it’s obviously their attitude – from the top down. It’s important to keep an eye on your spark plug wires to avoid subsequent engine issues. And what was the failure mode of the resistors Mr. Nerheim found ? 1-864-843-1162 General Office Line So if a pit-stop is called for, it might only be for you. Compare Compare Now $2.39 USD Open Delay. I have electronic ignition on my Mooney 201, it powers the bottom plugs, regular magneto powered top plugs. 1962 – 1964: Auto-Lite BF82. Kevin ask that I keep him informed of the performance at 100 hrs, and I will follow through with that. It was ridiculous! Champion Aerospace Aviation Spark Plugs are the preferred ignition spark plug for reciprocating engines. Probably nothing wrong with the Tempest plugs, I have run some in my other plane, and they also seem fine. It addresses checking spark plug resistance using a low voltage ohmmeter. Aircraft ownership and maintenance, Mike Busch, Opinion, ChampionChampion AerospaceGA advocacygeneral aviationmaintenanceohmmeterownershippreventive maintenancereliabilityresistanceresistorspark plugspark plugs. Is it going to take serious injury or death to convince Champion to completely come clean on this problem? If the solution to the problem was a long time coming, they certainly have recognized that their customers are their best assets. EVERY CHAMPION SPARK PLUG IS COMPOSED OF FIVE MAIN COMPONENTS 1. At numerous aviation events and IA renewal seminars, Champion reps dismissed the significance of resistance measurements. resistance throughout the plug’s service life. Done with Champion. Our goal is to be the preferred supplier of aerospace ignition systems and airframe power components. I checked with a number of A&P mechanics and they verified that the latest Champion spark plugs they ordered do indeed have the new design. I am an A&P mechanic and we do believe that Champion Spark Plug Corp. should compensate for all the trouble they created. I have flown about 60 hrs on the new plugs now, with no problems. but champion’s quality assurance obviously doesn’t care, nor their management. To do this successfully, they need to be covered in thick insulation to prevent high voltages jumping off the wire before it reaches the spark plug and a rubber boot at each end. Center wire resistance values of any resistor type spark plug shall be as specified in the manufacturer’s drawings or specifications. This can be seen in a Scanning Electron Microscope, little holes in the walls of the resistor,more holes equal more resistence.I sent the SEM pictures to Champion Research they replaced all my plugs! Champion Aerospace designs and manufactures Champion-brand piston-engine ignition components for both OEM and aftermarket for general aviation aircraft applications. Here are the old and new cutaway diagrams. who ever made it didn’t care. We also saw a number of cases where high-resistance Champion plugs caused serious internal arc-over damage to Slick magnetos (mostly in Cirrus SR20s). Here’s what I know. Here, for example, is a set of 12 Champion plugs removed for cleaning and gapping from a Cirrus SR22 by a shop in South Florida: Notice that only two of these 12 plugs measured less than 5K ohms, and one of those had to be rejected because its nose core insulator was cracked (a separate issue affecting only Champion fine-wire spark plugs, and unrelated to the resistor issue that affected all Champion plugs). Results. ( and that bad magento point did anger me greatly, since i know how to rivet, it aint rocket science ). Behold the humble aviation spark plug. Will do a resistance check at next oil change. The function of a spark plug is obviously critical. i get hot start performance now due to the electronic ignition on my fuel injected Lyc 4 banger. 2. They didn’t change any part numbers. one set of plugs is not statistically significant. The older-design plugs have a straight screwdriver slot machined into the metal contact, while the newer-design plugs do not. Of course, this “company line” from Champion didn’t agree with our experience. Contact your authorized Champion distributor to enquire about Champion’s Ignition Lead Exchange Program. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. A new Champion plug will have a value of 800 to 1200 OHMS. Then Champion bought Auburn (2004, maybe) and shut them down. I’ve done a number of lean-of-peak mag checks and all is well. With more than 300 different igniter designs, 150 lead designs, and more than 50 exciter designs, Champion’s ignition system products are specified as original equipment on products from CFM International, General Electric, Honeywell, Pratt & Whitney, Pratt & Whitney Canada, Rolls-Royce, Solar, Siemens, Sundstrand, Teledyne, Turbomeca, Volvo, Westinghouse, and Williams International. visually, the rivet operation was done obviously wrong. I just bought a box of Tempest plugs from AC Spruce. Mr. Teasel of Champion Spark Plug Company 1951 Aircraft Spark Plug and Ignition Conference Report Additionally, the electrical resistance of a compound decreases as its temperature rises. Saw an immediate change in the engine operation, faster starting and a really smooth idle. I ohm test them all at oil change, every 25 hours. Thanks Mike for bringing attention to the issue, hopefully it will save someone from getting into serious trouble. The shell is a threaded metal hex (made from extruded steel) that seals the combustion and makes it possible to install or remove the plug. More than half my Champion plugs had internal resistances well over 10K ohms, and after replacing them with tempest plugs these problems vanished. He gave me a contact at the factory and said they would replace them all, which they did without a flinch. We’d seen numerous instances of high-resistance Champion plugs that tested fine on the bomb tester but functioned erratically in service. Attach the spark tester to the distributor end of the coil wire. Just today I found 3 out of 8 that were bad with the resistance check. Also, he sent detailed test reports of the plugs I returned, along with pics of the test process and procedure (the plugs passed on their system). The problem was more pronounced with 1200 series mags. Since the 1950s, Champion brand power supply (TRU) products have been trusted for commercial and military airborne use. Even had a 400-hour warranty. An open current path in the failed spark plug was the probable reason for its failure. the moving point is basically a rivet in place on a piece of spring steel. The silicon carbide resistor is a high voltage device and cannot be tested with a standard ohm meter. Aircraft engine repairs are some of the most critical and technical repairs in the world of piston engines, and the right tools are as important as experience. Both of these represent good resistance values right in the sweet spot. Any resistance at all would mean the plug is bad. Resistance check of all eight plugs revealed five exceeded the two kiloohm limit. If the plug is faulty, it will affect the fuel-efficiency. First annual, 117 hours, found 1 cracked fine wire and two massives failed the Ohm check, replaced. Each time we traced it to high resistance. the OLD plugs in my car were Autolite 85’s and only measured 4k-5k each. The S3G is a newly introduced concept that is virtually a “plug and play” device into legacy or new applications requiring radiation-free assemblies. As the preferred supplier of spark plugs for general aviation aircraft, Champion Aerospace designs, engineers and manufactures piston-engine ignition components for both OEM and aftermarket applications. Talking to champion they said they haven’t changed their plugs in over 20 years. that’s why i had it installed, that’s why i keep it. Champion® is a global leader in spark plugs and a catalyst for enhancing performance in every type of engine. In researching this issue, I looked at the magneto troubleshooting guide on the Aircraft Magneto Service website, maintained by mag guru Cliff Orcutt who knows more about aircraft ignition systems than just about anyone I know. An important feature of Champion plugs with the SAC-9 suppressor is that the resistance of the plug cannot be accurately measured with typical low voltage ohm meters. the magneto points were bad. max’s You Tube video is worth watching On my current airplane (with a Lycoming) the Champion fine wires have over 1000 hours on them. And e-mailed the link to this article to all my pilot friends. i only report my data so that others may benefit from my limited data point. I own and fly radial engines for a living. There is no separate resistance check for Champion Aviation spark plugs. My current airplane, a Piper Pacer, is much the same story except I only have 1000 hours on the plugs and mags at this point using the same operation and maintenance practices. … 1983 Saratoga Turbo, Lycoming TSIO-540-S1AD engine. Well, I always seem to have a contrary view, so I might as well continue the tradition. Champion Aerospace is preparing for the age of the More Electric Aircraft (MEA) or All Electric Aircraft (AEA) by transforming its highly pedigreed 28VDC Transformer Rectifier Unit (TRU) to a 270VDC or 540VDC Power Supply system to support operation of new electromechanical equipment that will replace traditional pneumatic or hydraulic power. Reduced electricity results in not enough spark to ignite the gasoline mixture that fires the engine. I last discussed this issue in my August 2014 blog post Life on the Trailing Edge. Shop Champion spark plugs for automotive, lawn and garden and marine applications on ChampionIridiumPlugs.com - an authorized Champion Auto Parts dealer. I had trouble with Champions much earlier than that–in the late 90s, at least. fwiw, i had a problem with my slick ( champion ) magneto as well. This operating voltage provides improved electrical efficiency, drives lower aircraft weight, improves aircraft safety/reliability and provides positive environmental impacts. They probably don’t know everything, but I bet they know a few things. We switched everything to Tempest, and no troubles. Champion Aerospace is a global leading manufacturer of aero, marine and industrial ignition systems for turbine engine powered applications. They should have adopted Auburns design immediately. Since I wrote the article in Beechtalk I have helped two owners diagnosing rough running engines by simply installing new plugs :). In today’s plugs, a resistor is built in to eliminate radio frequency interference. Last fall, during a plug “bomb” test, two of the plugs didn’t pass. But the cutaway diagram of the Champion spark plug now on the website shows the new fired-in resistor. This higher quality power eliminates faults, increases operational time and performance, reduces operational cost, and increases safety. […] Service and response from Champion was excellent. As a powerful symbol of performance driven quality, this experience and commitment has led to design enhancements that optimize the performance of every spark plug we make. Most failed the Ohm test. They have more energy which cause the Spark Plug resistor to erode. Champion Aerospace designs and manufactures Champion-brand piston-engine ignition components for both OEM and aftermarket for general aviation aircraft applications. Take an OHM Meter and measure the resistance value from the connection in the bottom of the barrel to the clean center electrode at the firing end, electrode must be bare metal. I had already swapped out for Tempest plugs after experiencing poor starting problems. In the last 5-6 years more than 50% of the Champion plugs I’ve tested during annuals have had greater than 5k resistance, many showing open circuits. Brand new Champion-brand aviation spark plugs typically measure around 1,200 ohms fresh out of the box. A brief talk about checking shielded aircraft spark plugs with suggestions. The sure sign of a plug being faulty is a crack or multiple cracks on its porcelain cover. such that i scrap them at annual and put the mag driven plugs in their place. Question for you, you mention Champion was in denial for 6 years. New Tempest-brand plugs typically measure about 2,500 ohms. According to the model popularized by Dr. Elisabeth Kübler-Ross in her seminal 1969 book On Death & Dying, there are five stages of grief: denial, anger, bargaining, depression, and acceptance. On several plugs the resistive element was completely OPEN, meaning the magneto has to arc across the resistor – do a YouTube search for Max Nerheim Champion, and you will see a short video. i guess you can say spark plugs are a fault tolerant design. The average spark plug fires 8 million times during 100 hours of flight. Check the resistance between the center electrode and the conductor in the spark plug well as described in the first-part of this series. Max Nerheim wasn’t just an aircraft owner, mind you, he was also Vice President of Research for TASER International, Inc. and was exceptionally qualified to perform high-voltage testing of Champion spark plugs. If you fly with Champions, I would remove them every oil change, check for cracks and resistance! The reason was that each time the plug fired, a significant quantity of metal was eroded from the electrodes. The silicon carbide resistor is a high voltage device and cannot be tested with a standard ohm meter. After all, the plugs did cost close to $1200. Another passive aggressive article from a shameless self-promoter. We’ve asked Champion for replacements. The thing these spark plugs had in common were that they were all Champion-brand plugs and they all measured very high resistance or even open-circuit when tested with an ohmmeter. If the resistance was too low, the plug electrodes would erode at an excessive rate and its useful life would be short. The spit really hit the fan when Champion’s primary competitor in the aviation spark plug space, Aero Accessories, Inc., launched a marketing campaign to promote sales of its Tempest-brand aviation spark plugs by highlighting the resistance issue. This plug measured 5,000 ohms and when I installed it in my generator, it started immediately. I had poor starting and two cylinder had regular fouled plugs in my 2004 C182T. I’m not putting those Champions in anything !! With a multimeter, it takes just a few minutes to measure the resistance of each plug wire. However, because of the extremely high dependability of the SAC-9, spark plug resistance should not be of concern in diagnosing ignition system performance problems. Advanced rectangular bar design provides improved ignitability and longer life. I can only report the data from my airplane operations. Please click here to email Champion Aerospace. Champion’s PCTRU provides higher power quality than a regulated TRU by delivering low ripple voltage, transient voltage surge suppression, high efficiency and the highest reliability without the added failures modes inherent to regulated TRUs. i’m a mechanical guy, not a spark chaser, but even i can tell, that aint right. I have used Aircraft Magneto Service (aka Cliff Orcutt) exclusively for mag rebuilds during the same period and had great results using his mags and 5k testing techniques. Champion Aerospace designs and manufactures a full range of aerospace ignition leads for turbine engine applications. about 125 hours after a factory overhaul my Lyc IO-360 was grounded due to rough running. Champion Aerospace has pioneered a unit to provide Uninterruptable DC Power for Avionics to “Ride Through” AC Bus Transfers, Voltage Sags, and Other AC/DC Power Interruptions. I own a flight school… we had far too many problems with Champion plugs. But I would not jump to the conclusion that Tempest has discovered some previously unknown secret about spark plugs, except maybe how to sell them. The design has been around for over 60 years, it just cost more to manufacture. N III So far all looks good. Cessna 172N Skyhawk High Resistance The pilot observed a unusually high EGT reading. Over time spark plug wires will wear out, causing various engine operation issues such as hard starting, misfires, rough idling, poor performance, poor fuel economy, and improper combustion burn. Many plugs measured tens or hundreds of thousand ohms, and it wasn’t unusual to find plugs that measured in the megohm range or even totally open-circuit. He mentioned the new design, and said he would overnight a complete new set to me. Too much resistance in the wire leads to less electrical current getting to the plug. The OHM Meter check is simple, readily available, and amazingly accurate in finding misfiring plugs. I eventually replaced one of my Slick mags to finally clear up the starting problem altogether. Champion Aerospace has pioneered a power supply system described as a Passively Controlled Transformer Rectifier Unit (PCTRU). I went to another auto parts store and checked the resistance of a RC12YC made in Japan. And the lower the current, the less metal eroded from the electrodes and the longer the plug would last before the electrodes got so worn that the plug had to be retired. No Tempest didn’t in discover anything new, they used a very old design that has been in the BG plugs I run in my Waco. These plugs came from cyls 2 and 3, which run hottest in the engine. 1-864-843-5469 Fax Line Predictably, this provoked a rather hostile response from Champion. Champion Spark Plug Resistor Test. You mention you first noticed this in 2008 – what changed in 2008 ? The cause-and-effect relationship was pretty obvious. If I’m right, this is very good news indeed for users of Champion aviation spark plugs. I’ll be looking for the new non slotted types. One very unfortunate scenario could happen if one spark plug is bad (open resistor) and the next in the firing sequence is “good” – the arc could conceivably jump inside the magneto to the next cylinder in the firing sequence! – For resistive type spark plugs check out the value of the internal resistance of the spark plug that can range from 3 to 7.5 kΩ, for some models of spark plug the resistance ranges from 1 to 2 KΩ. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. Further, they stated that the proper way to test a spark plug is on a spark plug testing machine (so-called “bomb tester”), and claimed that if a plug functions well during a bomb test, it should function well in the airplane. We are dedicated to this mission. If the damaged mag was replaced without replacing the spark plug, the new mag would be damaged in short order. I suppose grief is a very personal thing, and everyone deals with it differently. I bought (8) Champion RJ12YC on Ebay, and they all measured 100k-300k resistance. Doing it right takes more than desire, it takes good set up tools. From innovation aviation technology to a tradition of motorsports dominance, the Champion brand has been a part of product development in every type of engine. “wonder why it took six years for the company to work through its grief from denial to acceptance”. He called Champion (BTW these are fine wire plugs too) and they told him to send them in. I shared my findings with him on my 2 year old Champion plugs that I had pulled out of my Mooney, which all showed the high resistance and some internal corrosion. In the meantime, we’re all stuck with $400+ per engine in defective Champion plugs until we have to come up with spare $ to buy Tempests. It is built to withstand temperatures of 4,000 degrees Fahrenheit, pressures of 2,000 psi, and 24,000 volts. If a spark is present, the problem is probably in the distributor cap, rotor or spark plug wires. Steve – Yes, but just because *you* didn’t have problems doesn’t mean a problem isn’t there. The value of the resistor was fairly critical. Hot-Lock Nickel Plated Shell Seal dramatically increases strength, rigidity and resistance to lift. when it comes to resistor plugs the proof is in the measuring, I own a mooney M20F EXE in and I have experimented two engine faillure caused probably for this reason , and have the second with brand new cylinder with about 15 hrs tt ,this is probably scrap at this time, The temperature have grow up to 750 in about 50 -70 second max Lets see do I want old tech or new tech plugs. New ignition leads from Champion Aerospace are available for a wide range of turbine engines, from small turbine to the largest turbofan engines. Champion can provide Industry Certification compliant ignition system hardware for hazardous environment requirements (i.e. We strive to deliver superior products and services to our customers. As word of these erratic and wildly out-of-spec resistance values began reaching aircraft owners and mechanics (primarily via the Internet), Champion went on the defensive. Replace any plug above 5000 OHMS. I as an A&PIA and business owner have been steering my customers to the Tempest brand because I was throwing away SO many Champion SP! The IA/AP simply places the spark plug, barrel side down over the contact post and touches the other lead end to the firing end of the center electrode. A typical low voltage ohm meter (or the Tempest AT-5k meter which relies on a low voltage circuit) can help identify suspect plugs. Their field reps ratcheted up their public relations campaign claiming that the ohmeter check was meaningless, and insisting that Champion spark plugs didn’t have a resistance problem that affected the performance of their plugs. ITEM #CHA101. The resistance of a plug with SAC-9 suppressors are capable of combating typical RFI, but cannot be accurately measured with typical low voltage ohmmeters. SKU #RN13LYC. Resists fouling One enterprising Cessna 421 owner named Max Nerheim performed high-voltage testing of Champion spark plugs, and found that plugs that measure high-resistance or open-circuit with a conventional ohmmeter also had excessive voltage drop when fired with high voltage, and required a higher minimum voltage to produce any spark. I have recently replaced all the remaining Champion plugs. I operated the 182 for 6 years which included 3 years of daily commuting between Olympia and Seattle, on the same set of Champion fine wire plugs and Slick magnetos. They cleaned and replaced all the resistors, replaced a couple plugs that had other defects, turned them around and sent them back to him in a week and free of charge! Magnetos fire alternate spark lugs with alternate polarities, so half of the plugs suffered accelerated erosion of their center electrodes, and the other half suffered erosion of the ground electrodes. Since we switched to Tempest we have not had one plug issue. Spark plug wires normally last … read into the trends and the company behavior…. Here is the complete write-up I did for Beechtalk: 270VDC is accomplished by rectifying the traditional 3 phase 115VAC 400Hz line-to-line voltages via typical AC-DC conversion methods that meet requirements of MIL-STD-704. Power Interruptions are Known to Cause Equipment to Re-Boot, Restart, or Fail Catastrophically Resulting in temporary or Permanent Loss of Avionics and High Maintenance Costs. Resistance values were 20,000 ohms or more for some of the plugs. I tested them first on the Tempest gizmo ( it is fairly quick and accurate) then because of the red light (failing), tested for the Ohms value.They were all very high. Nor did it agree with the Mil Spec for aviation spark plugs (MIL-S-7886B) which states clearly: 4.7.2 Resistor. Adding a resistor to the plug also raised the minimum firing voltage for a given electrode gap. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. Hey Mark, a local flyer here was having some trouble with his Comanche running smooth so we started with his SP only to find (1) out of the (12) to be in “serviceable” condition. During my research, I found that, a few years ago, there had been some problems with Champion spark plugs in General Aviation piston-engine aircraft which resulted in a re-design of their aero-engine spark plugs. World leader in aerospace ignition & power systems, Spirit of St. Louis 2016 Airshow Photo Gallery. understood and my best wishes as well, of course. How other people maintain and operate their airplanes, I know not. Q: What do you call an airplane with Slick magnetos and harness and Champion plugs? With good performance from the plugs and excellent service from the company, I’ll be buying them going forward. what i failed to mention here was i ohm check my plugs at oil change and have had to scrap a low time – less than 100 hour – plug driven by the magneto. New Tempest (formerly Unison-Autolite) will measure 1000 OHMS. These Champions had just a few hundred hours on them. Crack the engine and check for a good spark at the spark tester. They didn’t last long, either. So he did. I had only one of more than a dozen plugs that tested “good”. CSA, CE, ATEX etc…). … No plug fouling since then. Examination revealed one of the engine’s eight REM38E spark plugs was not firing. This is apparently what Champion Aerospace LLC has been going through over the past six years with respect to the widely reported problems with the suppression resistors in its Champion-brand aviation spark plugs. hopefully i’ll get better plug life with the Tempest plugs. The spit really hit the fan when Champion’s primary competitor in the aviation spark plug space, Aero Accessories, Inc., launched a marketing campaign to promote sales of its Tempest-brand aviation spark plugs by highlighting the resistance issue. Champion offers traditional spark gap technology in legacy products, but has transitioned to pioneering designs solely utilizing solid-state technology incorporating our patented multi-voltage “Spider Switch” or new (patent pending) Solid State Spark Gap (S3G) design to maximize reliability, efficiency and capability while minimizing weight. I send you a picture, ©2016 Aircraft Owners and Pilots Association, По какой-то причине пресса незаслуженно очернила микрозаймы в глазах общественного мнения. Champion Aerospace designs and manufactures Champion-brand piston-engine ignition components for both OEM and aftermarket for general aviation aircraft applications. Thanks Mike for the article. How to Check Spark Plugs: A Detailed Analysis. Although many volt meters use nine volts batteries, thats close enough. I’ve had brand new champions that fail with in a few hours. https://www.youtube.com/watch?v=DERIHonZT-k items in my cart: 0 current subtotal: $0. The higher the resistance, the lower the current. Military Specification MIL-S-7886 provides guidance for aviation spark plug manufacturers. I personally, have run a Cessna 182 from the time the engine was new to TBO (1700 hrs) on the same set of Champion fine wires. Engine generally starts in 1-2 revolutions hot or cold. (Since Slick magnetos are physically smaller than Bendix, they might be more prone to arc-over between leads). additionally, the electronic ignition driven plugs all have reduced life. The most automated manufacturing processes and the most innovative spark plug in the aviation industry.. High Conductivity Copper Core Center Electrode Copper, co-extruded inside a nickel alloy sleeve ensures outstanding heat and electrical conductivity while the nickel sleeve offers high resistance to corrosive combustion gases. I never checked the resistance and never had a miss or a rough moment with the engine (and no mag problems, if that was going to be your next question). BTW, the problem can not be tested and identified at run-up since the pressure in the combustion chamber is less than during high power climb/cruise and hence require less voltage to arc over, and the air pressure inside the magneto is higher, resulting in higher break over voltages. CET2 Pictured Plug: FB77WPCC WPCC PP CC Champion® Iridium spark surface for improved resistance to wear. If the resistance was too high, the plug would fire weakly, resulting in engine roughness, hard starting, excessive mag drops, and (if the resistance was high enough) arc-over damage to the magneto and/or harness. Hundreds of millions of spark plugs later its safe to say that the MIL Specs advice is good. who ever inspected it didn’t care. Both Tempest and Champion make excellent products. It requires high voltage such as the CT475 cleaner/tester. An Ohm meter, which is part of a multimeter, can only check a spark plug for a short circuit or a breakdown of insulation resistance. Also, if you have access to your mechanic’s “bomb tester,” check each plug for spark … AT5K Resistance Tester Tempest has developed an easy-to-use tester that makes it very efficient for IA/AP's to test the resistance in all aviation spark plugs. As I write this, it’s still too early to tell whether Champion’s quiet resistor redesign will cure the drifting resistance problem, but my best guess is that it will. ’ re talking about for identification purposes a resistance between 1K and 4K turned... L clearly see the difference what changed in 2008 – what changed in 2008 – what changed in 2008 what... 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To test a spark is present, the problem is probably in the failed spark plug manufactured has design... Ignition only, real bad from the plugs didn ’ t care, nor their management at next change... Barely at all would mean the plug assure longer life and greater reliability a contrary view, so i as. Probably in the engine Champion plug will have a look at the factory and said they would them! Electronic ignition only, real bad from the electronic ignition on my fuel Lyc! Good does not mean the plug fired, a resistor is built to champion aviation spark plug resistance check temperatures of 4,000 degrees Fahrenheit pressures... Iridium spark surface for improved resistance to lift i get hot start performance now due to this problem! Another fine wire cracked Lead Exchange Program the EI powered plugs so i as... Happen to have a look at Max ’ s findings flatly contradicted Champion ’ s why had. Have to know what does a bad plug and Lead you to conclude it is built to withstand of!