610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 INSTALLATION MANUAL FOR INSIGHT GEM 610C-001 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 If You Read Nothing Else Read This page! Follow these recommendations to minimize installation related problems. GEM 610C (G3) 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 Warranty policy The Insight Instrument Corp.’s 610C Graphic Engine Monitor (G3) 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 Table of Contents IF YOU READ NOTHING ELSE READ THIS PAGE! ................................................................. 2 G3 INSTALL LOCATION CAUTIONARY NOTICE ...................................................................... 2 G3 FUEL TOTALIZER CAUTIONARY NOTICE .......................................................................... 2 WARRANTY POLICY .....................................................................................
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 Table of Contents CHT PROBE WIRING ............................................................................................................... 13 ROUTING THE WIRING HARNESS ......................................................................................... 13 CONNECTING AND ROUTING THE OAT HARNESSES ......................................................... 13 CHECKING THE INSTALLATION ......................................................
10C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 INTRODUCTION This Installation Manual will acquaint you with the installation requirements, operational functions and some of the powerful features of the advanced 610C Graphic Engine Monitoring (G3). Please read it carefully and completely before starting. Insight Instrument Corp.’s G3 Graphic Engine Monitors provides simultaneous analog and digital) display of engine temperatures for nearly all makes and models of piston-powered aircraft.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 INTRODUCTION 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 Installing The Turbine Inlet Temperature Probes (Model G3) There are three types of Turbine Inlet Temperature (TIT) probes which can be used with the GEM G3 series system.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 Wiring Considerations The G3 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 engagement of the connector. Before installing, confirm that the factory fabricated harness connector matches wiring diagram, Drawing # 1200-018.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 CAUTION: For upgrade installations (GEM 602/603/610 to G3); 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 Checking The Installation Verify the power and ground connections before applying aircraft power. Pin 15 on the G3 series Display is aircraft ground and pin S is approximately +14V DC or +28V DC (See Drawing No. 1200-018). For Model G3, pin 15 must be connected to the ground bus (airframe ground). When power is initially applied, the GEM series Display will illuminate to full brightness.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 FLIGHT TESTING THE G3 It is essential that the G3 series Display 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 G3 series don’t hesitate to contact Insight Product Support.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 Trouble-shooting 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 G3 series Display does not illuminate. Cause: No ground return at Pin 15, of the edge connector either from the engine case or from airframe ground Symptom: The G3 series Display does not illuminate.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 Symptom: No CHT in one or more columns. Cause: Faulty probe. Turn top knob on G3 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 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.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 Drawings Drawing No.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL INSIGHT INSTRUMENT CORP. DOCUMENT No. 070906 REV. 1.
610C-001 INSTALLATION MANUAL DOCUMENT No. 070906 REV. 1.2 If you have difficulty installing or using a G3 system, please read the G3’s documentation. Every G3 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.
