breaker (1 Amp) that receives power
from the avionics bus or aircraft bus.
If the aircraft does not include an Avionics Master switch circuit or bus, we recommend that one be
installed or a separate switch (user provided) to remove power from the Display unit during engine
starts.
Connect the ground wire (black) to a common avionics ground bus (airframe ground).
CAUTION: For upgrade installations (from GEM 602 or 603) where the harness is grounded to the engine
case, 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 (14 or 28V). [Extensive damage may result from improper grounding and is not covered under
warranty.] Refer to Drawing No. 1200-018.
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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 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.
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 ensure it won’t come out. The most
common installation problems are the result of poor quality termination.
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 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.
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. 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 information to the pilot.
The probe/harness connections should be insulated with the high temperature fiberglass 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 buffeting.
The probe wiring harnesses are made of special alloy wire that 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.
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Connecting and Routing the OAT Harnesses
Refer to Drawings 1200-016 and 610C-315 for wiring information. Route the 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
Checking the Installation
Verify the power and ground connections before applying aircraft power. Pin 15 (connector P1) is aircraft
ground and pin S is approximately +14V DC or +28V DC (See Drawing No. 1200-018).
When power is initially applied, the GEM series Display will illuminate to full brightness.
Immediately upon power application the version number of the GEM software and other status messages will
appear in the display for approximately two seconds. Push and hold one of the control knobs at this time to remain on
this screen. If an engine vibration sensor is installed its software version will be displayed otherwise a vibration status message
will be shown.
After the status screen display, the GEM reverts to Monitor Mode operation. Monitor Mode is the default
power-on operating mode. EGT and CHT (and TIT) color-coded bar graph columns indicate their respective
cylinder temperatures, and supplementary values appear in cyan.
The GEM 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. Interference 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 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.
GEM Software Updates
Check the Insight website (www.insightavionics.com) or contact Insight Instrument Corp. for information
regarding software updates.
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FLIGHT TESTING THE GEM
It is essential that the G-series GEM installation be flight tested.
The GEM must be observed in all phases of flight for consistency in performance. If a problem is noted during
the flight test, discontinue the flight test and trouble-shoot the system.
Should you have any questions or problems during installation or trouble-shooting of the GEM don’t hesitate
to contact Insight Product Support. Please be ready to supply aircraft and engine type, GEM model and serial
number and software version.
WEIGHT and BALANCE DATA
1 G-series GEM Instrument
6 Clamp EGT Probes
6 Spring CHT Probes
6 Gasket CHT Probes
1 Adapter CHT Probe
1 TIT Probe
1 Oil Temperature Probe
1 Oil Pressure Sensor
1 Vibration Sensor
1 Fuel Flow Sensor
1 FF Signal Adapter
1 Carburetor Temperature Probe
1 8 ft Wiring Harness
1 24ft Wiring Harness
INSIGHT INSTRUMENT CORP.
0.5 lb
9 oz.
6 oz.
4 oz.
1 oz.
1 oz.
1 oz.
2 oz.
1 oz.
6 oz.
1 oz.
1 oz.
14 oz.
34 oz.
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Troubleshooting
The following is a compilation of the common symptoms and causes of problems which may be experienced
with the GEM Systems. Close examination of these symptoms should assist in identifying the cause of the
problem.
Symptom: The G-series Display does not illuminate.
Cause: No ground return at Pin 15, of the edge connector from airframe ground
Cause: Voltage is missing at Pin S, of the edge connector from the circuit breaker or bus.
Symptom: One or more columns will not illuminate.
Cause: G1 GEMs are factory-configured to match the engine type (4/6 cylinder, turbo, carburetor). If the
configuration is incorrect the G1 GEM must be returned to Insight for re-configuration. All other G-series GEMs
can be configured in the field. Consult the installation manual for configuration instructions.
Symptom: One or more columns will not illuminate or missing data.
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. Turn top knob on GEM to the probe analysis page
to check probe Integrity.
For 8 foot harness on probe analysis page resistance should be 8 - 3 EGT / 1 - 6 CHT
For 24 foot harness on probe analysis page resistance should be 26 - 10 EGT / 4 - 18 CHT
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. Turn top knob on GEM to the probe analysis
page to check probe Integrity.
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 the meter probes. Turn top knob on GEM to the probe analysis
page to check probe Integrity.
Symptom: No CHT in one or more columns.
Cause: Faulty probe. Turn top knob on GEM to the probe analysis page to check probe Integrity. For
8 foot harness on probe analysis page resistance should be 8 - 3 EGT / 1 - 6 CHT. For 24 foot
harness on probe analysis page resistance should be 26 - 10 EGT / 4 - 18 CHT.
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Symptom: No CHT in one or more columns.
Cause: Faulty probe. Turn top knob on GEM to the probe analysis page to check probe
Integrity. For 8 foot harness on probe analysis page resistance should be 8 - 3 EGT / 1 - 6
CHT. For 24 foot harness on probe analysis page resistance should be 26 - 10 EGT / 4 - 18
CHT.
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 apply 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 ignition harness,
unless both are faulty. Verify that the probe wires and GEM series system harness are isolated
from the ignition harness. If necessary, repair or replace the faulty ignition harness to eliminate
ignition related interference.
Symptom: Display is unstable.
Cause: Magneto ungrounded or defective P-lead. Check ignition harness for proper shielding,
grounding, and loose spark plug caps. Check magnetos for proper grounding or evidence of arcing.
Disconnect magneto P-leads one at a time. If this eliminates or reduces the problem, replace the Plead. A faulty ignition harness will typically cause all EGT readings 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 commutator.
Symptom: Display is affected by radio transmissions.
Cause: Proximity of probe and/or display unit to the radio power wiring and away from radios 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 required for proper operation of the
connector. Utilize shielded-twisted pair for power leads.
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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 carbureted 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 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 diagnostic information.
Symptom: All EGT readings too high.
Cause: Readjust the EGT “BAR HEIGHT” on the Display.
Cause: Possible aircraft ground fault. Test for this by temporarily removing the black GEM ground wire from
the airframe and provide an extension directly to the engine block. If this test fixes the bar height an engine
ground fault should be suspected. Use a DVM (digital voltmeter) to measure the difference between the
instrument ground and engine block ground with the engine running and the battery charging. If the difference
is greater than 2 V DC with the alternator charging, 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”.
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Drawings
Drawing No.
Revision #
Title
Date
#8252
E
GEM CONNECTIONS FOR CONTINENTAL ENGINES
MAR 31/08
#8253
E
GEM CONNECTIONS FOR LYCOMING ENGINES
MAR 31/08
#8254
C
GEM PROBE CONNECTIONS
MAR 31/08
#1200-016
C
OAT/IAT PROBE MOUNTING DETAIL
MAR 31/08
#610C-315
D
DSUB 25-PIN INTERCONNECT DIAGRAM P1
Sept 1/11
#610C-315
D
DSUB 25-PIN INTERCONNECT DIAGRAM P2
Sept 1/11
#G4-315
A
DSUB 37-PIN INTERCONNECT DIAGRAM P1
Dec 10/10
#G4-315
A
DSUB 37-PIN INTERCONNECT DIAGRAM P2
Dec 10/10
#930309
C
GEM/GEMINI DISPLAY OUTLINES
MAR 31/08
#1200-018
E
GEM WIRING DIAGRAM
NOV 1/11
#610C-001
D
GRAPHIC ENGINE MONITOR
Sept 1/11
#G4-001
A
G4 GRAPHIC ENGINE MONITOR
JUNE 21/10
#1000-303
D
FLOW SENSOR MOUNTING DIAGRAM 1 - 3
Dec 10/10
#101116
A
FUEL FLOW ADAPTER WIRING DIAGRAM
Dec 15/10
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If you have difficulty installing or using a G3 or G4 system, please read the G series documentation. Every G
series system is shipped with complete instructions for installation and use on a CD. You may also find the
same information on our website www.insightavionics.com under G3 Documentation.
The answers to many technical questions can be found in these documents. Insight provides customer support
free of charge for as long as you own the instrument. If you have any questions concerning G series 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
Educational Video on CD
To assist our customers in installing and using GEMs, Insight has produced an educational 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 initial configuration during installation, the G series requires no adjustment or routine maintenance. The G series routinely performs a self-test on power-up to test its vital functions. Should the G series fail this test, it will halt on a
red screen with a description of the error. Errors of this nature must be returned to the factory for service.
If the instrument performs the self-test successfully but you feel that the instrument is not functioning as expected discuss the problem with your dealer, or consult the troubleshooting section of the G series Installation Instructions. Keep in mind that in the vast majority of cases, erratic or unusual G series operation can be
traced to an installation problem, a problem with probes, wiring harness or the aircraft’s electrical system.
Due to its reliability and the extensive testing that it undergoes, the instrument itself is the least likely source of
trouble. For this reason we strongly 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. By contacting us first we may be able to assist you in correcting your
problem without the hassle and downtime of sending in an instrument that is not the source of the difficulty.
Technical Support Contact Phone Numbers:
(905) 871-0733
Web: www.insightavionics.com
E-mail: G3TechSupport@InsightAvionics.com
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