Alcor, Incorporated - ALCAL 2000ALCOR ® produces both types of ALCAL EGT/CHT System Tester User’s Guide 46 ALCAL EGT/CHT System Tester User’s Guide 3 NEW ALCOR P/N 86240 86255

ALCAL 2000®

USERS GUIDE

P/N 59207REV.B. 8/02

Take a Flight to OurWebSitewww.alcorinc.com

300 BreesportSan Antonio, Texas 78216Phone 210/349/6491Fax 210/308/8536Toll free 800/354/[email protected]

Web site: www.alcorinc.com E-Mail: [email protected]

ALCAL EGT/CHT System Tester User’s Guide

Millivolt: One Thousands of a volt.

Ohms: Unit of Resistance.

Peak: the demonstrated absolute positive value relative to sampled tem-perature range. The point at which the needle on a meter begins to fallwhile leaning mixture.

PMA: Part Manufacturing Approval

POH: Pilot Operating Handbook

Polarity: Correct connections in regards to positive + and negative –.

Potentiometer: A variable electrical resistor used to regulate current.

Probe: A thermocouple composed of two wires of dissimilar metals joinedtogether at one end. When this junction is heated, a millivolt signal is gen-erated. The word probe is used interchangeably throughout this manual.It can also be a thermistor /RTD device that does not output electricity butchanges the grounding potential or current/voltage to an amplified meterwith temperature.

Relative Scale: Does not depict true temperature but merely the relativemark on the dial that peak temperature was detected when leaning beforeneedle began to fall.

Resistance: The opposition to the flow of current that converts electricalenergy into heat. Unit of measurement is the Ohm.

RTD, Resistance Type Device: Any sensing device that varies resistance/current/voltage with temperature.

Set Point: The temperature selected with the heater control knob of theALCAL® 2000 and verified by the LCD display.

TBO: Time Before Overhaul

T/C: Thermocouple

Thermistor: See Resistance Type Device

Thermocouple: See Probe

TIT: Turbine Inlet Temperature

TOT: Turbine Outlet Temperature

Turbine Inlet Temperature: Temperature measured at the exhaust intakeof a turbocharger. The purpose being to provide an operational limit valuewhich is not to be exceeded (in most cases 1650°F).

Type-E: Thermocouple/Lead comprised of Chromel/Constantan wire. Thecolor-coding and polarity is +Brown/-Red. Industry Standard is +Purple/-Red.

Type-J: Thermocouple/Lead comprised of Iron/Constantan. The colorcoding and polarity is +Black/-Yellow. Industry Standard is +White/-Red.

Type-K: Thermocouple/lead comprised of Chromel and Alumel wire. Thecolor-coding and polarity is +Yellow/-Red.

UCS: Universal Cylinder Selector switch.

Un-Amplified: Relies totally on electricity produced by thermocouple tooperate. No aircraft bus voltage is required.

Ungrounded: Unconnected to or shielded from ground source.

TABLE OF CONTENTSI. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Basic Thermocouple/Meter Theory . . . . . . . . . . . . . . . . . . . . . . . . . . .2Component Items and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .7ALCOR® Meter and Probe Accessories . . . . . . . . . . . . . . . . . . . . . . .12Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

II. TESTING AND CALIBRATING METERS . . . . . . . . . . .14Method 1: Simulating Thermocouple Output . . . . . . . . . . . . . . . . . . .14Method 2: Using Thermocouple Output . . . . . . . . . . . . . . . . . . . . . .16Bench Testing EGT/TIT/CHT Meters . . . . . . . . . . . . . . . . . . . . . . . .18Miscellaneous, Non-ALCOR® Meters . . . . . . . . . . . . . . . . . . . . . . . .19

III. TESTING THERMOCOUPLES . . . . . . . . . . . . . . . . . ..20Method 1: Resistance Test, EGT/TIT/CHT . . . . . . . . . . . . . . . . . . . .20Method 2: Simple Functional Tests Using Heat . . . . . . . . . . . . . . . .20Method 3: Accuracy Test, EGT/TIT/CHT Thermocouples . . . . . . . . .22Method 4: Optional Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

IV. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .25Meters and Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Frequently Asked Questions, FAQ’s . . . . . . . . . . . . . . . . . . . . . . . . .27Engine Problems in Flight using EGT . . . . . . . . . . . . . . . . . . . . . . .30

V. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . .31Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Calibration & Repair of your Alcal® 2000 . . . . . . . . . . . . . . . . . . . .32ALCAL®2000 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Contact ALCOR® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

VI. TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Competitor Info & Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Temperature Vs Millivolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35ALCOR Product Cross Reference . . . . . . . . . . . . . . . . . . . . . . . . . .36Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

ALCAL EGT/CHT System Tester User’s Guide48 1

FIGURES1. 2 1/4” Single Front Adjust ............42. 2 1/4” Single Rear Adjust, screw .43. 2 1/4” Single Rear Adjust, plug....44. 3 1/8” Dual Front Adjustment.......45. 3 1/8” Dual Rear Adjust, screw....46. 2 1/4” Dual Front Adjust...............47. Multi Cyl Comb Analyzer .............48. Panel Components ......................69. Compartment Cover ....................810. Fuse...........................................911. Field Operating Instr.................1112. CHT Heater..............................12

13. EGT Heater..............................1314. EGT Ext Ref Thermocouple ...........1415. CHT Heater Thermocouple......1516. Test Cable................................1617. Ext Lead ..................................1718. Type K Transition Adapter .......1819. CHT Bayonet Adapter..............1920. CHT Gasket Adapter ...............2021. Calibration Screwdriver............2122. UCS Switch..............................2223. Reverse Stagger Jumper.........2324. Exhaust Hole Adapter..............2425. Fire Sleeve ..............................25

ALCAL EGT/CHT System Tester User’s Guide 47

GENERAL DESCRIPTIONThank you for purchasing the new ALCAL® 2000 EGT/TIT/CHTTester/Calibrator! The ALCAL® 2000 has long been a favorite test methodfor aviation technicians and mechanics since 1970. This latest generationtester comes complete ready to test and calibrate all ALCOR® type K, J, &E meters and thermocouples, as well as other types of temperature sens-ing equipment.

The rugged integrated circuit will achieve exceptional accuracy throughextreme temperature ranges. The large liquid crystal display is well suit-ed for this application because of its low power requirements, largenumerals, and readability in the widest range of lighting. An internal bat-tery allows complete portability for meter calibration, free of problemsassociated with getting power to the aircraft. Your ALCAL® 2000 comescomplete with batteries and all necessary components to perform metercalibrations and probe testing.

BASIC THERMOCOUPLE /METER THEORYA basic ALCOR EGT (Exhaust Gas Temperature), TIT (Turbine Inlet

Temperature) or CHT (Cylinder Head Temperature) system is com-posed of a thermocouple probe, an extension lead, and a mil-

livolt meter.

THERMOCOUPLEA thermocouple is composed

of two wires of special dissimilar metals joined together atone end. Different combinations of these dissimilar metals can beemployed to make a thermocouple, and each combination generates adifferent voltage at a given temperature. (See Chapter VI. Tables,Temperature vs Millivolt).

Regardless of manufacturer, it is important that the meter used isthe same type as the thermocouple and lead wire.

When this junction is heated, a millivolt (thousandths of a volt) is gener-ated. This voltage is proportional to the temperature difference betweenthe hot junction and the point where the voltage was measured (called theCold/Reference Junction).

Volts = S x (T2 - T1)

T2 equals the temperature at the hot junction, T1 equals the temperatureat the cold junction, and S equals the proportional constant. The propor-tional constant is referred to as the Seabeck coefficient. For example theSeabeck coefficient is about 22.2 microvolts per degree F for type K ,

I INTRODUCTION

ALCAL EGT/CHT System Tester User’s Guide2

GLOSSARYALCAL ® 2000: ALcor CALibrator

Alumel: A type of special thermocouple metal used on Type-K,Chromel/Alumel thermocouples. It is magnetic.

Amplified: The process of increasing the strength of a signal, current or power.

Analog: data represented by mechanical/physical means (i.e. a needle).

Calibration: Meter or thermocouple is compared to known values (Institute ofStandards and Technology)

Chromel: A type of special thermocouple metal used on Type-K,Chromel/Alumel thermocouples. It is non magnetic.

CHT: Cylinder Head Temperature

Constantan: A type of special thermocouple metal used on Type-E,Chromel/Constantan thermocouples. It is non magnetic.

Cylinder Head Temperature: Temperature measured either inside thecasting of the cylinder head by means of a hole under the lower spark plug(when provided) or measured by means of a round thermocouple sensorlocated under the spark plug.

Decade Box: A test apparatus used to simulate the lead/thermocoupleresistance when bench checking a meter.

EGT: Exhaust Gas Temperature

Element: Heat sensing portion of EGT/TIT thermocouple made using aspecial ALCOLOY® process.

Exhaust Gas Temperature: Temperature of exhaust gas inside theexhaust pipe.

Grounded: Mechanically bonded to negative electrical source on aircraft.

Indicators: See Meter

Iron: A component of Type-J thermocouples and wire that are composedof Iron and Constantan. It is sensitive to oxidation, especially at very hightemperatures and magnetic.

LED: Light Emitting Diode

LCD, Liquid Crystal Display: A common form of display device that relieson energizing crystals so that a letter or number can be displayed.

LCD: Liquid Crystal Display

Lead (lead): Provides pathway for electricity or resistance variations sothat those variables can be read in the form of temperature on an indica-tor.

MCCA: Multi Cylinder Combustion Analyzer(EGT/ 46353 & 46354, CHT-/ 46363, 46364,& 46365 / Piper)

MEL: Minimum Equipment List, all items listed must be in working orderor aircraft may not be considered airworthy.

Meter: Any digital or analog display that depicts temperature, pressure,etc. The words meter, indicator, gauge are used interchangeably.

Chromel/Alumel thermocouples. From this equation it can be seen thatthe voltage varies if the cold junction temperature changes, even if the hotjunction temperature does not change. Because of this, the cold junctiontemperature must be known if the hot junction temperature is to be deter-mined. By knowing the Seabeck coefficient for the thermocouple typeused, the cold junction temperature, and the measured voltage, then thehot junction temperature can be calculated. Most all thermocouple probesrequire an extension lead wire to carry the thermocouple voltage to theEGT, TIT, or CHT voltmeters. This extension wire is made of the sametype of wire as the thermocouple wire in the probe. This locates thecold junction at the back of the meter.

ALCOR® EGT/TIT, Type K and E thermocouples may be grounded orungrounded, depending on the meter being used (ALCOR® meters can useboth types). EGT and TIT probes come in two basic styles. Generally EGTprobes are attached to the exhaust pipe using a clamp and TIT probesscrew into the exhaust pipe just before the turbocharger.

ALCOR® CHT,Type J thermocouples are grounded. CHT bayonet styleprobes are mounted in a hole below the lower spark plug, using a specialadapter which allows for easy installation and removal. If the hole is usedfor a pre-heater or does not exist, then a gasket type thermocouple mustbe used and installed below the spark plug, replacing the standard copperwasher. It must be noted however that a gasket type can run 50°F to100°F (usually about 60°F) hotter than the bayonet style because of thelocalized heat sink characteristics of a spark plug. Bayonet styles that arenot spring loaded do not use special adapters to allow metal contact inthermal well bottom and are not as accurate as those that make contact.

Many manufacturers of EGT/CHT indicators, in particular digital instru-ments, use Type K for both CHT and EGT. (See Chapter VI. Tables)

Resistance Type Devices (RTDs), do not produce millivolts and thereforeare not to be confused with thermocouples. They are primarily used inCHT applications and the most common are approximately 1 inch longand look somewhat like a miniature spark plug (Delco AC and RochesterP/Ns 1514340, 1513431, 333A, and 333B). They have a single wire,which provides ground potential to the indicator. Other types are quarter-turn bayonet styles with two wires (AN5546-1). Two wire types rely onresistance changing voltage to the meter. Single and dual wire types caneasily be checked by comparing resistance from probe terminal to probebody or between terminal connectors at a given temperature. No informa-tion is currently available in Chapter VI, TABLES for resistance values ofthermistors.

METERSMeters/Indicators are either powered by the aircraft electrical system(amplified) or solely by the millivolts produced by the thermocouple (un-amplified) which use a meter movement. ALCOR® produces both types of

ALCAL EGT/CHT System Tester User’s Guide46 ALCAL EGT/CHT System Tester User’s Guide 3

NEW ALCOR P/N86240862558625586156862458627586275862818627586255863078630886309863108624086240862558625586l4386230861568615686149861538627586275862758622686226862458615986160861618616286202862512820286146 (RTD)

WIRE COLOR

R/YR/YR/YR/BRR/YR/YR/YR/YR/YR/YR/YR/YR/YR/YR/YR/YR/YR/YR/YR/YR/BRR/BRR/BRR/BRR/YR/YR/YR/YR/YR/YR/YR/YR/YR/YY/BLY/BL

Copper

TYPE

Screw-InClampClampClampScrew-InClampClampClampClampClampScrew-In UngroundScrew-In UngroundScrew-In UngroundClamp UngroundScrew-InScrew-InClampClampScrew-InScrew-InClampClampScrew-InScrew-InClampClampClampClampClampScrew-InScrew-InScrew-InScrew-InScrew-InSpark PlgBayonetAdapter for Bayonet probeBayonet

SIZE

7/16”-203 1/4” MAX3 1/4” MAX3 1/4” MAX7/16”-203 1/4” MAX3 1/4” MAX3 1/4” MAX3 1/4” MAX3 1/4” MAX1/4” NPT7/16”-20716”-202.35” MAX7/16”-207/16”-203 1/4” MAX3 1/4” MAX1/4” NPT Female1/4” NPT3 1/4” MAX3 1/4” MAX7/16”-201/4” NPT3 1/4” MAX3 1/4” MAX3 1/4” MAX3 1/4” MAX3 1/4” MAX7/16”-201/4” NPT7/16”-201/4” NPT1/8-27MPT18 MM

STAGGER

NormalNormalNormalNormalReverseReverseReverseNormalReverseNormalNormalNormalNormalNormalNormalNormalNormalNormalNormalNormalNormalNormalNormalNormalReverseReverseReverseReverseReverseReverseReverseReverseReverseReverse

RESISTANCE

.80±.1 ohms

.80±.1 ohms

.80±.1 ohms

.85±.15 ohms

.70±.10 ohms

.8±.1 ohms

.8±.1 ohms

.85±.10 ohms

.8±.1 ohms

.80±.1 ohms

.71±.03 ohms

.71±.03 ohms

.80±.1 ohms

.80±.1 ohms

.80±.1 ohms

.80±.1 ohms

.89±.10 ohms

.80±.1 ohms

.85±.15 ohms

.85±.15 ohms

.97±.15 ohms

.97±.15 ohms

.80±.1 ohms

.80±.1 ohms

.80±.1 ohms

.70±.10 ohms

.70±.10 ohms

.70±.10 ohms

.70±.10 ohms

.70±.10 ohms

.70 ±.1 ohms

.13+.15,-.05 ohms

.24±.05 ohms

OLD PART NUMBER8614286145861478615586157861658616786225862368625886271862728629186293001-005-3B001-005-5B001-005-A36001-005-A44001-005-N001-005-N2MCI-106-A36MCI-106-A44MCI-106-BMCI-106-HMCI-A106-A36MCI-A106-A36PMCI-A106-A44MCI-A106-A4453MCI-A106-A44SMCI-A106-BMCI-A106-HMCI-A106-J1MCI-A106-KMCI-A106-NAN5540-2AN5541-1AN4076-1AN5546-1

APPROX.LENGTH14.20”13.81”13.81”11.56”12.2”13.8”13.8”15.0”13.81”13.81”10.0”12.0”31.50”30.00”14.20”14.20”13.81”13.81”14.75”14.20”11.56”11.56”12.20”12.20”13.8”13.8”13.8”11.70”11.70”12.20”12.20”12.20”

9.50”12.75”12.0”15.0”

14.5”to15.5”

PROBE CROSS REFERENCE

Red and Yellow is Chromel Alumel Wires (R/Y)Red and Brown is Chromel Constantan (R/BR)Yellow and Black is Iron Constantan (Y/BL)Reverse Stagger is Short Yellow Wire instead of Short Red WireScrew-In: Probe screws into adapter welded on exhaust mostly for measuring TIT.Clamp: Uses Radiator Clamp to mount Probe on Exhaust

meters. All displays are in 25 degree increments with every fourth one rep-resenting 100 degrees for both Centigrade and Fahrenheit dials.

Un-amplified meters use meter movements powered solely by the milli-volts generated from the thermocouple probe. Meter movements will drawsome current, as much as 0.7mA. Because of this, differences in the resis-tance due to variations in length of the thermocouple extension lead willhave an effect on the indicator calibration. (Ohms Law, E=IR, E=Voltage,I=Current, R=Resistance, shows that current flow through a resistance willcause a voltage drop, so variations in resistance will cause variations involtage drop.) A potentiometer is provided to cali-brate the indicator to the combined lead/proberesistance. It is this potentiometer that is adjustedwhen using the ALCOR ® 2000 to calibrate an indi-cator to allow more or less current to reach themeter movement. Potentiometer access willeither be from the front or rear of the meterdepending upon manufacturer and age. ALCOR ®

meters that were manufactured since 1980will have a carbon potentiometer accessiblefrom the front througha small hole. All otherALCOR ® meters will havea rear adjustable rheo-stat-type potentiometeraccessible througheither: 1) a hole coveredwith a plug which isremoved and a #2 bladescrewdriver is inserted,or 2) a Phillips headplastic screw. Rearadjustable meters maynot be repairable due tounavailability of parts.ALCOR® provides a cali-bration screwdriver,(Item 33) which shouldremain in the cockpitafter installation forfuture calibration needs.

When resistance ischanged anywhere inan un-amplified system(i.e. lead is shortenedor lengthened), themeter will have to bere-calibrated. Amplified,


FIGURE 1

FIGURE 4

FIGURE 5

FIGURE 6

FIGURE 7

FIGURE 2

FIGURE 3


NEW ALCOR P/N461504615046150461504615046150461504615046150461504615046500-1246500-1246500-1246500-1246500-124615046500-1146500-1146500-546500-34615046500-1046500-9No Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct Cross

PART NO.210-8ALC/12V210-8ALC/24V210-8B210-8BL/12210-8BL/24210-8BLC/12V210-8BLC/24V210-9A210-9AL/210-9B210-9BL/12V210-10A210-10B210-10BL/12210-10BL/24210-10BTR210-13BTR210-16A210-16B210-16BL/12210-16BL/24210-17BTR210-17BTR/12210-17BTR/24210-19B214-2A217-3A PB217-3ATR217-3B217-3BL/12217-3BPB-4217-3BPB-6217-3BTR224-1B224-2B224-2BLTR/12224-3B224-4B224-5B224-6B226-1B226-1BL/24226-1BL/12226-2B226-3B226-3BL/12226-3BL/24

NOTESTR celsius dial, L12V, re-cal, 3.3 ohms @ 900°C Rd.Ln.TR celsius dial, L24V, re-cal, 3.3 ohms @ 900°C Rd.Ln.3.3 ohms 1550°FL12V, 3.3 ohms 1550°FL24V, 3.3 ohms 1550°FTR celsius dial, L12V, re-cal, 3.3 ohms @ 900°C Rd.Ln.TR celsius dial, L24V, re-cal, 3.3 ohms @ 900°C Rd.Ln.3.3 ohms 1550°FL24V, 3.3 ohms 1550°F3.3 ohms 1550°FL12V, 3.3 ohms 1600°FTR dial, 3.3 ohms 1600°FTR dial, 3.3 ohms 1600°F.TR dial, 3.3 ohms @ 1600°FTR dial, 3.3 ohms @ 1600°F TR dial, 3.3 ohms @ 1600°F 3.3 ohms @ 1650°F TR dial, 3.3 ohms @ 1650°F.TR dial, 3.3 ohms @ 1650°FTR dial, L12V, 3.3 ohms @ 1650°FTR dial, L24V, 3.3 ohms @ 1650°FTR celsius dial 3.3 ohms @ 900°CTR dial, 3.3 ohms @ 900°C3.3 ohms @ 900°C3.3 ohms @ 1650°F3.3 ohms @ 900°CCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1500°FCHT 2.0 ohms @ 500°F / EGT 3.7 ohms @ 1550°FCHT 2.0 ohms @ 500°F / EGT 3.7 ohms @ 1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1600°F 7.6 ohms @ 1550°F7.6 ohms @ 1600°F4.8 ohms @ 1650°F7.6 ohms @ 1600°F7.6 ohms @ 900°C6.1 ohms @ 1650°F7.6 ohms @ 1650°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°F

DESCRIPTION2 1/4 SE EGT C/A 90”L12 V2 1/4 SE EGT C/A 90”L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L12 V2 1/4 SE EGT C/A 90”L24 V2 1/4 SE EGT C/A 90”L12 V2 1/4 SE EGT C/A 90”L24 V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L12 V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L12 V2 1/4 SE EGT C/A 90”L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE TIT C/A 90”2 1/4 SE TIT C/A 90”2 1/4 SE EGT C/A 90”L12 V2 1/4 SE TIT C/A 90”L24 V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L12 V2 1/4 SE EGT C/A 90”L24 V2 1/4 SE EGT C/A VERTICAL 90”3 1/8 SE CHT/EGT I/C C/A 76”90”3 1/8 SE CHT/EGT I/C C/A 76”90”3 1/8 SE CHT/EGT I/C C/A 76”90”3 1/8 SE CHT/EGT I/C C/A L12V31/8 SE CHT/EGTI/CC/A 76”100”31/8 SE CHT/EGTI/CC/A 76”100”3 1/8 CHT/EGT I/C C/A 76”90”2 1/4 TE EGT/EGT C/A 240”2 1/4 TE EGT/EGT C/A 20’2 1/4 EGT L12V2 1/4 TE EGT/EGT C/A 20’2 1/4 TE EGT/EGT C/A 20’2 1/4 TE EGT/EGT C/A 25’2 1/4 TE EGT/EGT C/A 240”2 1/4 SE CHT/EGT I/C C/A 76”90”2 1/4 SE CHT/EGT I/C C/A L24V2 1/4 SE CHT/EGT I/C C/A L12V2 1/4 SE CHT/EGT I/C C/A 2 1/4 SE CHT/EGT I/C C/A 76”90”2 1/4 SE CHT/EGT I/C C/A L12V2 1/4 SE CHT/EGT I/C C/A L12V

No Direct Cross: There is no direct Cross Reference Number, call Alcor ®

2 1/4: Fits 2 1/4” diameter hole3 1/8: Fits 3 1/8” diameter holeSE: Single EngineTE: Twin EngineC/A: Chromel/Alumel. Type KI/C: Iron/Constantan, Type JC/C: Chromel/Constantan, Type EL: Lighted Internally

TR: True Temperature Reading DialXXX: Meter is calibrated to Lead LengthRe-cal: Re-calibrate*Option: change system to C/A because new

C/C costs more.PB: Piggy Back Switch

©1999 Alcor, Inc.

bus powered meters, are not affected in this manner, due to the fact thatthey have a solid state circuit that amplifies the millivolt signal. This ampli-fied signal powers the meter movement or digital display. This amplifierdraws very little current; therefore, differences in resistance due to varia-tions in length of the thermocouple extension lead have no effect on cal-ibration for resistance changes less than 25 ohms. Usually digital metersdo not require calibration in the field but ALCOR® indicators should be cal-ibrated to establish peak EGT at 4/5 scale (at the asterix * mark).

EXTENSION LEADS Since ALCOR® thermocouples or probesare only about 15 inches long, an exten-sion lead wire must be used to extend the

thermocouple wire from the probe to the meter.

Extension lead must match meter and thermocouple type.

Most extension leads are 18 gauge for EGT and 20 gauge for CHT, andboth are made of two, seven stranded wires. Leads over 25 feet in lengthrequire 16-gauge wire to minimize resistance on un-amplified meters.ALCOR® lead wires manufactured before the late 1970’s will have a wovencloth like cover as an outside insulator. Other manufacturers of amplifiedor digital-type meters are not concerned with resistance and generallyuse a much lighter gauge wire. Beware of inexpensive single strandlead or thermocouple wire since it is prone to premature break-age. Lead and thermocouples manufactured as one completeunit can also pose problems because entire lead/probe must bereplaced when probe fails. UUUU SSSS EEEE OOOO NNNN LLLL YYYY GGGG EEEE NNNN UUUU IIII NNNN EEEEAAAA LLLL CCCC OOOO RRRR RRRR EEEE PPPP LLLL AAAA CCCC EEEE MMMM EEEE NNNN TTTT PPPP AAAA RRRR TTTT SSSS

EGT/TIT Type K extension leads are covered in yellow Teflon and haveone each insulated Chromel/Alumel wire bundle. Type E extension leadsare covered in brown Teflon and have one each insulatedChromel/Constantan wire bundle. Type E is no longer used in newEGT/TIT products and have been replaced by Type K.

Note: ALCOR® continues to manufacture replacement Type E leadsand thermocouples, but at a greater cost than conventional Type K.If a Type E probe in a single engine system fails consider replacingmeter, lead, and probe with new Type K components! ContactALCOR® for details.

CHT Type J extension leads are covered in black Teflon and have oneeach insulated Iron/Constantan wire bundle. In order to maintain accura-cy CHT systems are required to have the same lead and probe loopresistance regardless of length. Systems dating before about 1978 were2 ohms and later changed to 8 ohms for both lead and probe. This isaccomplished by placing a small resistor into the lead itself thereby main-taining loop resistance regardless of lead length. In this way the indicatorwill be accurate regardless of the application and or lead length.


NEW ALCOR P/N461554615546155461554615546155461554615546000-146000-146000-1No Direct Cross46000-746150,42525,85255Opt:45993 or 4612546150,42525,8525546150,42525,8525546150,42525,852554616446150,42525,852554615046150,42525,852554615046150,42525,852554616446150,42525,85255461504615046150,42525,8525546150461644616446125461254612546125461254612546125461254612546125461254612546125No Direct Cross46199-7No Direct CrossNo Direct Cross46500-746500-7461504615046150461504615046150

PART NO.205-31B205-31/BL/24205-33A205-33B205-34A205-34B205-35A205-35B205-37B/20205-37B/28205-37B/22205-39B205-40B206-2A*206-2AD206-2B*206-7A*206-7B*206-7BL/24206-8A*206-8AL/24*206-8B*206-8BL/24*206-9A*206-9ATR*206-9B*206-9BL/12*206-9BL/24*206-10A*206-10B*206-10BTR*206-13BTR*209A-1A209A-1BTR209-1A209-1B209-1BL/12209-1BL/24209-1BLTR/12209-1BLTR/24209-1BTR209-7A1209A-7A2209A-7B3209-7B3209-17BTRC209-29A210-4A210-4B210-5A210-5B210-7A210-7AL/24210-7B210-7BL/24210-8A210-8AL/24

DESCRIPTION3 1/8 TE EGT/EGT C/A 16’3 1/8 TE EGT/EGT C/A 16’ L24V3 1/8 TE EGT/EGT C/A 25’3 1/8 TE EGT/EGT C/A 25’3 1/8 TE EGT/EGT C/A 42’3 1/8 TE EGT/EGT C/A 42’3 1/8 TE EGT/EGT C/A 25’3 1/8 TE EGT/EGT C/A 25’3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 28’3 1/8 TE EGT/EGT C/A 22’3 1/8 TE EGT/EGT C/A 240’3 1/8 TE EGT/EGT C/A 240’2 1/4 SE EGT C/C 100”3 1/8 TE C/C or 2 1/4 SE C/A2 1/4 SE EGT C/C 100”2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”L24V2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/A 90”L24V2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”TR2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”L12V2 1/4 SE EGT C/C 90”L24V2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 240”L12V2 1/4 SE EGT C/A 240”L24V2 1/4 SE EGT C/A 240”L12V2 1/4 SE EGT C/A 240”L24V2 1/4 SE EGT L/R C/A 240”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 240”3 1/8 SE EGT C/A 100°F 250R2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L24V

NOTESTR dial, 6.2 ohms @ 1650°FTR dial, L24V, 6.2 ohms @ 1650°FTR dial, re-cal, 6.1 ohms @ 1650°FTR dial, re-cal, 6.1 ohms @ 1650°FTR dial, re-cal, 7.7 ohms @ 1650°FTR dial, re-cal, 9.7 ohms @ 1650°FTR dial, re-cal, 6.1 ohms @ 1650°FTR dial, re-cal, 6.1 ohms @ 1650°FTR dial, re-cal, 7.6 ohms @ 1650°FTR dial, Re-cal, 6.8 ohms @ 1650°FTR dial, re-cal, 8.2 ohms @ 1650°F7.6 ohms @ 1725°F7.6 ohms @ 1650°F4.2 ohms @ 1650°FOptn: If 3 1/8 space use 45993 or 2 1/4 space use 461254.2 ohms @ 1650°F3.8 ohms @ 1550°F3.8 ohms @ 1650°FTR dial, 3.8 ohms @ 1650°F3.8 ohms @ 1550°F3.8 ohms @ 1550°F3.8 ohms @ 1550°FL24V, 3.8 ohms @ 1550°F3.8 ohms @ 1550°FTR dial, 3.8 ohms @ 1650°FTR dial, 3.8 ohms @ 1550°FL24V, 3.8 ohms @ 1550°FL24V, 3.8 ohms @ 1550°F3.8 ohms @ 1550°F3.8 ohms @ 1550°FTR dial, 3.8 ohms @ 1650°FTR dial, 3.8 ohms @ 1650°FRe-cal, 7.6 ohms @ 1500°FTR dial, re-cal, 7.6 ohms @ 1600°FRe-cal, 7.6 ohms @ 1500°FRe-cal, 7.6 ohms @ 1500°FL12V, re-cal, 7.6 ohms @ 1500°FL12V, re-cal, 7.6 ohms @ 1500°FTR dial, L12V, re-cal, 7.6 ohms @ 1600°FTR dial, L24V, re-cal, 7.6 ohms @ 1600°FTR dial, re-cal, 7.6 ohms @ 1600°FRe-cal, 7.6 ohms @ 1500°FRe-cal, 7.6 ohms @ 1500°FRe-cal, 7.6 ohms @ 1500°FRe-cal, 7.6 ohms @ 1500°F7.6 ohms @ 850°CF: 4.2 ohms, R: 9.2 ohms @ 1550°FTR dial (upside down), 3.3 ohms @ 1725°FTR dial (upside down), 3.3 ohms @ 1725°FTR dial (upside down), 3.3 ohms @ 1600°FTR dial (upside down), 3.3 ohms @ 1600°FTR dial, re-cal, 3.3 ohms @ 1650°FTR dial, L24V re-cal, 3.3 ohms @ 1650°FTR dial, re-cal, 3.3 ohms @ 1650°FTR dial, L24V re-cal, 3.3 ohms @ 1650°F3.3 ohms @ 1550°F L24V, 3.3 ohms 1550°F


FIGURE 8


NEW ALCOR P/N461994599346199-846199-846199-946199-946199-24599345993459934599346199-546199-546199-5 46199-4459934599346199-646199-746000-646000-446000-646000-4461554615546000-546000-5461554615546000-546000-546000-246000-1346000-24626046155461554615546155461554615546155 46155 460024600246002 46002 461554615546000-846000-8461554615546000-246000-346000-346155

PART NO.204-10BL/24/20204-11A204-15A204-15B204-16A204-16B204-16BL/24204-17A204-17B204-18A204-18B/20204-19A204-19B204-19BL/12204-19BL/24204-21A204-21B/18204-21B/250204-29B205-9A205-9AL/24205-9B205-9BL/24205-10A/16205-10A/20205-10AL/24/16205-10AL/24/20205-10B/16205-10B/20205-10BL/24/16205-10BL/24/20205-16A205-16AL/24205-16B205-16BL/24205-17A205-17B205-18A205-18AL205-18B/18205-18B/20205-18BL/24/20205-18BL/12/18205-19A205-19B205-19BL/24205-19BL/12205-21A205-21B205-21BY/225205-21BY/250205-23A205-23B205-24B205-29B205-29BY205-31A

DESCRIPTION3 1/8 TE EGT/EGT C/C 20’ L24V3 1/8 TE EGT/EGT C/C 250”3 1/8 TE EGT/EGT C/C 100°F250R3 1/8 TE EGT/EGT C/C 100°F250R3 1/8 TE TIT/TIT C/C 16’3 1/8 TE TIT/TIT C/C 16’3 1/8 TE TIT/TIT C/C 16’ L24V3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 20’ L12V3 1/8 TE EGT/EGT C/C 20’ L24V3 1/8 TE EGT/EGT C/C 18’3 1/8 TE EGT/EGT C/C 18’3 1/8 TE EGT/EGT C/C 250”3 1/8 TE EGT/EGT C/C 100°F250R3 1/8 TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’ L24V3 1/8 TE TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’ L24V3 1/8 TE EGT/EGT C/A 16’3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 16’ L24V3 1/8 TE EGT/EGT C/A 20’ L24V3 1/8 TE EGT/EGT C/A 16’3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 16’ L24V3 1/8 TE EGT/EGT C/A 20’ L24V3 1/8 TE TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’ L24V3 1/8 TE TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’ L24V3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 18’3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 20’ L24V3 1/8 TE EGT/EGT C/A 18’ L12V3 1/8 TE EGT/EGT C/A 20’ TR3 1/8 TE EGT/EGT C/A 20’ TR3 1/8 TE EGT/EGT C/A 20’ L24V3 1/8TE EGT/EGT C/A 20’TR L123 1/8 TE EGT/EGT C/A 18’3 1/8 TE EGT/EGT C/A 18’3 1/8 TE EGT/EGT C/A 225”3 1/8 TE EGT/EGT C/A 250”3 1/8 TE TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’3 1/8 TE EGT/EGT C/A100°F250R3 1/8 TE EGT/EGT C/A100°F250R3 1/8 TE EGT/EGT C/A 16’

NOTESL24V, re-cal, 8.9 ohms @ 1550°FF: 4.2 ohms @ 1650°F, R: 9.2 ohm @ 1550°FF: 4.2 ohms, R: 9.2 ohms @ 843°CF: 4.2 ohms, R: 9.2 ohms @ 843°CTR dial, 7.3 ohms @ 900°CTR dial, 7.3 ohms @ 900°CTR dial, 7.3 ohms @ 900°C8.9 ohms @1550°F8.9 ohms @1550°F8.9 ohms @1550°F8.9 ohms @1550°F8.9 ohms @ 1600°F8.9 ohms @ 1600°F8.9 @ 1600°F, L12VTR dial, 8.9 @ 1600°F, L24VRe-cal, 8.1 ohms @ 1550°FRe-cal, 8.1 ohms @ 1550°F9.2 ohms @ 1700°FF 4.2 ohms, R 9.2 ohms @ 1550°FTR dial, 6.2 ohms @ 1650°FTR dial, 6.2 ohms @ 1650°FTR dial, 6.2 ohms @ 1650°FTR dial, 6.2 ohms @ 1650°FRe-cal, 6.2 ohms @ 1550°FRe-cal, 7.6 ohms @ 1550°F6.2 ohms @ 1550°FRe-cal, 7.6 ohms @ 1550°FRe-cal, 6.2 ohms @ 1550°FRe-cal, 7.6 ohms @ 1550°F6.2 ohms @ 1550°FRe-cal, 7.6 ohms @ 1550°FTR dial, 6.2 ohms @ 900°CTR dial, 6.2 ohms @ 900°CTR dial, 6.2 ohms @ 900°CTR dial, 6.2 ohms @ 900°CRe-cal, 7.6 ohms @ 1550°F Re-cal, 7.6 ohms @ 1550°FRe-cal, 7.6 ohms @ 1550°FRe-cal, L24V, 7.6 ohms @ 1550°FRe-cal, 6.9 ohms @ 1550°FRe-cal, 7.6 ohms @ 1550°FRe-cal, L24V, 7.6 ohms @ 1550°FRe-cal, L12V, 6.9 ohms @ 1550°FTR dial, 7.6 ohms @ 1600°FTR dial, 7.6 ohms @ 1600°FTR dial, 7.6 ohms @ 1600°FTR dial, 7.6 ohms @ 1600°FRe-cal, 6.9 ohms @ 1550°FRe-cal, 6.9 ohms @ 1550°FRe-cal, 7.2 ohms @ 1700°FRe-cal, 7.8 ohms @ 170O°FTR dial, re-cal, 6.2 ohms @ 1650°FTR dial, re-cal, 6.2 ohms @ 1650°FTR dial, 6.2 ohms @ 900°CF: 3.6, R: 7.8 ohms @ 1550°FF: 3.6, R: 7.8 ohms @ 1550°FTIT dial, 6.2 ohms @ 1650°F

1. Heater Receptacle provides regulated power for both CHT and EGTheaters when used with heater reference thermocouples.

Caution: Never plug heater into heater receptacle or any 110-V recepta-cle without first connecting reference thermocouple.

2. Heater Light comes on when Heater Switch (Item 11) is turned toselected heater. A steady light will indicate that the heater is on and receiv-ing continuous 110-AC voltage and is 100 degrees F. or more belowdesired set point temperature. A blinking light indicates voltage is beingregulated and the temperature is 25 to 50 degrees F from target temper-ature. The light will be off if heater switch or power switch is turned off orheater has exceeded its set point and is in a cool down mode back to itspre-set point.

3. Reference Thermocouple Receptacle receives the heater control ref-erence probe for both CHT (probe externally located) and EGT (probeinternally located) heaters. Plug spade ends are different sizes so plugcan go into receptacle only one way.

4. Terminal Posts provides a connection for the Test Cable (Item 28) clipsin order to read actual heater temperature. Polarity must be correct forproper temperature readout in display.

5. Color Code Reference Bars represent the correct color code of typeJ, K, and E systems and their corresponding polarity (+/-). Type J may alsobe red - and white+, per military specifications. Also be aware that non-ALCOR® systems may have other color codes.

6. Battery Compartment houses the 9-Volt battery that powers the LCDdisplay and the millivolt-input circuit. A second wafer battery located on thecircuit board powers the millivolt output circuit. (See Chapter V. GenInfo/Maintenance)

7. Celsius/Fahrenheit Toggle Switch: selects the type of temperaturereadout, Fahrenheit or Celsius, depending on requirements of the techni-cian and system being tested.

8. Liquid Crystal Display (LCD) indicates the temperature of the heaters,the temperature produced by the thermocouple being tested, or the simu-lated temperature the meters are calibrated to. Battery voltage of 9-Voltbattery is also viewed when Battery Test Button (Item 19) is pressed.

9. Thermocouple Type Switch selects type of system being tested, either“Type J” (Iron/Constantan), Type “K” (Chromel/Alumel), or “Type E”(Chromel/Constantan).

10. Test Cable Receptacle receives Test Cable (Item 28) to input/outputa millivolt signal when testing thermocouples or meters.

11. Heater Switch selects type of thermocouple being tested.


COMPONENT ITEMS AND FUNCTIONNEW ALCOR P/N46500-4 w/UCS 8082546500-146500-1 4616446500-146500-1 46500-14616446500-146500-1 46500-1 46500-1 46164 4616446500-24615046150461504615046150-w/L4615046150-w/L46500-146500-246500-14624446500-2462444616246500-446500-14624446162462444616246500-1646500-446500-246500-246500-246500-2 w/UCS 8082546500-2 w/UCS 8082546500-646500-646500-8No Direct Cross46500-1346500-1346500-13w/UCS8082646199-1046199-1046199-345993459934599346199-1

PART NO.202-BTRYPB/90202A-1A202A-1AL/12202A-1ATR202A-1B202A-1BL/12202A-1BL/24202A-1BTR202-1B202-1BL/12202-1BL/24/90202-1BL/24/144202-1BLTR/24202-1BTR202A-2AY202A-4A202A-4B202-4B202A-5A202A-5AL/12202-5B202-5BL/12202A-7A202A-7AY202A-7B202A-7BG202A-7BY202A-7G202A-7H202A-7T202-7B202B-7BG202B-7H202-7BG202-7BH202-7BR202-7BT202-7BY/100202-7BY/140202-7BY/65202-7BYPB/90202-7BYPB/100202-13ATR202-13BTR202-17BTR202-18B202-20BY/100202-20BY/140202-20BY/PB/82204-9A204-9B204-9BL/24204-10A204-10B/20204-10B/16204-10BL/24/16

DESCRIPTION2 1/4 SE EGT CS7 C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90” TR2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90” L24V2 1/4 SE EGT C/A 90” TR2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90” L24V2 1/4 SE EGT C/A 144” L24V2 1/4 SE EGT C/A 96” L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 100” 2 1/4 SE EGT C/A 78”2 1/4 SE EGT C/A 78”2 1/4 SE EGT C/A 78”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L12V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”L12V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 100”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 100”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 96”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 78”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 100”2 1/4 SE EGT C/A 96”2 1/4 SE EGT C/A 100”2 1/4 SE EGT C/A 140”2 1/4 SE EGT C/A 65”2 1/4 SE EGT CS7 C/A 78”2 1/4 SE EGT CS7 C/A 100”2 1/4 SE EGT C/A 140”2 1/4 SE EGT C/A 140”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT 100” VERT.2 1/4 SE EGT 140” VERT.PB ANALYZER 82”3 1/8 TE TIT/TIT C/C 16’3 1/8 TE TIT/TIT C/C 16’3 1/8 TE TIT/TIT C/C 16’3 1/8 TE EGT/EGT C/C 16’3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 16’3 1/8 TE EGT/EGTC/C16’L24V

NOTESTR dial, 3.3 ohms @ 1500°F3.3 ohms @ 1500°FL12V, 3.3 ohms @ 1500°FTR dial, 3.3 ohms @ 1650°F3.3 ohms @ 1500°FL12V, 3.3 ohms @ 1500°FL24V, 3.3 ohms @ 1500°FTR dial, 3.3 ohms @ 1650°F3.3 ohms @ 1500°FL12V, 3.3 ohms @ 1500°FL24V, 3.3 ohms @ 1500°FRe-cal, 4.9 ohms @ 1500°FTR dial, L24V, 3.3 ohms @ 1650°FTR dial, 3.3 ohms @ 1650°F3.7 ohms @ 1650°FRe-cal, 3.0 ohms @ 1450°FRe-cal, 3.0 ohms @ 1450°FRe-cal, 3.0 ohms @ 1450°F3.3 ohms @ 1500°FL12V, 3.3 ohms @ 1500°F3.3 ohms @ 1500°FL12V, 3.3 ohms @ 1500°F3.3 ohms @ 1500°F3.7 ohms @ 1650°F3.3 ohms @ 1500°FTR dial, 7.6 ohms @ 1650°F3.7 ohms @ 1650°FTR dial, 7.6 ohms @ 1650°F3.3 ohms @ 1500°FTR dial, 3.5 ohms @ 1650°F3.3 ohms @ 1500°FTR dial, 7.6 ohms @ 1650°F3.3 ohms @ 1650°FTR dial, 7.6 ohms @ 1650°F3.3 ohms @ 1650°F3.7 ohms @ 1400°FTR dial, 3.5 ohms @ 1650°F3.7 ohms @ 1650°FRe-cal, 4.8 ohms @ 1650°FRe-calt, 2.7 ohms @ 1650°FRe-cal, 3.3 ohms @ 1650°F3.7 ohms @ 1650°FTR dial, 4.8 ohms @1650°F RedlineTR dial, 4.8 ohms @1650°F RedlineTR dial, 3.3 ohms @ 900°C3.3 ohms @ 1725°FTR dial, 3.7 ohms @ 1650°FTR dial, Re-cal, 4.8 ohms @ 1650°FTR dial, Re-cal, 3.2 ohms @ 1650°FTR dial, 7.3 ohms @ 1650°FTR dial, 7.3 ohms @ 1650°FTR dial, 7.3 ohms @ 1650°FRe-cal, 7.3 ohms @ 1650°F8.9 ohms @ 1550°FRe-cal, 7.3 ohms @ 1550°F7.3 ohms @ 1550°F


ALCOR PRODUCT CROSS REFERENCEMETER CROSS-REFERENCE P/N 202-BTR TO 226-3BL/24

12. Fuse is located below Compartment/Heater StorageCover (Figure 9) and provides overload protection forthe heater power circuit. For replacement informationsee Chapter V, Maintenance.

13. Main Power Cord provides power for heater opera-tion only and is plugged into a standard 110-V AC

grounded outlet. A notch is provided in the right cover (Item 21) to allowcover to be closed while cord is being used.

14. Heater Temperature Dial sets the desired heater temperature. Theknob controls temperatures for EGT, Type E, and K from 900 F to 1800 Faround the red ring and 100 F to 600 F for CHT, Type J, around the yel-low ring. This is an approximate setting with the actual temperature notedin digital LCD display, Item 8.

15. Reset Switch is used to reset unit in the event of a circuit malfunction.Reset can also be achieved by switching main power switch to off momen-tarily.

16. Indicate/Calibrate Switch is used to select item being tested.Indicate position receives a millivolt signal and is used to test a probe(Millivolt output adjust knob not used while in this position). Calibrate posi-tion sends out a millivolt signal and is used to test and calibrate a meter(Heater switch and heater temperature dial not used while in this position).

17. Millivolt Output Adjust Knob sets output millivolt to meter when incalibrate mode only. The output simulates the voltage that a thermocouplewould produce when heated.

18. Power On/Off Switch: the main power switch for your ALCAL® 2000.Ensure switch is in the off position when not in use to prolong battery life.

19. Battery Test Button tests for voltage output of 9-Volt battery locatedin battery compartment (Item 6) only. Wafer battery located on the maincircuit board will be inspected/replaced during re-calibration/inspection ofALCAL® 2000 by the ALCOR® Repair Department. (SeeChapter V.Gen Info/Maintenance)

20. Case: (See Chapter V. Gen Info/Maintenance)

21. Compartment/Heater Storage Cover pro-vides both heater storage and cable and com-ponent storage. The heaters must be installed inthe proper position for correct fit and securedwhen shipped. A convenient notch is provided inthe cover to allow power cord use while cover isin place.


FIGURE 9

FIGURE 10


PART NO.4624146242462434634746349463504635146353463544635646357463584636146362463654700447005470104701147012470134702947030

NEW ALCOR PART NO.462414624246243No Direct CrossNo Direct CrossNo Direct CrossNo Direct Cross4635346354No Direct CrossNo Direct Cross46000-10463614636246365No Direct CrossNo Direct Cross46150 w/UCS 8082546500-4 w/UCS 8082546500-2 w/UCS 8082546500-13 w/UCS 808254702947030

DESCRIPTION2 1/4 SE EGT/CHT C/A 2 1/4 TE EGT/EGT2 1/4 SE TIT C/A2 1/4 SE TIT/EGT C/A AMP’D L24V2 1/4 SE TIT C/A AMP’D L24V2 1/4 SE TIT C/A AMP’D2 1/4 SE TIT/EGT CS6 C/A AMP’D3 1/8 EGT MCCA 6 C/A AMP’D3 1/8 EGT MCCA 4 C/A AMP’D2 1/4 SE TIT C/A AMP’D2 1/4 SE TIT/EGT C/A AMP’D3 1/8 TE EGT/EGT (Radair)2 1/4 SE EGT C/A (Light option)2 1/4 SE EGT C/A 90” L28VMCCA CHT INDICATOR3 1/8 SE CHT/EGT I/C C/A 76” 100”3 1/8 SE CHT/EGT I/C C/A 76” 100”2 1/4 SE EGT CS6 C/A 90”PB2 1/4 SE EGT CS7 C/A 90”PB2 1/4 SE EGT CS7 C/A 100”PBPB Analyzer 82”2 1/4” SE CHT W/ color dial2 1/4”TE EGT/CHTIndicatorW/ colordial

NOTESEGT 3.63 ohms @ 1600°F / CHT 8.0 ohms @ 500°F7.44 ohms @ 1600°F3.63 ohms @ 1650°FScale @ 1300-1800°F 0-25Scale @ 1300-1800°F 0-25Scale @ 1300-1800°F 0-25Scale @ 1300-1800°F 0-25

Scale at 1300-1800°F 0-25Scale at 1300-1800°F 0-257.93 ohms @ 1650°F3.63 ohms @ 1600°F3.63 ohms @ 1600°FProprietary meter, call PiperCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1550°F3.6 ohms @ 1600°F3.3 ohms @ 1650°FRe-cal, 3.63 ohms @ 1600°F3.2 ohms @ 1650°F8.0 ohms @ 500°FEGT 5.26 ohms @ 1600°F / CHT 8.0 ohms @ 500°F

22. Field Operating Instructions, P/N40190, is located on a laminated cardlocated in the lid of the ALCAL® 2000provides the operator quick setup andtesting information at a glance. Thiscard provides sufficient information toperform all tests while in the field with-out needing to resort to this UsersGuide.

23. Users Guide, P/N 59207, is this oper-ating manual and contains complete operatinginstructions for your ALCAL® 2000.

24. CHT Heater, P/N 35311, is designed to test quarter turn locking bayonetprobes that use a pipe thread adapter (Item 31) and gasket-type thermocou-

ples that mount under the spark plug. The heater canbe plugged directly into the Heater Receptacle(Item 1) or hung in an aircraft’s engine compart-ment in order to heat the thermocouple while it isproviding output to the aircraft meter. This allowscalibration of the entire system, including thermis-

tor type systems. Extension Lead (Item 29) must be usedfor this application. (See Item 2, for Heater Light functionand operation.) Ground heater to engine using ground-ing wire clip provided when checking CHT thermistors.NOTE: WHEN TESTING TYPE K GASKET AND BAYO-NET THERMOCOUPLES USE REFERENCE PROBE,P/N 86264.

CAUTION: NEVER PLUG HEATER INTO 110V ACRECEPTACLE WITHOUT FIRST CONNECTINGEXTERNAL REFERENCE THERMOCOUPLE. (SEE

CHAPTER V. GEN INFO/SAFETY PRECAUTIONS)

25. EGT Heater, P/N 35290, comes equipped withan internal heater control thermocouple and can beused to test any Type K or E thermocouple. Theheater can be plugged directly into the HeaterReceptacle (Item 1) or hung in an aircraft’s enginecompartment in order to heat the thermocouplewhile it is providing power to the aircraft meter. Thisallows calibration of the entire system consisting ofmeter, lead(s), and probe(s). Extension Lead (Item 29)must be used for this application. Note: ALCAL® 2000 notcompatible with old style ALCAL® heater, P/N 35309 (P/N35290 uses ungrounded reference thermocouple).

CAUTION: NEVER PLUG HEATER INTO 110V ACRECEPTACLE WITHOUT FIRST CONNECTING ANINTERNAL OR EXTERNAL REFERENCE THERMO-COUPLE. (SEE CHAPTER V. GEN INFO/SAFETY PRECAUTIONS)


FIGURE 13

FIG. 12

FIGURE 11


PART NO.46077460784607946080460814608246083460844608546086460874608846089460904609146092460934609446095460964609846099*461254612646139*4615046154461554615646158461594616046164462004620146202462034620446205462064620846217462184622046224462254622646227462314623246233462354623646237462384623946240

NEW ALCOR PART NO.4612546000-14615946155461624624446500-846000-146155461504615046500-5461644599346199-1 46199-2 46199-146199-3461504615046000-84615046125461264615046150No Direct Cross461554615646000-1146500-144616046164No Direct CrossNo Direct Cross4615046000-7No Direct CrossNo Direct Cross46000-64615546500-1646500-1346500-64622446225

462314623246233462354623646237462384623946188-1

DESCRIPTION2 1/4 TE EGT/EGT C/A 240” L24V3 1/8 TE EGT/EGT C/A 28’3 1/8 TE EGT/EGT C/A 16’3 1/8 TE EGT/EGT C/A 20’ L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 90”3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 18’2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90”3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 20’ L24V3 1/8 TIT/TIT C/C 16’ L24V3 1/8 TE EGT/EGT C/C 16’ L24V3 1/8 TE TIT/TIT C/C 16’ L24V2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90” L24V3 1/8 TE EGT/EGT C/A 250”2 1/4 SE EGT C/C 90”2 1/4 TE EGT/EGT C/A2 1/4 SE EGT/CHT C/A2 1/4 SE EGT C/C 90” L24V2 1/4 SE EGT C/A 90”3 1/8 TE EGT/EGT C/C3 1/8 TE EGT/EGT C/A3 1/8 TE EGT/CHT C/A I/C3 1/8 TE EGT/EGT C/A 20’2 1/4 SE EGT C/A 90”3 1/8 TE EGT/EGT C/A2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 TE EGT C/A 240”2 1/4 SE EGT C/A 144” L24V3 1/8 TE EGT/EGT C/A 240”2 1/4 SE TIT C/A3 1/8 TE EGT/EGT C/A 240”3 1/8 TE TIT/TIT C/A3 1/8 TE EGT/EGT C/A 18’2 1/4 SE EGT C/A 100”2 1/4 SE EGT 100” VERT.2 1/4 SE EGT 140” VERT.3 1/8 TE TIT/TIT C/A2 1/4 SE EGT V.100 L24V C/A2 1/4 SE EGT VERT. L24V2 1/4 SE EGT CS C/A 82”CHT/TIT INDICATOR2 1/4 SE EGT 240” C/ASE TIT INDICATORCHT/TIT INDICATOR L14VTIT INDICATOR L14VEGT/CHT INDICATOR L14VCHT/TIT IND. L28VTIT IND. L28VEGT/CHT IND. L28V

NOTESTR dial, L24V, 7.6 ohms @ 1600°F TR dial, 6.8 ohms @ 1650°FRe-cal, 6.2 ohms @ 1550°FRe-cal, L24V, 7.6 ohms @ 1550°FTR dial, 3.3 ohms @ 1650°FTR dial, 7.6 ohms @ 1650°FTR dial, 3.3 ohms @ 900°CTR dial, 7.6 ohms @ 1650°FRe-cal, 6.9 ohms @ 1600°FTR dial, L24V, re-cal, 3.3 ohms @ 1650°F3.3 ohms @ 1650°FTR dial, 3.3 ohms @ 1650°FTR dial, 3.3 ohms @ 1650°F8.9 ohms @ 1550°FL24V, 7.3 ohms @ 1550°FL24V, 7.3 ohms @ 900°CL24V, 7.3 ohms @ 1550°FL24V, 7.3 ohms @ 1650°FTR dial, L12V, 3.3 ohms @ 1600°FTR dial, L24V, 3.3 ohms @ 1600°F7.7 ohms @ 1650°FL12V, 3.8 ohms @ 1550°F7.44 ohms @ 1600°FEGT 3.63 ohms @1600°F / CHT 8.0 ohms @ 500°FL24V, 3.8 ohms @ 1550°F3.63 ohms @ 1600°F13.5 ohms @ 1600°F 7.44 ohms @ 1600°FEGT 3.63 ohms @ 1600°F / CHT 8.0 ohms I/C @ 500°FTR dial, 7.6 ohms @ 1650°FTR dial, 3.63 ohms @ 1650°FTR dial, 7.6 ohms @ 1650°FTR dial, 3.63 ohms @ 1650°F3.3 ohms @ 1725°F7.6 ohms @ 850°CL24V, re-cal, 4.9 ohms @ 1500°FTR dial, 7.6 ohms @1650°F3.3 ohms @ 1650°F7.6 ohms @ 1725°FTR dial, 6.2 ohms @ 1650°FRe-cal, 6.9 ohms @ 1550°F3.7 ohms @ 1400°FTR dial, 3.7 ohms @ 1650°FTR dial, 4.8 ohms @ 1650°FTR dial, 7.44 ohms @ 1650°FL24V, 3.7 ohms @ 1650°F3.3 ohms @ 1500°F 3.2 ohms @ 1650°FTIT 3.63 ohms @ 1650°F / CHT 8.0 ohms @ 500°F7.6 ohms @ 1650°F3.63 ohms @ 1650°FTIT 3.63 ohms @ 1650°F / CHT 8.0 ohms @ 500°FTR dial, L143V, 7.6 ohms @ 1500°FL14V, EGT 3.63 ohms @ 1600°F / CHT 8.0 ohms @ 500°FL28V, TIT 3.63 ohms @ 1650°F / CHT 8.0 ohms @ 500°FL28V, 3.63 ohms @ 1650°F L28V, EGT 3.63 ohms @ 1600°F / CHT 8.0 ohms @ 500°F

26. Optional External EGT Reference Thermocouple,P/N 86188, is used for more accurate testing of thermo-

couples. It measures the exact same location in the heaterthat the probe tested will measure.

Note: The heater has a separate internal thermo-couple that regulates the heater temperature andshould not be confused with this external reference

thermocouple. Contact ALCOR® to order

27. CHT Heater Control Thermocouple, Type J , is usedto control the set point established with the Heater

Temperature Dial (Item 14). It does so in the same way that the internalEGT heater probe regulates temperatureexcept it is external and not a part of the heatercore assembly. It is inserted into the hole in thetop of the CHT Heater (Item 24) near the testhole or in the side of the copper CHT GasketAdapter (Item 32) when testing gasket typeCHT thermocouples. (See Chapter V. GenInfo/Safety Precautions”)

NOTE: CANNOT BE USED TO CHECK TYPE KTHERMOCOUPLES.

CAUTION: NEVER PLUG HEATER INTO ANY 110-V AC RECEPTACLEWITHOUT FIRST CONNECTING CONTROL THERMOCOUPLE.FAILURE TO DO SO WILL CAUSE A RUNAWAY CONDITION, CAUSINGHEATER CORE MELTDOWN AND HEATER FAILURE!

28. Test Cable, P/N 42399, this test cable contains 8 wires, one copper andthree thermocouple lead pairs (Type K, J, and E).

These wires input the temperature millivolt signalwhen testing thermocouples. The copper wiresoutput a millivolt signal to the system/meterbeing tested/calibrated, simulating temperaturefrom a thermocouple. The clip ends marked +

and - are to be used to connect the ALCAL® 2000either to a probe or meter being tested or to its own

Terminal Posts (Item 4) to check actual heater coretemperature. The plug end incorporates a positive lock-ing feature that ensures a secure connection while a

test is being performed. The technician must assure correct polarity whenconnecting clips (Item 5) to terminal posts when reading heater tempera-ture or testing/calibrating.

Note: Do not attempt to lift or move the ALCAL® 2000 with the TestCable attached as cable damage may occur.

29. Extension Lead, P/N 97076, is a heavy-duty extension cord that incorpo-rates two external thermocouple extension leads, black for the CHT Heater(Item 24) and yellow for the EGT Heater (Item 25). It is used to remotely


FIGURE 14

FIGURE 15

FIGURE 16


PART NO.459944599545996*4599845999460004600146002460034600446005460064600746008460094601046011*4601246013460154601646019460204602246023*460244602646027460294603146033460344603546036*46037460384604246046460484604946051*460524605346055*46056460574605846059460614606446065460664606846069460704607446075

NEW ALCOR PART NO.46155 46199-1046150,42525,& 8625546150 w/UCS 8082546500-1246500-12 w/UCS 8082546002 w/switch4600246002 w/switchNo Direct CrossNo Direct CrossNo Direct CrossNo Direct Cross461504616446199-54616446150

46500-746500-11No Direct Cross46000-64626046150,42525,862554615546500-14599346500-946000-13461554615046199-846150,42525,86255No Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct Cross4615546150,42525,86255No Direct Cross46500-1046150461504615046500-946155No Direct CrossNo Direct Cross4615046150No Direct Cross46199-6461554616446125

DESCRIPTION3 1/8 TE EGT/EGT C/A 18’L12V3 1/8 TE TIT/TIT C/C 16’2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/A 90” PB2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” PB3 1/8 TE EGT/EGT C/A 20’ TR3 1/8 TE EGT/EGT C/A 20’ TR3 1/8 TE EGT/EGT C/A 20’ TR3 1/8 SE CHT/EGT I/C C/A 76” 90”3 1/8 SE CHT/EGT I/C C/A 76” 90”3 1/8 CHT/EGT I/C C/A 76” 90”3 1/8 CHT/EGT I/C C/A 76” 90”2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90”3 1/8 TE EGT/EGT C/C 20’2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE TIT C/A 90”2 1/4 SE CHT/EGT I/C L12V3 1/8 TE TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’ L24V2 1/4 SE EGT C/C 90”3 1/8 TE EGT/EGT C/A 20’ L24V2 1/4 SE EGT C/A 90” L24V3 1/8 TE EGT/EGT C/C 20’2 1/4 SE EGT C/A 90” L24V3 1/8 TE TIT/TIT C/A 16’3 1/8 TE EGT/EGT C/A 20’ L24V2 1/4 SE EGT C/A 90”3 1/8 TE EGT/EGT C/C 100°F 2502 1/4 SE EGT C/C 100”2 1/4 TE EGT/EGT CS 100°F 250R2 1/4 SE CHT/EGT I/C C/A L24V2 1/4 SE CHT/EGT I/C C/A L12V2 1/4 SE CHT/EGT I/C C/A L24V3 1/8 SE CHT/EGT I/C C/A L12V3 1/8 TE EGT/EGT C/A 20’2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/C 90” L24V2 1/4 SE EGT C/C 90” L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L24V3 1/8 TE EGT/EGT C/A 25’2 1/4 SE CHT/EGT PB2 1/4 TE EGT/EGT C/A 240”2 1/4 SE EGT C/A 65”2 1/4 SE EGT C/A 140”2 1/4 EGT C/A L12V3 1/8 TE EGT/EGT C/C 250”3 1/8 TE EGT/EGT C/A 20’ L12V2 1/4 SE EGT C/A 90” L24V2 1/4 TE EGT/EGTC/A 240” L12V

NOTESRe-cal, 7.6 ohms @ 1550°F, L12VTR dial, 7.3 ohms @ 1650°F3.8 ohms @ 1550°FTR dial, 3.3 ohms @ 1550°FTR dial, 3.3 ohms @ 1600°FTR dial, 3.3 ohms @ 1600°FTR dial, 7.6 ohms @ 1600°FTR dial, 7.6 ohms @ 1600°FTR dial, 7.6 ohms @ 1600°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @1600°FTR celsius dial, L24V, re-cal, 3.3 ohms @ 900°C 3.3 ohms @ 1650°FTR dial, 8.9 ohms @ 1600°FTR dial, 3.8 ohms @ 1600°FL12V, 3.3 ohms @ 1550°F3.3 ohms @ 1550°FTR dial, upside down, 3.3 ohms @ 1650°FTR dial, 3.3 ohms @ 1650°F CHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1600°FTR dial, 6.2 ohms @ 1650°FTR dial, 6.2 ohms @ 900°C3.8 ohms @ 1550°FTR dial, L24V, re-cal, 7.6 ohms @ 1600°FL24V, 3.3 ohms @ 1500°F8.9 ohms @ 1550°FTR celsius dial, L24V, 3.3 ohms @ 900°CTR dial, 6.2 ohms @ 900°CRe-cal, L24V, 7.6 ohms @ 1550°F3.3 ohms @ 1550°FF: 4.2 ohms R: 9.2 ohms @ 843°C4.2 ohms @ 1650°FF: 4.2 ohms R: 9.2 ohms @ 1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F / EGT 3.3 ohms @ 1550°FRe-cal, 7.6 ohms @ 1550°F3.8 ohms @ 1650°FTR dial, upside down, 3.3 ohms @ 1725°FTR dial, L12V , 3.3 ohms @ 900°CL24V, 3.8 ohms @ 1550°FL24V, 3.8 ohms @ 1550°FTR celsius dial, re-cal, 3.3 ohms @ 900°C Rd.Ln.TR dial, L24V, 3.3 ohms @ 900°CTR dial, 6.1 ohms @ 1650°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1550°F7.6 ohms @ 1650°FRe-cal, 2.7 ohms @ 1650°FRe-cal, 4.8 ohms @ 1650°F4.8 ohms @ 1650°F9.2 ohms @ 1700°FTR dial, L12V, Re-cal, 7.6 ohms @ 1600°FL24V, 3.63 ohms @ 1650°FL12V, re-cal, 7.6 ohms @ 1500°F


operate a heater with its corresponding HeaterControl or Reference Thermocouple. This cableallows the operator to do thermocouple testingwhile connected to the aircraft system. It is usedwhen checking a thermocouple system for accu-

racy as a whole or can be used when testing ther-mistor type thermocouples where the non-thermo-

couple type meter in the aircraft is checked for accu-racy. When not being used for remote heater use it

can be used for plugging the ALCAL® 2000 into a remotepower source.

Caution: Never plug heater into any 110-V receptacle with-out first connecting Reference Thermocouple. Only agrounded 110-V receptacle may be used with the powercord!

30. “Type-K” Transition Adapter, P/N 23946, is used onlywhen External Reference EGT Thermocouple (Item 26) isused providing a convenient place to attach Test Cable (Item 28)

clips to Reference Thermocouple.

31. CHT Bayonet Adapter, P/N 28202, isinserted into CHT heater in order to test bayonet typethermocouples or thermistors. It is the same adapterthat allows bayonet thermocouple installation below

the lower spark plug on most horizontally opposedengines (AN4076-1).

32. CHT Gasket Adapter, P/N 28283 is used to test CHTgasket type thermocouples. CHT Heater ControlThermocouple (Item 27) is placed in the side of theadapter while the probe to be tested is placed betweenthe copper adapter and top insulator. The entire unit isthen screwed into the CHT heater. See Field OperatingInstructions (Item 22).

33. Calibration Screwdriver, P/N 89222, is used to cali-brate front adjustable meters only. It is non-magnetic toeliminate error in meter movement magnets and non-metallic to prevent damage to delicate carbon poten-tiometer. Note: It only fits front adjust meters manu-factured since 1993. Older meters require a smallerdiameter screwdriver.

FIGURE 17

FIGURE 19

FIGURE 18

FIGURE 20

FIGURE 21


NEW ALCOR PART NO.46000-546000-246000-24615546155461554600246000-846000-346000-3461554615546155No Direct CrossNo Direct Cross4615046150461624615046155No Direct CrossNo Direct CrossNo Direct CrossNo Direct Cross45993No Direct Cross461254599346000-246000-44615046500-346150 w/UCS 80825462444612546150 w/UCS 8082546500-12 w/UCS 808254615546002No Direct Cross46500-4No Direct CrossNo Direct CrossNo Direct CrossNo Direct Cross4616446500-146000-146000-5No Direct Cross461504615046155459904599146199-945993

DESCRIPTION3 1/8 TE EGT/EGT C/A 20’ L24V3 1/8 TE TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’ L24V3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 20’3 1/8 TE EGT/EGT C/A 20’ TR3 1/8 TE EGT/EGT C/A 225”3 1/8 TE EGT/EGT C/A 100 F 250 F3 1/8 TE EGT/EGT C/A 100 F 250 F3 1/8 TE EGT/EGT C/A 25’3 1/8 TE EGT/EGT C/A 42’3 1/8 TE EGT/EGT C/A 25’DUAL C/A 20’DUAL C/A 20’2 1/4 SE EGT C/A 78”2 1/4 SE EGT C/A 90” L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”3 1/8 TE EGT/EGT C/A 20’2 1/4 SE CHT/EGT I/C C/A 2 1/4 TE EGT/EGT C/A 20’2 1/4 TE EGT/EGT C/A 20’2 1/4 SE CHT/EGT I/C C/A 76” 90”3 1/8 TE EGT/EGT C/C 18’2 1/4 TE EGT/EGT C/A 25’2 1/4 TE EGT/EGT C/A 240”3 1/8 TE EGT/EGT C/C 16’3 1/8 TE TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’ L24V2 1/4 SE EGT C/C 90”2 1/4 SE TIT C/A L24V2 1/4 SE EGT PB ANALYZER2 1/4 SE EGT PB ANALYZER TR2 1/4 TE EGT/EGTCS L/R C/A 240”2 1/4 SE EGT C/A 90” PB2 1/4 SE EGT C/A 90” PB3 1/8 TE EGT/EGT C/A 20’ PB3 1/8 TE EGT/EGTC/A 20’ TR2 1/4 TE EGT/EGT C/A 240”2 1/4 SE EGT C/A 96”3 1/8 SE CHT/EGT I/C C/A 76”90”3 1/8 SE CHT/EGT I/C C/A 76” 90”3 1/8 SE CHTEGT I/C C/A 76” 90”2 1/4 SE CHT/EGT I/C C/A 76” 90”2 1/4 SE EGT C/C 90”TR2 1/4 SE EGT C/A 90”3 1/8 TE EGT/EGT C/A 22’3 1/8 TE EGT/EGT C/A 16’ L24V2 1/4 TE EGT/EGT C/A 20’2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90”3 1/8 TE EGT/EGT C/A 20’2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90” L24V3 1/8 TE TIT/TIT C/C 16’3 1/8 TE EGT/EGT C/C 20’

NOTES7.6 ohms @ 1550°FTR dial, 6.2 ohms @ 900°CTR dial, L24V, 6.2 ohms @ 900°CRe-cal, 7.6 ohms @ 1550°FRe-cal, 7.6 ohms @ 1550°FRe-cal, 7.6 ohms @ 1550°F L24VTR dial, 7.6 ohms @1600°F7.2 ohms @ 1700°FF 3.6 ohms R 7.8 ohms @ 1550°FF 3.6 ohms R 7.8 ohms @ 1550°FTR dial, 6.1 ohms @ 1650°FTR dial, 9.7 ohms @1650°FTR dial, re-cal for 25’ leads 6.1 ohms @1650°F7.6 ohms @ 1550°F7.6 ohms @ 900°CRe-cal, 3.3 ohms @ 1450°FL24V, 3.3 ohms @ 1550°F3.3 ohms @1650°FTR dial, re-cal, 3.3 ohms @1650°F Re-cal, 7.6 ohms @ 1550°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @1600°F7.6 ohms @ 1600°F7.6 ohms @ 1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1600°FRe-cal, 8.1 ohms @ 1550°F6.1 ohms @ 1650°FRe-cal, 7.6 ohms @ 1500°FRe-cal, 7.3 ohms @ 1550°FTR dial, 6.2 ohms @900°CTR dial, 24VL, 6.2 ohms @ 1650°FTR dial, 3.8 ohms @ 1550°FTR dial, 3.3 ohms @ 1650°F, 24VL3.3 ohms @1500°FTR dial, 7.6 ohms @ 1650°FRe-cal, 7.6 ohms @1600°F3.3 ohms @ 1550°F3.3 ohms @ 1600°FRe-cal, 7.6 ohms @ 1550°F7.6 ohms @1600°F7.6 ohms @ 1550°FTR dial 3.5 ohms @ 1650°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @1550°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @1550°F TR dial, 3.8 ohms @ 1600°F3.3 ohms @ 1500°F8.2 ohms @ 1650°F6.2 ohms @ 1550°F7.6 ohms @ 900°CL12V, 3.3 ohms @ 1500°F3.3 ohms @ 1500°FRe-cal, 7.6 ohms @ 1550°FL12V 3.3 ohms @ 1550°FL24V 3.3 ohms @ 1550°FTR dial,7.3 ohms @ 900°C8.9 ohms @ 1550°F

PART NO.45893458944589545896458974589845899459014590445905459084590945910459114591245933459344594245944459454594645947459494595145952459534595445955459564595745958*459594596245963459644596545966459674596845969459704597345974459754597645977*4597845980459814598645987459884598945990459914599245993

UCS Switch, P/N 80825 & 80827, (Universal Cylinder Selector Switch) isan inexpensive way to upgrade any ALCOR® 2 1/4” diameter meter to ananalyzer. This modification can be done in the field by removing the meterfrom the panel, attaching UCS wires, and inserting into the switch.

Note:Un-amplified meters, manufactured since the early eighties, will havea third terminal stud on the back. This is used in con-

junction with a special Universal Cylinder SelectorSwitch box that has a secondary potentiometeradjustment (P/N 80828, 80826). This was providedto be able to have a separate channel, either the

fifth or seventh, in order to calibrate sepa-rately for TIT, (Turbine Inlet Temperature), orfor true absolute temperature.

Reverse stagger jumper, P/N 42523, was designed tocorrect the reverse stagger problem when replacing old(1970’s) Economix line of thermocouples. Wires maybe pulled together or this Alumel wire jumpermay be used.

Exhaust Hole Adapter, P/N 74291 is a thermocoupleexhaust adapter developed to either oversize a leakingthermocouple exhaust hole for an ALCOR® probe or allowan ALCOR® probe to replace a larger competitors probe.Hole in exhaust must be enlarged to15/64’s of an inch.

Fire Sleeve, P/N 49297,is provided with eachthermocouple to protect the probe/lead connec-tion and prevent shorting to the airframe/engine. It is recommended to be used in allinstallations.

Optional EGT Heater, P/N 35291, is designed to testcompetitor’s probes that are approximately 1/8” (.125”)diameter. Call ALCOR® for details.

Optional CHT Heater Control Thermocouple, P/N 86264, Is used whentesting both Type J as well as Type K Bayonet/Gasket Thermocouples.Call ALCOR® for details.


ALCOR® METER AND PROBE ACCESSORIES

FIGURE 22

FIGURE 23

FIGURE 24

FIGURE 25


PART NO. 45804 4580645807458084580945810458114581245813458144581545816458174581845819*45820*45821*45822*45823*45824*45826458274582845829458304583145832458334583445835458374583845839458404584145847458484584945850458514586445867458694587045871458724587345874458774587845879458804588145882458904589145892

NEW ALCOR PART NO.4616446500-246150461504615046500-146500-146500-24624446500-2462444616246500-646199-746150,42525,86255*46150,42525,86255*46150,42525,86255*46150,42525,86255*4616446150,42525,86255

46500-746150461504615046150461504615046500-1246500-114612546125461254612546125No Direct CrossNo Direct CrossNo Direct CrossNo Direct CrossNo Direct Cross46150No Direct Cross4599346199-5459934599346199-746119-746199-10459934599346199-846199-94599346000-646000-446155

DESCRIPTION2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 100”2 1/4 SE EGT C/A 78”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 100”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 100”2 1/4 SE EGT C/A 240”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 140”3 1/8 TE C/C2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 7.5’2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 90”2 1/4 SE EGT C/C 100”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L24V2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” L2 1/4 SE EGT C/A 90”2 1/4 SE TIT C/A 90”2 1/4 TE EGT/EGT C/A 240”2 1/4 TE EGT/EGT C/A 240” L24V2 1/4 TE EGT/EGT C/A 240”2 1/4 TE EGT/EGT C/A 240”2 1/4 TE EGT/EGT C/A 240”2 1/4 SE CHT I/C 76” VERTMETER W/PB SWITCH EGT C/AMETER W/PB SWITCH EGT C/AEGT ANALYZER C/A 90”EGT ANALYZER C/A 90”2 1/4 SE EGT C/A 90”VERTICAL 7.5’3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 20’3 1/8 TE EGT/EGT C/C 18’3 1/8 TE EGT/EGT C/C 18’3 1/8 TE EGT/EGT C/C 100°F 250R3 1/8 TE EGT/EGT C/C 100°F 250R3 1/8 TE TIT/TIT C/C 16’3 1/8 TE EGT/EGT C/C 16’3 1/8 TE EGT/EGT C/C 250”3 1/8 TE EGT/EGT C/C 100°F 250R3 1/8 TE TIT/TIT C/C 16’3 1/8 TE EGT/EGT C/C 20’3 1/8 TE TIT/TIT C/A 16’3 1/8 TE TIT/TIT C/A 16’ L24V3 1/8 TE TIT/TIT C/A 20’

NOTESTR Dial 3.3 ohms @ 1650°FRe-cal 3.7 ohms @ 1650°FRe-cal 3.0 ohms @ 1650°F3.3 ohms @ 1500°FTR Dial 3.3 ohms @ 1500°F3.3 ohms @ 1500°F3.3 ohms @ 1500°F3.7 ohms @ 1650°F7.6 ohms @ 1650°F3.3 ohms @ 1650°F7.6 ohms @ 1650°F3.3 ohms @ 1650°F4.8 ohms @ 1650°FF: 4.2 ohms, R: 9.2 ohms @ 1550°F3.8 ohms @ 1550°F3.8 ohms @ 1550°F3.8 ohms @ 1550°FTR dial, 3.8 ohms @ 1600°FTR dial, 3.8 ohms @ 1650°F4.2 ohms @ 1650°FTR dial upside down dial, 3.3 ohms @ 1725°FTR dial upside down dial, 3.3 ohms @ 1600°FTR dial, re-cal 3.3 ohms @1650°FTR dial, re-cal, 3.3 ohms @1650°F L24V3.3 ohms @ 1550°FL24V 3.3 ohms @ 1550°F3.3 ohms @ 1550°F3.3 ohms @ 1550°FTR dial & red ptr., 3.3 ohms @ 1600°F3.3 ohms @ 1650°FRe-cal, 7.6 ohms @1500°FRe-cal, 7.6 ohms @1500°FRe-cal, 7.6 ohms @1500°FRe-cal, 7.6 ohms @1500°FRe-cal, 7.6 ohms @1500°F2.0 ohms @ 500°F3.3 ohms @ 1500°F3.3 ohms @ 1500°F 3.3 ohms @ 1500°F3.3 ohms @ 1500°F3.3 ohms @ 1500°F3.3 ohms @ 900°C8.9 ohms @ 1550°FTR dial, re-cal, 8.9 ohms @1550°FRe-cal, 8.1 ohms @ 1550°FRe-cal, 8.1 ohms @ 1550°FF: 4.2 ohms R: 9.2 ohms @ 1550°FF: 4.2 ohms R: 9.2 ohms @ 1550°FTR Dial, re-cal, 7.3 ohms @1650°FRe-cal, 7.3 ohms @1650°FF: 4.2 ohms R: 9.2 ohms @ 1550°FF: 4.2 ohms R: 9.2 ohms @ 843°C7.3 ohms @ 900°C8.9 ohms @1550°FTIT dial, re-cal, @ 1650°FTIT dial, L24V, re-cal, 6.2 ohms @ 1650°FRe-cal, 7.6 ohms @1550°F

Case Dimensions:16 inches long, 13 inches wideand 7 inches deep

Total Weight:12 lbs. including heaters andaccessories

Battery Power:Millivolt Input/Indicator Circuit, 9 Volt Lithium Battery, P/N 89050

Millivolt Output/Calibrator Circuit, 3 Volt Wafer Style, P/N 89250

Note: 3-volt battery not fieldreplaceable

Battery Life:9 Volt, Replace before reaching7.30 volts (approximately 60 hoursuse)

3 Volt Wafer, minimum 3 years

Battery Condition Indicator:Push Button Switch selectable for9 volt Output unattainable for 3 volt

Readout Display:Solid State LCD Display resolution 1°F, from 0° to1999°

FuseField Replaceable P/N 29721Type 2 amp Fast BLO

Operating Temperature:25° F to 130° FAvoid direct sunlight

Calibration Accuracy:Type K and E +/- 0.5% of full scale +/-0.25% @ 1650°F

Type J+/- 3°F from 200°F to 600°F+/- 1.5°F @ 500°F

Calibration Standard, NT (NationalInstitute of Standards andTechnologies)

Response Time:<1.0 seconds

Reference JunctionCompensation:CHT 0.03 degrees/degreeEGT 0.022 degrees/degree

Heater Controller:Temperature Range

CHT @ 100° F-600°FEGT @ 900° F-1800°F

Voltage 110-volt AC

EGT Heater Assembly:Voltage 110-volt AC @ 150 wattsMaximum Temperature Intermittent@ 1700°FMaximum TemperatureContinuous @ 1500°F

CHT Heater Assembly:Voltage-110-volt AC @ 150 wattsMaximum TemperatureContinuous @ 500°F

TECHNICAL SPECIFICATIONS


PART NO.055460554705550055510555205553055540555505556055570555805559055600556105562055630556405564055680558005581055820558305584055850560005601056020560305604056050561205613056200562105622056230562405625056400564105642056430565005651056520565305660056610566205663457964579745800458014580245803

NEW ALCOR PART NO.No direct crossNo direct crossNo direct crossNo direct cross4615546155No direct crossNo direct crossNo direct cross4615046150461504615046500-14612546500-1No direct cross4615046150No direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct crossNo direct cross4616446164461644616446500-12

46500-1246500-1246500-12No direct crossNo direct crossNo direct crossNo direct crossNo Direct Cross46500-446500-146500-146500-146500-1

DESCRIPTION2 1/4 SE CHT I/C 76” VERT.2 1/4 SE CHT I/C 76” VERT.3 1/8 SE CHT/EGT I/C C/A3 1/8 SE CHT/EGT I/C C/A3 1/8 SE CHT/EGT C/A 20’3 1/8 SE CHT/EGT C/A 20’3 1/8 TE ANALYZER3 1/8 TE ANALYZER3 1/8 TE ANALYZER2 1/4 SE EGT C/A 90” ANALYZER 2 1/4 SE EGT C/A 90” ANALYZER2 1/4 SE EGT C/A 90” ANALYZER2 1/4 SE EGT C/A 78” ANALYZER2 1/4 SE EGT C/A 90”2 1/4 TE EGT/EGT C/A 240”2 1/4 SE EGT C/A 90”CS6 ANALYZER2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90”2 1/4 TE EGT/EGT C/A 240”2 1/4 TE EGT/EGT C/A 20’2 1/4 TE EGT/EGT C/A 20’ CS42 1/4 TE EGT/EGT C/A 240”2 1/4 TE EGT/EGT C/A 20’2 1/4 TE EGT/EGT C/A 20’2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 SE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT CS4 W/ TIT2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT I/C CA 76” 90”2 1/4 TE CHT/EGT CS6 W/ TIT2 1/4 SE EGT C/A 90” TR2 1/4 SE EGT C/A 90” TR2 1/4 SE EGT C/A 90” TR2 1/4 SE EGT C/A 90” TR2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” CS4 W/ TIT2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” CS6 W/ TIT3 1/8 SE CHT/EGT I/C CA 76” 90”31/8 TECHT/EGT I/C CA 76”90”W/TIT

2 1/4 TE EGT/EGT CS L/R C/A2 1/4 SE EGT C/A 96”2 1/4 SE EGT C/A 90”2 1/4 SE EGT C/A 90” 2 1/4 SE EGT C/A 90” L12V2 1/4 SE EGT C/A 90” L12V

NOTES2.0 ohms @ 500°F2.0 ohms @ 500°FCHT 2.0 ohms @ 500°F /EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F /EGT 3.3 ohms @ 1550°F7.6 ohms @ 1550°F 7.6 ohms @ 1550°F 8.9 ohms @ 1550°F9.7 ohms @ 1550°F9.7 ohms @ 1550°F3.3 ohms @ 1550°F3.3 ohms @ 1550°F3.3 ohms @ 1550°FRe-cal, 3.30 ohms @ 1450°F3.3 ohms @ 1500°FRe-cal, 7.6 ohms @ 1500°F3.3 ohms @ 1500°F4.9 ohms @ 1550°F3.63 ohms @ 1600°3.63 ohms @ 1600°7.6 ohms @ 1550°F 7.6 ohms @ 1600°F 7.6 ohms @ 1600°F 7.6 ohms @ 1550°F7.6 ohms @ 1600°F 7.6 ohms @ 1600°F CHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1550°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1600°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1600°FTR Dial 3.3 ohms @ 1650°FTR Dial 3.3 ohms @ 1650°FTR Dial 3.3 ohms @ 1650°FTR Dial 3 .3 ohms @ 1650°FTR Dial 3.3 ohms @ 1600°FTR Dial 3.3 ohms @ 1650°FTR Dial 3.3 ohms @ 1650°FTR Dial 3.3 ohms @ 1650°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1500°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1500°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1500°FCHT 2.0 ohms @ 500°F/EGT 3.3 ohms @ 1500°F7.6 ohms @1500°F3.5 ohms @ 1650°F3.3 ohms @ 1500°F3.3 ohms @ 1500°FL12V 3.3 ohms @ 1650°FL12V 3.3 ohms @ 1650°F

ALCOR PRODUCT CROSS REFERENCEMETER CROSS-REFERENCE P/N 05546 TO 47030


This chapter will cover calibration procedures to test ALCOR® EGT, CHT,and TIT meters using a simulated millivolt source provided by the ALCAL®

2000 or using millivolts provided by a probe located in an ALCAL® 2000 heater.Before using your tester, first visually inspect the EGT, CHT, or TIT systemon the aircraft for obvious defects, such as bad connections, or heat dam-aged and shorted wires. Quick resistance measurements of the thermo-couple with a multimeter can also save time in detecting the problem. Referto Chapter IV.Troubleshooting”and Chapter III.Testing Thermocouples, foradditional help.

METHOD 1: SIMULATING THERMOCOUPLE OUTPUT This test will check the meter for function and calibration error with leadand probe connected. For testing just the meter, refer to Bench TestingMeters at the end of this chapter. Place ALCAL® 2000 so that the operatorcan view the display and have access to controls while viewing/calibratingaircraft meter unless help is available. The following detailed instruc-tions are contained in an abbreviated schematic form in the lid of theALCAL® 2000. (Field Operating Instructions, Item 22) also refer toComponents Items/Function which can be found on Page 7.

A. ALCAL® 2000 Setup1. Check calibration sticker to ensure that ALCAL® 2000 certification by the

ALCOR® Repair Department has not expired.

2. Turn Power Switch (Item 18) to on and push Battery Test (Item 19) toensure adequate voltage is above 7.3 volts.

3. Plug and lock Test Cable(Item 28) into Test Receptacle, (Item 10) andplace Indicate/Calibrate Switch (Item 16) to calibrate.

4. Select the type of system being tested, either J (CHT), K, or E(EGT/TIT) with the TC TYPE Switch (Item 9). UsingFahrenheit/Celsius Switch, (Item 7) choose correct temperaturereadout of meter being tested.

5. Disconnect wire between the lead and probe. If Type K or E systemdisconnect the red wire. If Type J system disconnect the yellow wire.It is not necessary to remove probe from cylinder or exhaust.

6. If Type K or Type E, clip the + Test Cable clip to the red probe wireand the - Test Cable clip to the red lead wire. If Type J, clip the +TestCable clip to the yellow probe wire and the –Test Cable clip to yellowlead wire. This puts the ALCAL® 2000 in series with the system to bechecked and will simulate the millivolt output of the probe as if it was

II TESTING & CALIBRATING METERS

ALCAL EGT/CHT System Tester User’s Guide 35ALCAL EGT/CHT System Tester User’s Guide14

100010251050107511001125115011751200122512501275130013251350137514001425145014751500152515501575160016251650167517001725175017751800

F°21.3121.9022.4923.0823.6824.2724.8624.2526.0326.6227.2027.7928.3728.9629.5430.1230.7031.2731.8532.4232.9833.5534.1234.6835.2435.8136.3636.9237.4838.0238.5839.1239.67

MV5505756006256506757007257507758008258508759009259509751000

F°21.7822.8423.9124.9826.0327.0828.1429.1830.2331.2732.3033.3234.3435.3536.3637.3638.3539.3440.31

MV75˚ F 25˚ C

Type K,Chromel/AlumelYellow (+)/ Red (–)

100010251050107511001125115011751200122512501275130013251350137514001425145014751500152515501575160016251650167517001725175017751800

F°38.6339.7640.8842.0143.1344.2645.3846.5047.6148.7349.8450.9652.0753.1854.2855.3856.4957.5958.6859.7860.8761.9663.0464.1365.2066.2767.3368.4169.4770.5371.5972.6473.69

MV5505756006256506757007257507758008258508759009259509751000

F°39.5541.5843.6045.6347.6349.6451.6453.6455.6257.6159.5861.5463.4965.4367.3569.2771.1873.0874.95

MV75˚ F 25˚ C

Type E,Chromel/ConstantanBrown (+)/ Red (–)

100125150175200225250275300325350375400425450475500525550575600625650675700

F°0.721.452.192.943.694.445.205.966.727.498.269.039.8110.5811.3712.1212.9013.6614.4315.2015.9616.7317.5018.2719.04

MV5075100125150175200225250275300325350375400

F°1.302.643.995.356.728.119.5010.8512.2813.6615.0516.4317.8119.1920.57

MV75˚ F 25˚ C

Type J,Chromel/ConstantanYellow (–)/ Black (+)

TEMPERATURE VS MILLIVOLT REFERENCEJUNCTION TEMPERATURE

EGT MILLIVOLT TABLE CHT MILLIVOLT TABLE

in operation. It is important that the probe and lead be included inthis procedure to provide proper system resistance for calibration.

B. FUNCTIONAL TEST1. Slowly rotate the Millivolt Output Knob (item 17) clockwise and note

movement of meter needle (disregard ALCAL® 2000 temperature read-out for now). Needle movement should be smooth with no pauses orjumping from first dial mark to full scale. Repeat this procedure sev-eral times. If movement needle is not smooth (erratic movement)then jewel bearings are worn and meter needs to be repaired orreplaced.

2. If smooth needle movement is confirmed then put the needle mid-scale and gently tap the meter face and note movement (the handleof a small screwdriver/phillips may be rotated against case also tosimulate vibration). If needle moves more than 25° or 1° incrementthen the jewel in the movement is worn and has friction requiring themeter to be repaired or replaced.

3. If there is no reading at all, recheck all connections and settings. Ifstill no reading is obtained bypass the probe and connect test cabledirectly to lead terminals and note reading. If meter reading isobtained then remove probe from aircraft and test. Refer to ChapterIII. Testing Thermocouples.

C. TEST AND CALIBRATIONCalibration of ALCOR® EGT/TIT and CHT meters manufactured after1980 are performed through a small hole in the front of the meter. Asmall plastic slotted screwdriver is recommended because a metalscrewdriver, if not used carefully, may damage the potentiometer.ALCOR® provides one, P/N 89222, with new meters since 1993 whichshould remain in the cockpit after installation for future calibrationneeds. Older indicators manufactured before 1980 have the calibrationadjustment from the rear and may not be repairable due to unavail-ability of parts. See Chapter I.INTRO/METERS

All Meters Displaying Actual Temperature1. Complete FUNCTIONAL TEST above and reinstall a functioning

probe if removed.

2. Reconnect Test Cable to probe and lead and ensure proper type sys-tem being tested is selected as described in ALCAL® 2000 Setup.

3. Adjust the Millivolt Output knob to the desired calibration temperatureas noted in LCD Display of the ALCAL® 2000. To find the correct cali-bration temperature for meter being tested, refer to Chapter VI.TABLES, ALCOR PRODUCT CROSS-REFERENCE where code“TR” is found in the notes column. If meter part number is not listedsee operating limits in the Pilot Operating Handbook (POH) for the


VI TABLES

Note: An attempt has been made to include all pertinent manufacturers but list may not be com-plete or up to date.Call for compatibility with Alcor® replacement parts.

CROSS REFERENCE TABLE #3, COMPETITORSCOMPETITOR

Allegro Avionics(520) 327-3695

ElectronicsInternational(541) 318-6060Grand Rapids DigitalTechnology(616) 583-8000Horizon (714)524-1919(800) 541-8128

Insight, GEM(716) 852-3217

JP Instruments(714) 557-3805

K&S(800) 346-4469

Mitchell Aircraft(847) 615-2887

Norwich Aero(607) 336-7636

Rocky Mountain(307) 864-9300

UMA(800) 842-5578

Universal(970) 242-5262

Vision Microsystems(360) 714-8203

Westburg (Westach)(707) 938-2121

METERS

DigitalAmplified, Analog

Amplified, LCD, Digital

Digital

Analog/DigitalReverse LCD

Amplified, LED, Bargraph, and Digital

Amplified, LED, Bargraph, and Digital Analog, Amplified,

Analog, Amplified

Analog

Not Compatible

Digital LCD

Un-amplifiedAnalog

Probes only

Digital

Un-amplifiedAnalog

APPROVAL &SYSTEM TYPE

Homebuilt only

STC/PMA, EGT/CHT Type K, ungrounded

Homebuilt OnlyGrounded probes

Both, ungrounded & grounded Type K & J

Type K groundedType J grounded

Both, ungrounded & grounded Type K & JCall JPI with analyzer serial number.

Type K ungrounded

Selected Models , PMA Type K Ungrounded, Type J Ungrounded

All types

Homebuilt only

All types

Homebuilt OnlyType K UngroundedType J Ungrounded

TSO, Selected ModelsEGT Type K, CHT Type JNoTemperature Compensation!

aircraft being tested. Find the maximum redline temperature for thetype of system being calibrated and calibrate the meter to that tem-perature. Typically for CHT it would be 450°-500° F and for EGT/TITit would be 1600°-1700° F. In this way redline temperature would bethe most accurate since meter accuracy is not 100% linear. This iswhy it is also important to check temperature at other points of thedisplay scale (25° per increment) as necessary to check for exces-sive calibration errors.

4. Adjust the potentiometer so that the critical or redline tempera-ture matches the readout of the ALCAL® 2000. (See ChapterI.INTRO/METERS, for potentiometer locations.)

EGT Meters with Relative Scale1. Ensure that the meter, lead, and probe are still connected as outlined

in Setup.

2. Turn the Millivolt Output Knob clockwise and note a reading ofapproximately1600° F on the LCD Display then note the meter read-ing which should be 4/5 scale or at the asterisk mark *. This calibra-tion applies to most meters when they leave the factory (metersbefore early 80’s were 1550° F). If used with the correct lead how-ever the meter can be used just like a true temp meter if the factorycalibration has not been changed. However, it is recommended tocalibrate the meter to the * or 4/5 scale in flight where peak occurs,using EGT Meter Installation Instructions, P/N 59185. In this way theindication has a greater temperature range for the pilot to use. It mustbe noted that peak will not always occur at the asterisk because ofvariables influencing peak, such as altitude, power settings, andambient air temperature as well as changes in system resistance ofmeter, lead, and probe over time.

NOTE: The above procedures do not take into account the error ofthe thermocouple. The following heater method allows more accuratecalibration of the entire system by compensating for variations inprobe output.

METHOD 2:USING THERMOCOUPLE OUTPUT This is the most accurate method for calibrating not only a Type K, E, or JType system but also thermistor type systems as long as the sensor fits inthe appropriate ALCAL® 2000 Heater. This method calibrates the system asa whole and takes into account not only resistance variations as noted inthe previous procedures but also millivolt output variations of the probe.This method also confirms the function (not accuracy) of the thermocou-ple without performing a separate test. The following detailed instruc-tions are contained in an abbreviated schematic form in the lid of theALCAL® 2000, Field Operating Instructions, (Item 22) and ComponentItem List which can be found on Page 7. See Chapter V, GeneralInformation/Safety, for precautions on heater use.


ALCAL® 2000 TROUBLESHOOTING

Frequently Asked Questions, FAQ’sI’m getting a reading in the LCD display 1) that is off by several hundred degrees. 2) That shows the number “1” in the display.

1) Check that the Fahrenheit/Celsius switch is in the correct location.2) Probe has no continuity/open.

Have a BAT indication in the display but the battery checks OK.

Polarity is reversed when checking a thermocouple. Switch lead clips.

Can’t seem to reach temperature selected with Heater Temperature Dial.

Check battery voltage and replace if below 7.3 volts.

All EGT/TIT probes I test seem to read about 30° to 100°F low.Probes are not being fully inserted into heater.

When testing Type K CHT Thermocouples I get extremely high readings in the display.

Use optional CHT Heater Control Thermocouple, P/N 86264.

CONTACT ALCOR®

Located in beautiful San Antonio, Texas for over 35 yearsPlease visit ALCOR®’s Web Page www.alcorinc.com, Email [email protected] or call 1-800-FLI-SAFE (800-354-7233) or 210-349-6491. Fax us at 210-308-8536.

WARRANTY INFORMATION

To activate warranty and receive customer referrals ALCOR® mustreceive a completed warranty card!

ALCOR® Inc., warrants all parts in your new ALCAL® 2000, product to be freefrom defects in material and workmanship under normal use. Our obligationunder this warranty is limited to repair or exchange of any defective part ofthis unit if returned, transportation prepaid, within one year from the date

of purchase. The replacement parts carry a warranty for the balance of the warranty.

Under this warranty, ALCOR®, is not responsible for any service charges or

any other consequential damages.

This warranty is void on any product which has been subjected to misuse,accident, negligent damage, repaired by other than the ALCOR® Repair

Department, or damaged in transit handling. If in the opinion of ALCOR®, thewarranty seal has been altered or defaced, the warranty is voided.

This warranty is in lieu of all other warranties expressed or implied and allother obligations of liability on ALCOR® 's part, and it neither assumes nor authorizes any other person to assume for ALCOR® any other liability in

connection with the sale of ALCOR® products.

A. ALCAL® 2000 Setup for either Thermocouple or Thermistor, RTD systems showing true temperature.

1. Check calibration sticker to ensure that ALCAL® 2000 certification by theALCOR Repair Department has not expired.

2. Plug Power Cord (Item 13) into a standard grounded 110-Volt ACsocket and plug and lock Test Cable (Item 28) into Test Receptacle(Item 10).

3. Clip Test Cable to Terminal Posts (Item 1) ensuring correct polarity sothat correct heater temperature will show in ALCAL® 2000 Display (Item8).

4. Plug one end of heater Extension Lead (Item 29) into HeaterReceptacle (Item 1) and the other end into ALCAL® 2000 heater beingused.

Important: Also plug the external thermocouple extensionlead (Black for Type J, Yellow for Type K or E) that is part ofheater Extension Lead into corresponding Heater ReferenceThermocouple. The Reference Thermocoupler is internal on EGTHeater (unless optional method is used) and external on CHTHeater.

5. Disconnect lead wire(s) from thermocouple/thermistor. Remove fromcylinder/exhaust then screw/insert thermocouple/thermistor intoappropriate heater. Hang on nearby cylinder, cable, etc. keepingheater clear of surrounding wires.

EGTPlug Internal Reference Thermocouple into Reference ThermocoupleReceptacle (Item 3). Clamps on clamp style probes must be openedwide to allow full insertion into heater. All types must be inserted asfar down as possible for best thermal conductivity.

CHTBayonet Type J ThermocoupleFirst screw in CHT Bayonet Adapter (Item 31) into CHT Heater (Item24), then insert and lock bayonet thermocouple to be tested intoadapter. Insert CHT Heater Control Thermocouple (Item 27) in holenext to adapter. NOTE: Some are direct screw in type that do not uti-lize an adapter and may not be as accurate as ones that contact thebottom of the thermal well.

Gasket Type ThermocoupleInsert CHT Gasket Adapter (Item 32) fitted with gasket thermocoupleto be tested into heater. Then insert CHT Heater ControlThermocouple (Item 27) into side of adapter and associated plug intoReference Thermocouple Receptacle (Item 3).

Resistance Type DeviceThis is the easiest way to check the function and accuracy of this typeof system since it is based on resistance and not millivolts. RTD’s


replaced when the voltage drops below 7.3 volts DC. Alkaline batteriesmay be used but longevity will be compromised. Periodically check theBattery Compartment for battery leakage. The 3 volt wafer battery islocated on the circuit board and is not field replaceable, but is replacedif necessary when the ALCAL® 2000 is sent in for calibration.

FuseFuse, (Item 12), is accessed beneath Compartment/Heater Cover(Item 21). If fuse fails repeatedly then a problem exists somewhere inthe circuit and the ALCAL® 2000 must be returned to Alcor for repair. Onlyuse the recommended type as a higher rating can cause internalfailure to electronic components.

SAFETY PRECAUTIONS

In order to test thermocouples, your ALCAL®2000 comes equipped withheaters that can cause injury and fire if not handled correctly.

Caution:Never plug heater into any 110-V receptacle without first con-necting reference thermocouple. Without the reference thermo-couple the heater will exceed its design limits and burn up! TheCHT heater will melt! DO NOT place heater in close proximity toflammable materials. Never leave a heater unattended while it ison! The CHT heater can exceed 500° F and the EGT heater canexceed 1800° F! It is best to allow the heater to cool before han-dling, but if that is not possible, use a kitchen pot holder/mitt andthe convenient hook built into the heater. Avoid placing a hotheater on any flammable materials such as plastic, wood, paper,etc. The life of the heating element will be greatly increased if theunit is turned off when not immediately in use. Use extreme carewhen removing hot thermocouples from heater after testing!

CALIBRATION & REPAIR OF YOUR ALCAL® 2000

ALCOR® recommends calibration and inspection on an annual basis.Calibration and repairs may only be done by qualified ALCOR® repairtechnicians. Calibrations are traceable to National Institute ofStandards and Technology, and include a letter of certification. CallALCOR® to schedule repair/calibration and include your name, tele-phone number, and a full description of the problem. Keep shipping boxthat ALCAL®2000 was shipped in so that it may be reused to returnALCAL®2000 for certification/repair.

come in both bayonet and screw-in styles as noted above but themost accurate design is one that has a spring loaded tip that ensuresfull contact at bottom of thermal well. It is imperative that the ground-ing clip on the CHT Heater be secured to engine while performing thistest. Be careful in handling as RTDs are more fragile than thermo-couples.Note: Do not plug heater into any 110V AC receptacle withoutfirst connecting Reference Thermocouple. (See Chapter V.General Information/Safety Precautions)

6. Reconnect lead wires from aircraft meter to thermocouple/thermistor.

7. Place Indicate/Calibrate Switch (Item 16) to Indicate and select thetype of system being tested with the TC Type Switch (Item 9) whichwill be the same as heater type being used, CHT, Type J or EGT,Type K and E.

8. Ensure correct temperature readout is selected depending on meterdial readout using Fahrenheit/Celsius Switch (Item 7).

9. Set Heater Temperature Dial (Item 14) to the temperature you wishto check meter accuracy.

10.If meter is amplified, turn aircraft power on first, then turn ALCAL® 2000Power Switch (Item 18) to On. Heater Light (Item 2) should be on.Push Battery Test Button (Item 19) and check for a minimum of 7.3volts displayed in LCD.

B. System Test

1. Once selected temperature has stabilized, read temperature dis-played on aircraft meter and compare with reading in ALCAL® 2000 LCDDisplay (Item 8).

2. Recalibrate ALCOR® meter as noted previously in CALIBRATIONTEST. With all other meters contact the meter manufacturer. See listin Chapter VI. TABLES.

BENCH TESTING EGT/TIT/CHT METERSThe ALCAL® 2000 can be used to provide a millivolt source to calibrate anyType J, K, or E. meters. But in order to calibrate an un-amplified meter cor-rectly you must first find the resistance value on the meter label or mea-sure the loop resistance of the lead and probe that will be used with themeter. Input these values into a Decade Box or similar device then cali-brate the meter (See Chapter VI. TABLES). The most accurate method forcalibrating true temperature reading meters is to heat the probe to aknown temperature and then re-calibrate the meter in the aircraft asshown previously in Chapter II.

Note: In some cases meters that test favorably on the bench will not oper-ate correctly in the aircraft. This may be due to the millivolt test box on thebench producing more milliamps than a thermocouple. The same holds


MAINTENANCE

HeatersIf heaters are operated within their temperature limits for short periods,they should provide many hours of reliable operation. It is recom-mended on EGT heaters (P/N 35290) however to periodically keep thetest hole cleaned with a .#44 drill bit (.086). This allows maximum inser-tion depth for greater accuracy. CHT heaters require that the threadsbe lubricated occasionally with a high temp spark plug type lubricant orequivalent. Take care not to drop heater as insulation damage mayoccur.

CaseYour ALCAL® 2000 Tester/Calibrator is rigidly mounted in a durable air-tight and watertight plastic case resistant to most oils, fuels, and chem-icals. It comes equipped with an E-Z PURGE pressure control. If thecase will not open after air travel/altitude change (i.e. high to lower alti-tude), open black plastic knob behind handle to equalize pressure. Ifnecessary, the case can be locked with an ordinary padlock, which isnot provided. The case may be cleaned by ordinary household clean-ers. Periodically inspect case for loose components (i.e., tightness ofcontrol knob allen set screws, lid hinge pins, etc.). Inspect case hingesand latches for proper operation. Periodically inspect condition of o-ring seal located in lid perimeter and lubricate with silicon.

MoistureYour ALCAL® 2000 is neither waterproof nor water-resistant while in use.It must never be exposed to nor operated in wet conditions, espe-cially with unit plugged into a 110-Volt outlet! If the unit is exposedto water, unplug power cord immediately, invert and drain excesswater, and wipe off any remaining water. Allow to air dry thoroughlybefore attempting to power up or damage to internal electronic circuitmay result.

Battery replacementThe ALCAL® 2000 has two batteries, one 9 volt to provide input power,and one 3 volt wafer battery to provide output power. Your unit comessupplied with a 9 volt Lithium, P/N 89050, for long life and is easilyreplaced by pushing Battery Compartment Cover (Item 6) down andforward and then pulling upward. It is recommended that this battery be

V GENERAL INFORMATION

true when a previously inoperative meter begins working with a new ther-mocouple only to have it become inoperative soon after. This is becausethe milliamp output of a new probe is slightly greater than the old probetemporarily overcoming the excess resistance of a bad potentiometerfound in meters made before 1980. See Chapter I. INTRO/BASIC METERTHEORY.

If you do not have a Decade Box or the appropriate probe/lead combina-tion then the following table is provided to allow bench checking/calibrat-ing of meters. Refer to Chapter II, TESTING & CALIBRATING METERSbut ignore section that refers to disconnecting lead and probe and connectTest Cable Clips directly to meter to ensure correct polarity. Please notethat the actual temperature that you are setting the meter to is theMETER READING column, not the ALCAL® 2000 READING.


ENGINE PROBLEMS IN FLIGHT USING EGTSYMPTOM

75-100°F rise for one cylinder(usually suddenbut sometimes

gradual)

75-100°F rise forALL cylinders

Increase or decrease,

especially afterignition system maintenance

Loss of peak EGT

Decrease in EGTfor all cylinderswith no change

in mixture setting.

Decrease in EGTfor one cylinder

Slow rise in EGTfor one cylinder

Decrease inpeak and flat

--SUDDEN--OFF SCALE RISEfor one cylinder

ANY Decrease

ANYIncrease

PROBABLE CAUSESpark plug not firing due to fouling,faulty plug, lead, or distributor.During rich mixture operation suchas take-off and climb, this symptomcan also mean a leaking intake pipe.

One magneto not operating.

Improper ignition timing. An increase in EGT means retarded ignition. A decrease meansadvanced ignition.

Poor ignition or if fuel injection engine, this symptom can bycaused by vapor in fuel system.Carbureted engines: Enrichment ofmixture possibly due to carburetorice. All engines: Decrease in totalairflow to engine, such as inductionice.

1. Intake valve not opening fully, such as faulty lifter or carbon or lead fouling on valve stem.

2. Scored cylinder or broken piston rings to cause low compression (Can also cause increase in EGT due to plug fouling from high oil consumption.

Burned exhaust valve

Detonation, usually the result ofputting 80-octane fuel into a 100-octane engine.PREIGNITION!

If one of the above causes is not inevidence, then suspect a low read-ing probe or faulty connection.

TROUBLEBecause any malfunction of exhaustprobe, lead or meter can only causea decrease in EGT

SOLUTION1. Enrich mixture to return EGT to

cylinder with high EGT.2. Go to single magneto operation. When

magneto firing bad spark plug is selected, EGT will suddenly drop to bottom of scale, defining plug that is not firing.

3. Replace plug.

1. Enrich mixture to return EGT to normal.2. Have magneto repaired

1. Check EGT rise for each mag todetermine any uneven timing.

2. Take corrective action.

Have magneto tested.

Check for change in manifold pressure.

1. Have valve lift checked2. Go to single mag operation to check for

plug fouling.3. Have compression checked.

Have compression checked

Enrich mixture, reduce power, and relean mix-ture. Repeat, if necessary, to find power setting where normal peak is obtained or run rich.DURING TAKE OFFAbort if possible and if not, go to full rich andreduce power if excess power is available.DURING CRUISECut throttle back quickly and reopen until EGTreturns to normal and if it does not, reduce power topoint of eliminating pre-ignition.

Check calibration with ALCAL® 2000 or reverseprobes to determine whether low reading moveswith probe or stays with cylinder.

SYSTEM TYPE

TYPE JI/C

TYPE KC/A

TYPE EC/C

RESISTANCE

8.00 Ohms

3.30 Ohms3.637.607.44

8.90 Ohms

METER READING

500° F

1500° F1600° F1650° F1700° F

1550° F

ALCAL READING

375° F

1276° F1358° F1085° F1094° F

1254° F

VALUES TO BENCH CHECK METERS WITHOUT LEAD/PROBE

MISCELLANEOUS, NON-ALCOR METERSThe ALCAL® 2000 can be used to test meters other than those manufac-tured by ALCOR®. If the system uses a Type J, K, or E thermocouple, fol-low the instructions in Chapter II. to verify function and accuracy. Contactthe appropriate manufacturer for individual instructions on proper cali-bration procedures.

Note: Some manufacturers may only authorize factory calibration, espe-cially if meter/analyzer is in warranty. Probe fit in ALCAL® 2000 EGT heaters(except P/N 35291 ) may pose a problem with most non-ALCOR® sys-tems. Refer to Chapter VI. TABLES, for list of ALCOR® competitors.


wiggle the probe lead to check for changes in reading. See Chapter III,Testing TC/Method I.

Do EGT/TIT probes require periodic maintenance and can they be repaired?

No, probes do not require cleaning but deposits may have a negligibleeffect on response time. Probes are sealed and cannot be repaired.

How do I re-calibrate a relative reading meter in flight?

See EGT Meter Installation Instructions P/N 59185.

Can I have my meter repaired by any instrument shop?

This is not recommended. To control quality, ALCOR® does not sell replace-ment parts and as a result when a shop says it has overhauled your meterit may have only cleaned and re-calibrated it at an inflated price. If meterhas a small hole (manufactured after 1980) in front for calibration, it isrepairable. RRRReeeellll yyyy oooonnnnllll yyyy oooonnnn GGGGeeeennnnuuuuiiiinnnneeee AAAA LLLL CCCC OOOO RRRR® PPPPaaaarrrr ttttssss.

Refer to Product Installation Instruction booklets:

EGT/CHT Indicators . . . . . . . . . . . . . . . . . . . . . .P/N 59185

Probe, CHT . . . . . . . . . . . . . . . . . . . . . . . . . . . .P/N 59188

Probe, EGT . . . . . . . . . . . . . . . . . . . . . . . . . . . .P/N 59180

Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P/N 59181

Universal Cylinder Selector Switch . . . . . . . . . . .P/N 59187

Multi Cylinder Combustion Analyzer . . . . . . . . . .P/N 59182

©1999 Alcor, Inc.©1999 Alcor, Inc.

This chapter will cover test procedures to test thermocouples using bothresistance and heat. Before using your ALCAL® 2000, visually inspect theEGT, TIT, or CHT systems on the aircraft for obvious defects, such asbad connections, or heat damaged and shorted wires. The followingmethods will verify correct operation/accuracy of any Type J, K, and EType thermocouples, given limitations due to heater test hole size.Limited thermistor testing is also described. (See Chapter IV.Troubleshooting, for solutions to common problems, and Chapter VI.TABLES, for resistance values.)

METHOD 1: RESISTANCE TEST, EGT/TIT/CHTThis is a simple test to determine the integrity of a thermocouple by ver-ifying loop resistance at room temperature using a multimeter. TheALCAL® 2000 is not required for test method 1 and 2.

A. Setup

Multimeter capable of sensing tenths of and ohm, preferably digital,with clips on test lead.

1. With thermocouple at room/ambient temperature while still installedin cylinder/exhaust, disconnect thermocouple lead wire. Clip leadterminals with multimeter test lead clips (polarity is unimportant).

2. Set multimeter to read in tenths of an ohm.

Note: Do not connect multimeter directly to lead wire going to back ofmeter to check meter condition because relative high voltage frommultimeter may quickly snap and loop an un-amplified meter hair-spring.

B. Test

1. Make note of resistance displayed on multimeter while moving ther-mocouple lead back and forth. This will test for internal condition ofthe thermocouple wire and determine if there is an intermittent prob-lem due to broken wire strands. Extreme fluctuations in the resis-tance reading indicate that the probe should be discarded butensure fluctuation is not due to multimeter clips shifting on terminals.See Chapter VI. TABLES/PROBE CROSS REF., for resistance val-ues to test to.

2. If the probe passes resistance test then it is probably in working con-dition.The following test using uncalibrated heat can only determinefunction and not the accuracy of the thermocouple output. SeeChapter IV. TROUBLESHOOTING

III TESTING THERMOCOUPLES


It is not recommended. The correct type thermocouple wire may be addedor removed, as long as meter is re-calibrated either in flight or with ALCAL®

2000. If amount added or removed causes maximum potentiometer adjust-ment, full-scale meter linearity may be compromised. Terminals need notbe thermocouple type material (ie: Type J, K, or E) unless connection is ata bulkhead/firewall and terminals are different temperatures. Otherwisethe temperature differential will be indicated on aircraft meter.

Should I be concerned about the gray stains around the EGT probe?

Yes. This indicates a loose/leaking thermocouple causing exhaust gasleakage and may result in rapid erosion of the exhaust system thermo-couple hole. Oversize the hole and insert ALCOR® exhaust hole AdapterP/N 74291 if using ALCOR® thermocouples; otherwise close hole by weld-ing or other FAA approved methods and drill new hole.

What does it mean when engine reaches lean misfire before peak indication isreached?

Probe is located in one of the richest running cylinders. Move probe toanother cylinder . Plug hole with old probe or weld hole using FAAapproved methods.

Should I lubricate the threads on a screw-in probe before I install it?

Yes, but use only high-temperature anti-seize lubricant for such as Fel-ProC5-A or equivalent. If not high temperature probe may be difficult toremove later.

What should I do if the lead and probe stagger connection doesn’t match?

Just pull the wires together keeping the color codes matched. An alumelwire jumper adapter, P/N 42523, is available for those who wish a neaterinstallation.

Does it matter how I route the lead wires?

Yes, otherwise you might introduce stray induction if a lead is routed withcurrent carrying alternator/generator wire or high voltage ignition wires.This may cause higher than normal readings in un-amplified systems. Totest for this simply turn Master and Alternator/Generator Switch to off andsee if reading drops simultaneously.

Do I need to remove an EGT probe to test it?

No, just perform a resistance check with the disconnected lead wires ofthe probe. While reading the ohms (approximately 1-ohm for EGT/TIT),

METHOD 2: SIMPLE FUNCTIONAL TESTS USING HEATA. Setup for EGT/TIT Thermocouples

Safety Glasses with side shields Propane torch or equivalent Multimeter capable of sensing millivolts, preferably digital with clips ontest lead.

1. Disconnect probe from leads and remove from exhaust/cylinder.

2. Set multimeter to millivolts, DC and connect test clips to probe termi-nal ends.

3. Move to an area away from aircraft and flammable materials and usesensible safety precautions. Use fire resistant gloves or equivalentand have fire extinguisher ready.

Test

1. Carefully heat just the probe element tip with a propane torch until itbegins to glow a dark cherry red color. At this point, the probe shouldbe producing approximately 33 to 36 millivolts (1500°F-1650°F) forred/yellow, Type K or 61 to 67 millivolts (1500°F-1650°F) forred/brown, Type E systems. See Chapter VI. TABLES/TEMPERA-TURE VS MILLIVOLT.

B. Setup for CHT Thermocouples

Safety glasses with side shieldsBoiling waterCandy thermometer or equivalentMultimeter capable of sensing millivolts, preferably digital

1. Bring water to a boil and verify 212°F with thermometer.

2. Set multimeter to millivolts, DC and connect test clips to probe termi-nal ends.

Test

1. Place Type J (Black/Yellow) probe into boiling water

2. Check multimeter millivolt reading of 3.69.

C. Functional Test, Thermistors (RTDs)

Heat probe to a known temperature and then read corresponding tem-perature on aircraft meter as noted in Chapter II.Method 2, UsingThermocouple Output.

ALCAL EGT/CHT System Tester User’s GuideALCAL EGT/CHT System Tester User’s Guide22

Frequently Asked Questions, FAQ’sWhat cylinder should I install my new EGT or CHT thermocouple on?

EGT probe should be located on the leanest cylinder, which is the cylin-der that peaks first (1450°F-1650°F) while leaning the mixture (this maynot necessarily be, the hottest cylinder). This can be different on identicalaircraft too because of differences in fuel/air flow characteristics, altitude,ambient air temp/humidity, power settings (RPM and Manifold), injectorflow rates, etc. On carbureted engines it is sometimes the cylinder far-thest from the carburetor or cylinder with the shortest intake pipe on inject-ed engines. If lean misfire is reached before peak then probe is incorrect-ly installed in the richest running cylinder. Poor mixture distribution can beimproved by moderate use of carburetor heat. Refer to Alcor publicationEGT Combustion Analysis in a Nutshell. CHT must be installed on thehottest cylinder, which is usually the one that gets the least airflow. This istypically a rear cylinder for horizontal engines, or number one cylinder onradial engines. The hottest cylinder can be determined by moving probeto each cylinder and test flying the aircraft. It is best to use the bayonetstyle if possible for better accuracy because gasket type can run hotter(50° to 100°F, usually about 60°F). Correct CHT meter calibration iscrucial for engine to reach TBO.

Where do I find identification on an Alcor Lead, Probe, or Meter?

All ALCOR® products are STC/FAA approved and will have FAA/PMA andan ALCOR® part number printed on their labels. Leads have a shrink labelat either the thermocouple or meter ends. It has the part number and theweek and year it was manufactured for warranty purposes. Yellow lead isType K, brown is Type E, and black is Type J. Thermocouples have a hightemp shrink label (older ones have a stamped aluminum placard) thatshows the part number and the week and year it was manufactured.Meters have a placard on top, which shows its part number and theprobe-lead loop resistance it is calibrated to. A round paper sticker locat-ed on the side will show the Quality Inspector’s stamp and the date ofmanufacture/inspection. The rear of a meter will have color-coded labelbetween the terminal studs depicting the type of system, either J, K, or E.

Can I replace an Alcor® probe with a competitor’s or a competitor’s probe withALCOR?

Yes, as long as the same type, either J, K, or E, with same fit, and samestyle whether grounded or un-grounded is used. But since ALCOR®’s EGTprobes are smaller than most other probes, a special adapter, ALCOR® P/N74291, must be used. Incompatibility between lead and probe connectorsmay be solved by replacing with compatible aviation grade connectors.UUUUsssseeee GGGGeeeennnnuuuuiiiinnnneeee AAAAllllccccoooorrrr RRRReeeeppppllllaaaacccceeeemmmmeeeennnntttt PPPPaaaarrrr ttttssss ,,,,, which will extend replace-ment interval periods resulting in lower labor costs for the owner.

Can I cut (or add) lead wire when I install an un-amplified system?

METHOD 3: ACCURACY TEST, EGT/TIT/CHT THERMOCOUPLESThese tests will utilize the ALCAL® 2000, and its EGT and CHT heaters toaccurately test thermocouples and thermistors up to their max operatingrange. If the probe drives a true reading TIT indicator then it should betested to 1650°F, being the typical redline for most turbochargers other-wise 1500°F is adequate to prolong heater life. CHT, probes should bechecked at a redline temperature of 400-500°F. For optimum TIT or CHTsystem accuracy, refer to Chapter 2., Method 2. The following detailedinstructions are contained in an abbreviated schematic form in the lid ofthe ALCAL® 2000 (Field Operating Instructions, Item 22). Also refer toComponent Items and Function which can be found on page 7. SeeChapter V, General Information/Safety, for precautions on heater use.

A. Setup, EGT

1. Check calibration sticker to ensure that ALCAL® 2000 certification by theALCOR Repair Department has not expired.

2. Plug power cord into a standard grounded 110-Volt AC socket andplug and lock Test Cable (Item 28) into Test Receptacle.

3. Attach Test Cable clips to Terminal Posts (Item 4) ensuring correct polar-ity so that heater temperature will show in ALCAL® 2000 Display.

4. Place Indicate/Calibrate Switch (Item 16) to Indicate.

5. Select the type of thermocouple being tested, either J (CHT), K, or E(EGT/TIT), with the TC Type Switch (Item 9). Using Fahrenheit/CelsiusSwitch (Item 7), choose preferred temperature scale.

6. Select heater type, either EGT (Type K or E), or CHT (Type J) withHeater Switch (Item 11) and plug corresponding heater into HeaterReceptacle (Item 1).

EGTPlug internal reference thermocouple in EGT Heater (Item 25) intoReference Thermocouple Receptacle (Item 3). Clamps on clamp styleprobes must be opened wide to allow full insertion into heater. Alltypes must be inserted as far down as for best thermal conductivity.

CHTBayonet Type J ThermocoupleFirst screw in CHT Bayonet Adapter (Item 31) into CHT Heater (Item24), then insert and lock bayonet thermocouple to be tested intoadapter. Insert CHT Heater Control Thermocouple (Item 27) in holenext to adapter. NOTE: Some are direct screw in type that do not uti-lize an adapter and may not be as accurate as the ones that contactthe bottom of the thermal well.

27


ALCOR ® METERS AND THERMOCOUPLESPROBABLE CAUSE

Shorted or open lead and probecircuit.

Possible probe/meter/lead incom-patibility.Meter out of calibration.

Friction in movement.

Bad or dirty and corroded potentiometer.

Meter out of calibration.

Thermocouple wire touching togetherother than at probe tipcausing secondary thermocouple junction.EGT Type K probe on Type E system.High resistance in system

Bad or dirty and corroded potentiometer.

Meter out of calibration.

EGT Type E Probe on Type K system.An open thermocouple, RTD, or connection on some types ofamplified systems.CHT Engine cooling baffling isleaking.CHT Gasket Thermocouple isused.Lead receiving bus currentthrough induction. Test by turningoff Master Switch andalternator/generator.Bad potentiometer or friction inmovement.Internal probe lead wires broken causing intermittent connection.Lead chafed and grounding intermittently.Friction in movement or old stylepot needs exercising or replacing.

EGT Indicator begins at 1200° F, allEngines may not reach1200° F atrun-up power while leaned.CHT Needs adequate time for warm up, meter out of calibration,or meter/probe inop.Check probe/lead resistance. If OKexcessive resistance/friction inmeter or pot in poor condition.

SYMPTOM

No indicationon meter.

Lowreading.

Highreading.

ErraticReading.

IndicatorChanges when

tapped.No Indication

at run-up.

Indicator workson bench, butnot in flight.

SOLUTION

Repair lead/replace probe and recheck lead andprobe loop resistance. Do system check withALCAL® 2000.Check that meter, lead, and thermocouple are thesame type by checking Color Codes/Part Numbers.Re-calibrate in flight if relative reading or with ALCAL® 2000 if true temperature reading meter.Worn jewels. Call ALCOR ® for meter repair orreplacement.Attempt to move pot back and forth to self-clean and then recalibrate. If no solution, call ALCOR ® torepair or replace.Re-calibrate in flight if relative reading EGT or with ALCAL® 2000 if true temperature reading meter.Inspect thermocouple and lead connection and insu-lation. Perform loop resistance check of lead andprobe. If Ok do heat check on probe. Correct con-nection or replace component.Install Type E probe or replace entire system.

Check probe and lead loop resistance. Replace if outof tolerance.Attempt to move pot back and forth to self-clean andthen recalibrate. If no solution, call ALCOR ® torepair or replace.Re-calibrate in flight if relative reading EGT or with ALCAL® 2000 if true temperature reading meter.Install Type K probe.

Test and if found defective replace component.

Repair/replace baffling.

Spark plug is higher temperature than cylinder.

Re-route lead away from current carrying wire.

Call ALCOR ® to repair or replace.

Check probe resistance while wiggling wire andreplace if out of tolerance or fluctuates.Insulate from airframe.

Call ALCOR ® to repair or replace.

Check operation while in Flight.

Test System.

Call ALCOR ® Repair or Replace.

Gasket Type ThermocoupleInsert CHT Gasket Adapter (Item 32) fitted with gasket thermocoupleto be tested into heater. Then insert CHT Heater ControlThermocouple into side of adapter and associated plug intoReference Thermocouple Receptacle (Item 3).

Resistance Type DeviceThis is the easiest way to check the function and accuracy of this typeof system since it is based on resistance and not millivolts.RTD’scome in both bayonet and screw-in styles as noted above but themost accurate design is one that has a spring loaded tip that ensuresfull contact at bottom of thermal well. It is imperative that the ground-ing clip on the CHT Heater be secured to engine while performing thistest. Be careful in handling, RTDs are more fragile than thermocou-ples.

Note: Do not plug heater into any 110V AC receptacle withoutfirst connecting Reference Thermocouple. (See Chapter V,General Information/Safety Precautions)

1. Turn Power Switch (Item 18) to ON and push Battery Test (Item 19)to ensure adequate voltage is above 7.3 volts.

2. Ensure Heater Light (Item 2) is on and set Heater Temperature Dial(Item 14) to desired test temperature.

B. Test

1. When temperature has stabilized (heater light is blinking) check tem-perature in Display (Item 8) and make final adjustment to establishcorrect test temperature.

2. Once desired temperature is set, disconnect Test Cable clips thatwere previously connected in setup and connect to test thermocou-ple leads ensuring correct polarity. Reverse connection will causeincorrect temperature readout. Refer to Color Code Reference Bars(Item 5).

3. Compare temperatures. Small thermocouple errors can be correctedby following system calibration procedures in Chapter 2, Method 2.

METHOD 4: OPTIONAL METHODEGT/TIT ProbesFor greater accuracy, an external EGT Reference Thermocouple is usedto measure actual temperature of thermal test well of heater. This isbecause of distance between thermal well (test probe location) and inter-nal reference thermocouple in the Heater. Measuring the actual tempera-ture in the test hole with a calibrated EGT Reference Thermocouple willallow greater accuracy than the standard method.


IV TROUBLESHOOTING

METERS AND THERMOCOUPLES Thermocouples (Probes)ALCOR ® probes usually work up until an open condition occurs. Thelikely failures are 1) In the probe lead where it exits the body/radiator,2) Near or at the spot weld connection between the element tip and thelead wire in the probe body, 3) The tip itself becoming eroded, which israre .In all three cases probe replacement in required. Clamp breakagecan also be found on earlier probes manufactured before 1983. A quickresistance check can usually determine the condition of the probe.(See Chapter VI Tables, for resistance values.)

Meters (Indicators)ALCOR ® meters built before 1980 have wire wound type potentiometerswhich are susceptible to corrosion and wear. If the meter is that ageand the pilot or mechanic has to tap meter glass to get movement tomove, most likely the problem is in the potentiometer. Exercising cali-bration potentiometer may restore meter function, otherwise the move-ment has friction from jewel wear and must be overhauled or replaced.Meters built after 1980 are free of problems associated with poten-tiometer corrosion and wear but exercising of movement can oftenhelp.

LeadsALCOR ® leads should never need attention. The only problems could beincorrect resistance requiring re-crimping of terminals or wire becom-ing burned/damaged. If a lead becomes damaged and if replacementis not cost effective then a new piece of lead wire may replace dam-aged portion as long as splice connection is not located at a bulkhead.Note: It is very important that correct thermocouple type wire beused for correct meter operation. Meter must be re-calibrated ifCHT or true temp reading EGT/TIT.


©1999 Alcor, Inc. ©1999 Alcor, Inc.

A. ALCAL® 2000 SETUP

1. Complete Setup as outlined in Method 3, but instead of using internalreference probe in EGT Heater, the optional external EGT ReferenceThermocouple (Item 26) is used to set heater temperature.

2. Insert Reference Thermocouple into small test hole in EGT Heater.Plug Transition Adapter (Item 30) into Reference ThermocoupleReceptacle (Item 3).

3. Remove Test Cable clips from Terminals (as attached in Method 2)and clip to tips of Transition Adapter ensuring correct polarity.

4. When temperature has stabilized, readjust Heater Temperature Dial(Item 14) to desired temperature.

B. CALIBRATE

1. When temperature has stabilized (heater light is blinking and ALCAL®

2000 LCD readout matches Heater Temperature Dial control set point)read meter in the cockpit and compare the two temperatures.

2. Recalibrate meter per Test and Calibration procedure.

Documents

Alcor, Incorporated - ALCAL 2000ALCOR ® produces both types of ALCAL EGT/CHT System Tester User’s Guide 46 ALCAL EGT/CHT System Tester User’s Guide 3 NEW ALCOR P/N 86240 86255