Kevin ask that I keep him informed of the performance at 100 hrs, and I will follow through with that. i’m a mechanical guy, not a spark chaser, but even i can tell, that aint right. 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. If the damaged mag was replaced without replacing the spark plug, the new mag would be damaged in short order. Will do a resistance check at next oil change. The number of plugs that measured over 5,000 ohms was eye-opening. 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. Last week, I replaced the 12 fine wire Champions in my plane with Tempest due to this resistance problem. It’s easy to tell whether a given Champion spark plug is of the old or new variety. Champion management tried to cover it up by lying… so we won’t be purchasing their plugs again – even with the improved design. the moving point is basically a rivet in place on a piece of spring steel. I’ll be looking for the new non slotted types. I checked the resistance once, out of curiosity after the Tempest advertising blitz began, and found them all over the place, but the engine didn’t seem to know; always starts and runs perfectly. 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. The silicon carbide resistor is a high voltage device and cannot be tested with a standard ohm meter. I just went through this with automotive plugs. The EI powered plugs have shown a much accelerated effect of increased resistance as compared to the mag powered plugs. i guess you can say spark plugs are a fault tolerant design. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. The result is a hotter, more well-defined spark that improves ignition consistency and reduces cycle-to-cycle variation. 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. 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. We are dedicated to this mission. Champion Spark Plug Resistor Test. 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. Also, if you have access to your mechanic’s “bomb tester,” check each plug for spark … Brand new Champion-brand aviation spark plugs typically measure around 1,200 ohms fresh out of the box. … Saw an immediate change in the engine operation, faster starting and a really smooth idle. Resistance check of all eight plugs revealed five exceeded the two kiloohm limit. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. Military Specification MIL-S-7886 provides guidance for aviation spark plug manufacturers. Thanks Mike for the article. Eventually, the ground electrodes became so thin or the center electrode became so elliptical that the plug had to be retired from service. Predictably, this provoked a rather hostile response from Champion. At numerous aviation events and IA renewal seminars, Champion reps dismissed the significance of resistance measurements. I’ve had brand new champions that fail with in a few hours. 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. 2. 1962 – 1964: Auto-Lite BF82. Contact your authorized Champion distributor to enquire about Champion’s Ignition Lead Exchange Program. Mike, can you show pictures of the old and new metal contact you’re talking about for identification purposes? CHAMPION AVIATION SPARK PLUG TESTERS 110V AND 220V Designed to clean and test all 14mm & 18mm massive and fine-wire electrode aviation sparkplugs. If a spark is present, the problem is probably in the distributor cap, rotor or spark plug wires. An open current path in the failed spark plug was the probable reason for its failure. There is no separate resistance check for Champion Aviation spark plugs. The remainder were either cracked or open resistance. after 125 hours it was quite loose. Advanced rectangular bar design provides improved ignitability and longer life. But once the plug’s resistance value exceeds 5000 ohms, the plug should be replaced. 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. Too much resistance in the wire leads to less electrical current getting to the plug. 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. such that i scrap them at annual and put the mag driven plugs in their place. 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. 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). 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. After all, the plugs did cost close to $1200. They have more energy which cause the Spark Plug resistor to erode. Aircraft ownership and maintenance, Mike Busch, Opinion, ChampionChampion AerospaceGA advocacygeneral aviationmaintenanceohmmeterownershippreventive maintenancereliabilityresistanceresistorspark plugspark plugs. Pictured Plug: FB77WPCC WPCC PP CC Champion® Iridium spark surface for improved resistance to wear. Our goal is to be the preferred supplier of aerospace ignition systems and airframe power components. It addresses checking spark plug resistance using a low voltage ohmmeter. 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. 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. 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. In the DC-3 I fly every day, we have had the same experience and we have quite a few plugs to check to find one that’s bad. Our broad range of plugs provide performance, fuel economy, durability and reliability. I am glad that Champion is finally doing something about it. 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. Results. I have electronic ignition on my Mooney 201, it powers the bottom plugs, regular magneto powered top plugs. these components have been in production for how many years now ? We’ve asked Champion for replacements. 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). Champion Aerospace manufactures a broad range of high-performance inductive or capacitive discharge ignition exciters in configurable, customer driven designs. 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. So far as I have been able to tell, they didn’t even issue a press release. I remove plugs at 100 hours to clean the lead out of the bottom plugs, manually, I do not sandblast; I never had to re-gap them. Still, I can’t help but wonder why it took six years for the company to work through its grief from denial to acceptance. 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 hopefully i’ll get better plug life with the Tempest plugs. Just today I found 3 out of 8 that were bad with the resistance check. 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. Then Champion bought Auburn (2004, maybe) and shut them down. Doing it right takes more than desire, it takes good set up tools. Both Tempest and Champion make excellent products. 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. Sometime in late 2014, it appears that Champion very quietly changed the internal design of their spark plugs to use a sealed, fired-in resistor element that appears to be quite similar to the design of the Tempest/Autolite plug. Early aviation spark plugs didn’t contain resistors. Well, I always seem to have a contrary view, so I might as well continue the tradition. I’m not putting those Champions in anything !! (Aero Accessories acquired the Autolite line of aviation spark plugs from Unison Industries in 2010, an re-branded them under its Tempest brand.) 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! There is no separate resistance check for Champion Aviation spark plugs. Simply look at the metal contact located at the bottom of the “cigarette well” on the harness end of the plug. Please click here to email Champion Aerospace. New Tempest (formerly Unison-Autolite) will measure 1000 OHMS. CET2 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. 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. 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. 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. http://www.beechtalk.com/forums/viewtopic.php?f=37&t=59668&p=671584&hilit=Max+Nerheim+champion+Cessna+421+cracked#p671584. 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. 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. Experimentation showed that a resistance between 1K and 4K ohms turned out to be a good compromise between ignition performance and electrode longevity. 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. They probably don’t know everything, but I bet they know a few things. It was ridiculous! Champion Aerospace designs and manufactures a full range of aerospace ignition leads for turbine engine applications. but champion’s quality assurance obviously doesn’t care, nor their management. Here is the complete write-up I did for Beechtalk: 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. My tempest are working great. Although many volt meters use nine volts batteries, thats close enough. The design has been around for over 60 years, it just cost more to manufacture. So far all looks good. A typical low voltage ohm meter (or the Tempest AT-5k meter which relies on a low voltage circuit) can help identify suspect plugs. More than half my Champion plugs had internal resistances well over 10K ohms, and after replacing them with tempest plugs these problems vanished. Check the resistance between the center electrode and the conductor in the spark plug well as described in the first-part of this series. Done with Champion. Each time we traced it to high resistance. Champion Aerospace is a global leading manufacturer of aero, marine and industrial ignition systems for turbine engine powered applications. The silicon carbide resistor is a high voltage device and cannot be tested with a standard ohm meter. ( and that bad magento point did anger me greatly, since i know how to rivet, it aint rocket science ). The function of a spark plug is obviously critical. In April of 2014, I stopped by the Champion booth at Sun & Fun and spoke to the main person there. 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. You could have very easily been lucky and gotten a “good” set of plugs that performed better-than-average. I first became aware of the Champion spark plug resistor problem in 2010, although there’s evidence that it dates back to 2008. Champion® is a global leader in spark plugs and a catalyst for enhancing performance in every type of engine. Champion should provide us with good replacement resistors for our perfectly good spark plugs. 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. Resists fouling A brief talk about checking shielded aircraft spark plugs with suggestions. My engine starts first time, every time, and runs much smoother. resistance throughout the plug’s service life. 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. I bought (8) Champion RJ12YC on Ebay, and they all measured 100k-300k resistance. 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. 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. And it happened regularly, not just to me but to others at my airport. Crack the engine and check for a good spark at the spark tester. 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. No plug fouling since then. Loss of business will hopefully get the Champion leadership fired, sending a message to Corporate America that this behavior is not tolerable. My mechanic told me about the champion plug problem and I check mine at annual. This plug was made in Mexico. 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). – 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. Talking to champion they said they haven’t changed their plugs in over 20 years. Last annual, ALL massives failed Ohm check, found another fine wire cracked. Champion Aerospace has pioneered a power supply system described as a Passively Controlled Transformer Rectifier Unit (PCTRU). 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. If a spark plug falls off a workbench or is dropped, it’s possible for the carbon resistor to break. Replaced ALL plugs with tempests. Cessna 172N Skyhawk High Resistance The pilot observed a unusually high EGT reading. understood and my best wishes as well, of course. 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. I had only one of more than a dozen plugs that tested “good”. 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. I had poor starting and two cylinder had regular fouled plugs in my 2004 C182T. If the solution to the problem was a long time coming, they certainly have recognized that their customers are their best assets. the OLD plugs in my car were Autolite 85’s and only measured 4k-5k each. I opened the magnetos at 1000 hours just to see how they were doing; only the carbon block was worn slightly out of limits. Now then, Champion has been building spark plugs for a while, a long while. who ever made it didn’t care. This operating voltage provides improved electrical efficiency, drives lower aircraft weight, improves aircraft safety/reliability and provides positive environmental impacts. – To conventional spark plugs check out the spark plug continuity, using the megohmmeter, spark plugs without continuity should be replaced. 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 send you a picture, ©2016 Aircraft Owners and Pilots Association, По какой-то причине пресса незаслуженно очернила микрозаймы в глазах общественного мнения. Center wire resistance values of any resistor type spark plug shall be as specified in the manufacturer’s drawings or specifications. I had trouble with Champions much earlier than that–in the late 90s, at least. I have recently replaced all the remaining Champion plugs. 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! And I’ve had nothing but issues with Chapion spark plugs. A spark plug is a device installed at the top of an engine cylinder that generates sparks at the tip of its electrode when a high voltage is applied across its terminal ends, thus igniting the compressed air-fuel mixture in the cylinder. These Champions had just a few hundred hours on them. 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. about 125 hours after a factory overhaul my Lyc IO-360 was grounded due to rough running. Even had a 400-hour warranty. 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. The S3G is a newly introduced concept that is virtually a “plug and play” device into legacy or new applications requiring radiation-free assemblies. I hope they’ll honor the request. Examination revealed one of the engine’s eight REM38E spark plugs was not firing. I was floored! Delayed Shipping. 1-864-843-5469 Fax Line Since 2008! fwiw, i had a problem with my slick ( champion ) magneto as well. This plug measured 5,000 ohms and when I installed it in my generator, it started immediately. did you happen to have a look at Max’s you tube video ? 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. 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. A new Champion plug will have a value of 800 to 1200 OHMS. 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. 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. He mentioned the new design, and said he would overnight a complete new set to me. “wonder why it took six years for the company to work through its grief from denial to acceptance”. Since this was a new engine (about 40 hrs since new), I called Champion and was able to talk to Kevin Gallagher, their Piston and Airframe Manager. Steve – Yes, but just because *you* didn’t have problems doesn’t mean a problem isn’t there. The low voltage referred to doesnt hinge on exactly 8 or 10 … 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. 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. Lets see do I want old tech or new tech plugs. Champion Aerospace designs and manufactures Champion-brand piston-engine ignition components for both OEM and aftermarket for general aviation aircraft applications. How other people maintain and operate their airplanes, I know not. I had already swapped out for Tempest plugs after experiencing poor starting problems. Thanks Mike for bringing attention to the issue, hopefully it will save someone from getting into serious trouble. Very hard starting signaled the problem for me. it’s obviously their attitude – from the top down. (Since Slick magnetos are physically smaller than Bendix, they might be more prone to arc-over between leads). EVERY CHAMPION SPARK PLUG IS COMPOSED OF FIVE MAIN COMPONENTS 1. 1983 Saratoga Turbo, Lycoming TSIO-540-S1AD engine. This higher quality power eliminates faults, increases operational time and performance, reduces operational cost, and increases safety. We were seeing numerous cases of Champion spark plugs that were causing bad mag drops, rough running and hard starting even though they looked fine and their electrodes weren’t worn anywhere near the retirement threshold. Most Champion "R" type resistor plugs are Champion SAC-9 suppressors. Probably nothing wrong with the Tempest plugs, I have run some in my other plane, and they also seem fine. I just bought a box of Tempest plugs from AC Spruce. Liberty, South Carolina 29657 Champion Aerospace designs and manufactures Champion-brand piston-engine ignition components for both OEM and aftermarket for general aviation aircraft applications. In today’s plugs, a resistor is built in to eliminate radio frequency interference. Service and response from Champion was excellent. Q: What do you call an airplane with Slick magnetos and harness and Champion plugs? Ve had brand new Champion-brand aviation spark plugs trouble they created mention Champion was in denial for years. My data so that others may benefit from my limited data point but Champion ’ and. Their customers are their best assets the fuel-efficiency, and said he would overnight a complete new set to but! 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