i get hot start performance now due to the electronic ignition on my fuel injected Lyc 4 banger. Talking to champion they said they haven’t changed their plugs in over 20 years. The older-design plugs have a straight screwdriver slot machined into the metal contact, while the newer-design plugs do not. Delayed Shipping. I had poor starting and two cylinder had regular fouled plugs in my 2004 C182T. I just bought a box of Tempest plugs from AC Spruce. https://www.youtube.com/watch?v=DERIHonZT-k 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! SKU #RN13LYC. 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! Adding a resistor to the plug also raised the minimum firing voltage for a given electrode gap. resistance throughout the plug’s service life. Any resistance at all would mean the plug is bad. Each time we traced it to high resistance. I went to another auto parts store and checked the resistance of a RC12YC made in Japan. I had only one of more than a dozen plugs that tested “good”. 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. 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. 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. And what was the failure mode of the resistors Mr. Nerheim found ? The problem was more pronounced with 1200 series mags. Champion Aerospace is a global leading manufacturer of aero, marine and industrial ignition systems for turbine engine powered applications. after 125 hours it was quite loose. hopefully i’ll get better plug life with the Tempest plugs. 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. I suppose grief is a very personal thing, and everyone deals with it differently. My tempest are working great. You could have very easily been lucky and gotten a “good” set of plugs that performed better-than-average. Question for you, you mention Champion was in denial for 6 years. They didn’t change any part numbers. Center wire resistance values of any resistor type spark plug shall be as specified in the manufacturer’s drawings or specifications. My engine starts first time, every time, and runs much smoother. 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. 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. CHAMPION AVIATION SPARK PLUG TESTERS 110V AND 220V Designed to clean and test all 14mm & 18mm massive and fine-wire electrode aviation sparkplugs. The cause-and-effect relationship was pretty obvious. An open current path in the failed spark plug was the probable reason for its failure. 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. 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. who ever made it didn’t care. Well, I always seem to have a contrary view, so I might as well continue the tradition. If the plug is faulty, it will affect the fuel-efficiency. Behold the humble aviation spark plug. Champion should provide us with good replacement resistors for our perfectly good spark plugs. You mention you first noticed this in 2008 – what changed in 2008 ? 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. 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. The higher the resistance, the lower the current. 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. Champion® is a global leader in spark plugs and a catalyst for enhancing performance in every type of engine. 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 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. We strive to deliver superior products and services to our customers. i guess you can say spark plugs are a fault tolerant design. 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. Last week, I replaced the 12 fine wire Champions in my plane with Tempest due to this resistance problem. fwiw, i had a problem with my slick ( champion ) magneto as well. I hope they’ll honor the request. Since I wrote the article in Beechtalk I have helped two owners diagnosing rough running engines by simply installing new plugs :). 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. 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. My mechanic told me about the champion plug problem and I check mine at annual. I ohm test them all at oil change, every 25 hours. At numerous aviation events and IA renewal seminars, Champion reps dismissed the significance of resistance measurements. 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 management tried to cover it up by lying… so we won’t be purchasing their plugs again – even with the improved design. Nerheim also disassembled the resistor assemblies of a number of high-resistance Champion plugs and found that the internal resistor “slugs” were failing. Most Champion "R" type resistor plugs are Champion SAC-9 suppressors. I own a flight school… we had far too many problems with Champion plugs. When the job has to be done, we always say, do it right. Nerheim’s findings flatly contradicted Champion’s company line, and agreed with what we were seeing in the field. EVERY CHAMPION SPARK PLUG IS COMPOSED OF FIVE MAIN COMPONENTS 1. Thanks Mike for the article. I was floored! understood and my best wishes as well, of course. 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. 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. 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! 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! Both of these represent good resistance values right in the sweet spot. Eventually, the ground electrodes became so thin or the center electrode became so elliptical that the plug had to be retired from service. 3. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. We switched everything to Tempest, and no troubles. Then Champion bought Auburn (2004, maybe) and shut them down. Service and response from Champion was excellent. items in my cart: 0 current subtotal: $0. If you fly with Champions, I would remove them every oil change, check for cracks and resistance! Q: What do you call an airplane with Slick magnetos and harness and Champion plugs? Too much resistance in the wire leads to less electrical current getting to the plug. Since 2008! Simply look at the metal contact located at the bottom of the “cigarette well” on the harness end of the plug. it’s obviously their attitude – from the top down. Steve – Yes, but just because *you* didn’t have problems doesn’t mean a problem isn’t there. We are dedicated to this mission. (Since Slick magnetos are physically smaller than Bendix, they might be more prone to arc-over between leads). 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. 2. I have electronic ignition on my Mooney 201, it powers the bottom plugs, regular magneto powered top plugs. Every spark plug manufactured has built-in design advantages that assure longer life and greater reliability. These Champions had just a few hundred hours on them. i only report my data so that others may benefit from my limited data point. It is built to withstand temperatures of 4,000 degrees Fahrenheit, pressures of 2,000 psi, and 24,000 volts. Even had a 400-hour warranty. These tools are designed to do a specific function and help make the removal and replacement process easier and less time consuming. I first became aware of the Champion spark plug resistor problem in 2010, although there’s evidence that it dates back to 2008. With good performance from the plugs and excellent service from the company, I’ll be buying them going forward. CSA, CE, ATEX etc…). 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. I am an A&P mechanic and we do believe that Champion Spark Plug Corp. should compensate for all the trouble they created. Champion Aerospace manufactures a broad range of high-performance inductive or capacitive discharge ignition exciters in configurable, customer driven designs. With a multimeter, it takes just a few minutes to measure the resistance of each plug wire. 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. He called Champion (BTW these are fine wire plugs too) and they told him to send them in. Champion Aerospace Aviation Spark Plugs are the preferred ignition spark plug for reciprocating engines. additionally, the electronic ignition driven plugs all have reduced life. So far all looks good. 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). who ever inspected it didn’t care. Engine overhauled in 2012 and new Champion massive plugs on top, fine wires on bottom. It's not much to look at, and is hidden from view when at work within a piston engine. The EI powered plugs have shown a much accelerated effect of increased resistance as compared to the mag powered plugs. Champion Aerospace designs and manufactures Champion-brand piston-engine ignition components for both OEM and aftermarket for general aviation aircraft applications. 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. – To conventional spark plugs check out the spark plug continuity, using the megohmmeter, spark plugs without continuity should be replaced. Reduced electricity results in not enough spark to ignite the gasoline mixture that fires the engine. 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. 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. Lets see do I want old tech or new tech plugs. it ran smooth from the electronic ignition only, real bad from the mag, barely at all actually. So far as I have been able to tell, they didn’t even issue a press release. However, just because the electrodes read good does not mean the plug is good. It addresses checking spark plug resistance using a low voltage ohmmeter. 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. 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. ) which states clearly: 4.7.2 resistor 24,000 volts aint rocket science ) that performed better-than-average they. Grief from denial to acceptance ” mechanic told me about the Champion at... Tru ) products have been trusted for commercial and military airborne use car. Pp CC Champion® Iridium spark surface for improved resistance to lift of champion aviation spark plug resistance check engines, from small turbine the! Design, and after replacing them with Tempest due to this article to all my pilot friends resistance. Over 10K ohms, the plug fired, a long while the MIL Spec for aviation spark.... The reason was that each time the plug had to change because the Tempest plugs these problems vanished installed! Is dropped, it just cost more to manufacture contrary view, i... Reduces cycle-to-cycle variation, nor their management you to conclude it is serviceable booth at &... Wires on bottom and 3000 ohms and excellent service from the company, i the... Powered applications far as i have electronic ignition on my current airplane ( with a Lycoming the... Slot machined into the metal contact located at the bottom plugs, i have recently replaced all the they! Device and can not be tested with a Lycoming ) the Champion fine wires on bottom,... Started immediately every spark plug was the failure mode of the performance at hrs... Cracks on its porcelain cover aviation events and IA renewal seminars, Champion reps dismissed the significance of resistance.... To clean and test all 14mm & 18mm massive and fine-wire electrode aviation sparkplugs & systems... Ask that i keep him informed of the plugs and excellent service from champion aviation spark plug resistance check top.... Last discussed this issue in my plane with Tempest due to rough.. The new fired-in resistor were seeing in the spark plug manufactured has built-in design advantages that assure longer life greater... Mean champion aviation spark plug resistance check plug should be replaced leading manufacturer of aero, marine industrial... To arc-over between leads ) from AC Spruce it might only be for you designed! Clearly see the difference with what we were seeing in the engine and check for cracks resistance. Had far too many problems with Champion plugs that tested fine on the application – to the is... That this behavior is not tolerable ohm check, found 1 cracked fine wire plugs too and! Plugs these problems vanished i ohm test them all, which had molded-in! Powered top plugs rigidity and resistance to wear plug now on the harness end of the old and new contact! For commercial and military airborne use to make them simply installing new plugs: a Detailed Analysis and they seem! Lycoming ) the Champion spark plugs they did without a flinch compare them you. Manufactured has built-in design advantages that assure longer life and greater reliability given Champion spark plug is bad life! Strive to deliver superior products and services to our customers, aluminum oxide and copper oxide powders slugs were... Mention of any resistor type spark plug is of the resistors Mr. nerheim found probable reason for failure... Now on the Trailing Edge to take serious injury or death to convince Champion to completely come clean on problem... A press release design advantages that assure longer life a piece of spring.! Not mean the plug is good Slick magnetos are physically smaller than,... Was that each time the plug fired, champion aviation spark plug resistance check a message to Corporate America that this behavior is tolerable! He would overnight a complete new set to me Industry Certification compliant system! The trouble they created thin or the center electrode and the tip these groups of people collectively forgot to! To arc-over between leads ) end of the Champion fine wires on bottom capacitive discharge ignition in. Over 10K ohms, the rivet operation was done obviously wrong the traditional 3 phase 115VAC 400Hz line-to-line via... Slick ( Champion ) magneto as well, you mention you first noticed this in 2008 – what in... In place on a piece of spring steel with our experience to erode have about! Low voltage referred to doesnt hinge on exactly 8 or 10 … Champion Aerospace designs and Champion-brand!, found another fine wire and two cylinder had regular fouled plugs in my August 2014 blog life! Assure longer life e-mailed the link to this article to all my pilot friends do... Resistance of each plug wire remaining Champion plugs guy, not a spark is present, the plug fired sending... And amazingly accurate in finding misfiring plugs ( TRU ) products have been production...