How other people maintain and operate their airplanes, I know not. Military Specification MIL-S-7886 provides guidance for aviation spark plug manufacturers. 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. Please click here to email Champion Aerospace, Applications for virtually every aviation reciprocating/piston engine, Sales, Technical and Customer Services available, Sales, technical and customer services available, Applications for virtually every military and commercial aero turbines and most ground turbine applications, Proven Pedigree and Quality of Solid State Designs since the 1990s; Developed the first High Tension Solid State Exciter, Commitment to Advancing Existing/Emerging Technologies, Advanced Engineering Test and Analysis Capability, Designs suited for any turbine based engine; compliant designs to ABD100 and Boeing 7E7 requirements, Commitment to technology advancements and resolving in-service challenges, Custom or standard ignition lead designs available for all turbine applications, Plug Master Ratchet Wrench (Formerly CT-405), Magnetic Spark Plug Socket (Formerly CT-430), Commitment to Technology Advancements for Cleaner Power, Advance Engineering and Unmatched On-site Engineering Support, Power Conversion and Bus Hold Up Applications for Virtually Every Turbine Based Airframe, Bus Hold Up Applications for All Airframe Applications, Sales, Technical and Customer Services Available. i get hot start performance now due to the electronic ignition on my fuel injected Lyc 4 banger. Champion Aerospace is a global leading manufacturer of aero, marine and industrial ignition systems for turbine engine powered applications. Champion Aerospace designs and manufactures Champion-brand piston-engine ignition components for both OEM and aftermarket for general aviation aircraft applications. Last fall, during a plug “bomb” test, two of the plugs didn’t pass. I am glad that Champion is finally doing something about it. Champion should provide us with good replacement resistors for our perfectly good spark plugs. 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. These tools are designed to do a specific function and help make the removal and replacement process easier and less time consuming. 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. Hundreds of millions of spark plugs later its safe to say that the MIL Specs advice is good. Meanwhile, the Champion field reps continued to insist to anyone who would listen that claims of resistor problems in Champion spark plugs were false and that the ohmmeter test was meaningless. They explained that the silicon carbide resistor in Champion-brand plugs is made to show the proper resistance whenever a high-voltage pulse is present, and can’t necessarily be measured properly with an ohmmeter. Kevin ask that I keep him informed of the performance at 100 hrs, and I will follow through with that. Service and response from Champion was excellent. New Tempest (formerly Unison-Autolite) will measure 1000 OHMS. 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. I fly a turbo-normalized Cessna 177RG with the STC’d IO-390. Just today I found 3 out of 8 that were bad with the resistance check. Nor did it agree with the Mil Spec for aviation spark plugs (MIL-S-7886B) which states clearly: 4.7.2 Resistor. I last discussed this issue in my August 2014 blog post Life on the Trailing Edge. Eventually, the ground electrodes became so thin or the center electrode became so elliptical that the plug had to be retired from service. Spark plug wires deliver thousands of volts – up to 45.000V, depending on the application – to the spark plugs. A good spark plug should show an open circuit between the center electrode and the tip. Advanced rectangular bar design provides improved ignitability and longer life. Steve – Yes, but just because *you* didn’t have problems doesn’t mean a problem isn’t there. 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). max’s You Tube video is worth watching Too much resistance in the wire leads to less electrical current getting to the plug. the magneto points were bad. Simply look at the metal contact located at the bottom of the “cigarette well” on the harness end of the plug. I opened the magnetos at 1000 hours just to see how they were doing; only the carbon block was worn slightly out of limits. I’ve had brand new champions that fail with in a few hours. It requires high voltage such as the CT475 cleaner/tester. 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. We switched everything to Tempest, and no troubles. it’s obviously their attitude – from the top down. They have more energy which cause the Spark Plug resistor to erode. No plug fouling since then. In the face of both overwhelming technical evidence from the field that their spark plugs had a resistor problem, and a virtual blitzkrieg from their principal competitor that was starting to erode their dominant market share, Champion began having some self-doubts. 1983 Saratoga Turbo, Lycoming TSIO-540-S1AD engine. 06-17-2020 - Champion Aerospace awarded Elite Supplier Status from Lockheed Martin, 05-10-2018 - Champion Aerospace announces AS9100 Rev D Certification, 1230 Old Norris Road additionally, the electronic ignition driven plugs all have reduced life. New Tempest-brand plugs typically measure about 2,500 ohms. Resistance values were 20,000 ohms or more for some of the plugs. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. Very hard starting signaled the problem for me. 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. 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. You could have very easily been lucky and gotten a “good” set of plugs that performed better-than-average. He called Champion (BTW these are fine wire plugs too) and they told him to send them in. A brief talk about checking shielded aircraft spark plugs with suggestions. the OLD plugs in my car were Autolite 85’s and only measured 4k-5k each. Saw an immediate change in the engine operation, faster starting and a really smooth idle. Nerheim also disassembled the resistor assemblies of a number of high-resistance Champion plugs and found that the internal resistor “slugs” were failing. Champion Aerospace designs and manufactures Champion-brand piston-engine ignition components for both OEM and aftermarket for general aviation aircraft applications. If you fly with Champions, I would remove them every oil change, check for cracks and resistance! Champion Aerospace Aviation Spark Plugs are the preferred ignition spark plug for reciprocating engines. Hopefully they will take care of the people out there that have spent money on the bad plugs and replace them with the new design. Since we switched to Tempest we have not had one plug issue. These plugs came from cyls 2 and 3, which run hottest in the engine. We are dedicated to this mission. Resistance check of all eight plugs revealed five exceeded the two kiloohm limit. As the plug ages, values below 5000 ohms are acceptable. I just bought a box of Tempest plugs from AC Spruce. 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 i guess you can say spark plugs are a fault tolerant design. Well, I always seem to have a contrary view, so I might as well continue the tradition. My mechanic told me about the champion plug problem and I check mine at annual. but champion’s quality assurance obviously doesn’t care, nor their management. The result is a hotter, more well-defined spark that improves ignition consistency and reduces cycle-to-cycle variation. The silicon carbide resistor is a high voltage device and cannot be tested with a standard ohm meter. Video tutorial on how to test a spark plug wires. about 125 hours after a factory overhaul my Lyc IO-360 was grounded due to rough running. Results. I had already swapped out for Tempest plugs after experiencing poor starting problems. My tempest are working great. The Champion Aerospace website makes no mention of any recent design changes or product improvements. The EI powered plugs have shown a much accelerated effect of increased resistance as compared to the mag powered plugs. 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. Since 2008! 1-864-843-5469 Fax Line So far all looks good. It’s easy to tell whether a given Champion spark plug is of the old or new variety. these groups of people collectively forgot how to make them ? 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. Champion turbine igniters are a product of the Champion Aerospace commitment to the highest standards of quality and technology – a commitment that has made Champion the #1 igniter choice of engine manufacturers, maintenance technicians, and pilots around the world. Cessna 172N Skyhawk High Resistance The pilot observed a unusually high EGT reading. fwiw, i had a problem with my slick ( champion ) magneto as well. Reduced electricity results in not enough spark to ignite the gasoline mixture that fires the engine. 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. A VERY bad thing! I have recently replaced all the remaining Champion plugs. He gave me a contact at the factory and said they would replace them all, which they did without a flinch. 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. Champion Aerospace manufactures a broad range of high-performance inductive or capacitive discharge ignition exciters in configurable, customer driven designs. 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. 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. To draw a recent analogy from the automotive world: A lot of people drove GM cars with faulty ignitions and never had a problem; but that doesn’t mean people weren’t killed and a recall wasn’t necessary. The reason was that each time the plug fired, a significant quantity of metal was eroded from the electrodes. Another passive aggressive article from a shameless self-promoter. 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. More than half my Champion plugs had internal resistances well over 10K ohms, and after replacing them with tempest plugs these problems vanished. Even had a 400-hour warranty. When you are in a pinch for a spark plug and your preferred brand is out of stock, a quick check of the spark plug cross-reference chart can help you out. 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. Loss of business will hopefully get the Champion leadership fired, sending a message to Corporate America that this behavior is not tolerable. He mentioned the new design, and said he would overnight a complete new set to me. https://www.youtube.com/watch?v=DERIHonZT-k An open current path in the failed spark plug was the probable reason for its failure. Check the resistance between the center electrode and the conductor in the spark plug well as described in the first-part of this series. Also, if you have access to your mechanic’s “bomb tester,” check each plug for spark … And what was the failure mode of the resistors Mr. Nerheim found ? Examination revealed one of the engine’s eight REM38E spark plugs was not firing. And e-mailed the link to this article to all my pilot friends. hopefully i’ll get better plug life with the Tempest plugs. In February 2013, they issued a Tempest Tech Tip titled “The Right Way to Check Spark Plug Resistors,” started selling a fancy spark plug resistance tester, and launched a big “What’s Your Resistance” advertising campaign in the general aviation print media. I was floored! these components have been in production for how many years now ? Delayed Shipping. 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. At numerous aviation events and IA renewal seminars, Champion reps dismissed the significance of resistance measurements. Done with Champion. You can be sure they will not compensate, but you can get a certain amount of satisfaction by never buying anything from Chanpion again (and recommending the same practice to all of your customers). 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). I have electronic ignition on my Mooney 201, it powers the bottom plugs, regular magneto powered top plugs. 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. 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. Doing it right takes more than desire, it takes good set up tools. Two layers of corrosion protection. 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. World leader in aerospace ignition & power systems, Spirit of St. Louis 2016 Airshow Photo Gallery. Our broad range of plugs provide performance, fuel economy, durability and reliability. Probably nothing wrong with the Tempest plugs, I have run some in my other plane, and they also seem fine. that’s why i had it installed, that’s why i keep it. I ohm test them all at oil change, every 25 hours. After all, the plugs did cost close to $1200. SKU #RN13LYC. Max Nerheim discussed his high-voltage test findings with Kevin Gallagher, Manger of Piston and Airframe at Champion Aerospace, and Gallagher acknowledged that Champion was looking into the issue with the resistor increasing in impedance, but did not have it resolved yet. Replaced ALL plugs with tempests. They didn’t last long, either. It was ridiculous! (Since Slick magnetos are physically smaller than Bendix, they might be more prone to arc-over between leads). We have a culture based on values that encourage the continual improvement of our products, processes and quality system. I eventually replaced one of my Slick mags to finally clear up the starting problem altogether. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. How to Check Spark Plugs: A Detailed Analysis. In April of 2014, I stopped by the Champion booth at Sun & Fun and spoke to the main person there. A typical low voltage ohm meter (or the Tempest AT-5k meter which relies on a low voltage circuit) can help identify suspect plugs. 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). These Champions had just a few hundred hours on them. It requires high voltage such as the CT475 cleaner/tester. after 125 hours it was quite loose. CSA, CE, ATEX etc…). They should have adopted Auburns design immediately. In reading Cliff’s troubleshooting guide, I came across the following pearls of wisdom: We started asking the maintenance shops we hired to maintain our clients’ aircraft to ohm out the plugs at each 50-hour spark plug maintenance cycle. Replace any plug above 5000 OHMS. The average spark plug fires 8 million times during 100 hours of flight. Engine generally starts in 1-2 revolutions hot or cold. As a “Motörhead” I often wonder what the perfect spark gap voltage is, well in this case it is about 0.05′ across the spark plug gap and another about 0.5′ gap across the resistor! Is it going to take serious injury or death to convince Champion to completely come clean on this problem? Each spark plug shall be checked for stability of internal resistance and contact by measurement of the center wire resistance by the use of a low voltage ohmmeter (8 volts or less). i only report my data so that others may benefit from my limited data point. 3. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. 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. So he did. This plug was made in Mexico. it ran smooth from the electronic ignition only, real bad from the mag, barely at all actually. If I’m right, this is very good news indeed for users of Champion aviation spark plugs. Still, I can’t help but wonder why it took six years for the company to work through its grief from denial to acceptance. There is no separate resistance check for Champion Aviation spark plugs. Social media is so effective. The higher the resistance, the lower the current. Compare Compare Now $2.39 USD Open Delay. resistance throughout the plug’s service life. Since the 1950s, Champion brand power supply (TRU) products have been trusted for commercial and military airborne use. I went to another auto parts store and checked the resistance of a RC12YC made in Japan. Well, you first have to know what does a bad spark plug look like before knowing how to check spark plugs. http://www.beechtalk.com/forums/viewtopic.php?f=37&t=59668&p=671584&hilit=Max+Nerheim+champion+Cessna+421+cracked#p671584. I’ll be looking for the new non slotted types. But the cutaway diagram of the Champion spark plug now on the website shows the new fired-in resistor. Shop Champion spark plugs for automotive, lawn and garden and marine applications on ChampionIridiumPlugs.com - an authorized Champion Auto Parts dealer. such that i scrap them at annual and put the mag driven plugs in their place. Brand new Champion-brand aviation spark plugs typically measure around 1,200 ohms fresh out of the box. The number of plugs that measured over 5,000 ohms was eye-opening. understood and my best wishes as well, of course. Question for you, you mention Champion was in denial for 6 years. 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. First annual, 117 hours, found 1 cracked fine wire and two massives failed the Ohm check, replaced. I had trouble with Champions much earlier than that–in the late 90s, at least. Lets see do I want old tech or new tech plugs. But once the plug’s resistance value exceeds 5000 ohms, the plug should be replaced. 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. 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. who ever inspected it didn’t care. Engine overhauled in 2012 and new Champion massive plugs on top, fine wires on bottom. i’m a mechanical guy, not a spark chaser, but even i can tell, that aint right. Please click here to email Champion Aerospace. I applaud Champion Aerospace for improving its product. Last week, I replaced the 12 fine wire Champions in my plane with Tempest due to this resistance problem. Champion® is a global leader in spark plugs and a catalyst for enhancing performance in every type of engine. Our goal is to be the preferred supplier of aerospace ignition systems and airframe power components. Since I wrote the article in Beechtalk I have helped two owners diagnosing rough running engines by simply installing new plugs :). I had poor starting and two cylinder had regular fouled plugs in my 2004 C182T. Each time we traced it to high resistance. I’ve done a number of lean-of-peak mag checks and all is well. Crack the engine and check for a good spark at the spark tester. We used to use Auburns, which had that molded-in resistor, amd they lasted forever. The older-design plugs have a straight screwdriver slot machined into the metal contact, while the newer-design plugs do not. When spark plugs are new, the resistance value is between 500 and 3000 ohms. – 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. I’m not putting those Champions in anything !! Champion Spark Plug Resistor Test. We strive to deliver superior products and services to our customers. 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. The low voltage referred to doesnt hinge on exactly 8 or 10 … 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. N III I first became aware of the Champion spark plug resistor problem in 2010, although there’s evidence that it dates back to 2008. Liberty, South Carolina 29657 The cause-and-effect relationship was pretty obvious. If you call them to send them in they may replace them all for you. visually, the rivet operation was done obviously wrong. Spark plug manufacturers found that they could extend the useful life of their plugs by adding an internal resistor to limit the current of the spark that jumps across the electrodes. These extremely reliable resistors are formed from strontium carbonate, aluminum oxide and copper oxide powders. Both Tempest and Champion make excellent products. Spark plug wires normally last … При всём том, что, Champion Aerospace: From Denial to Acceptance, http://www.beechtalk.com/forums/viewtopic.php?f=37&t=59668&p=671584&hilit=Max+Nerheim+champion+Cessna+421+cracked#p671584, https://www.youtube.com/watch?v=DERIHonZT-k, BACK UP FOR IGNISTION FAILURE (WHAT IF) - Page 4. After reading your article, I’m suspecting that the defective plugs may have caused my 2 year old mag to fail as well, but I hold little hope that Champion will freely replace or reimburse that item! Behold the humble aviation spark plug. We’d seen numerous instances of high-resistance Champion plugs that tested fine on the bomb tester but functioned erratically in service. ... Champion 101 RN13LYC Nickel Spark Plug. This operating voltage provides improved electrical efficiency, drives lower aircraft weight, improves aircraft safety/reliability and provides positive environmental impacts. Cliff owns and operates my favorite mag specialty shop, and that’s where I send the mags on my own airplane every 500 hours for inspection and tune-up. Champion Aerospace also produces ignition systems for global industrial and marine based endusers, including land and marine power plants; oil, gas, and coal furnaces; oil rig operations; and pumping stations. Most Champion "R" type resistor plugs are Champion SAC-9 suppressors. CET2 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. 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. 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