AMS 272, P/P ELECTRICAL SYS

Unit 2

THE NEW
MILITARY -
long range,
stealth, & can
be paid
PEANUTS

Slick 4300/6300 Magnetos -
Unison
http://media.avit.und.edu/f7_Virtua
l%20Engine/f1_Magneto/Virtual%
20Engine.php
The Bendix S4LN-xxx, S4RN-xxx,
S6LN-xxx, and S6RN-xxx are the
most common series of Bendix
magneto. These are slowly being
replaced by the newer SC series
magneto. S200 are the retard
breaker magnetos "shower-of-sparks
http://www.youtube.com/watch?v=sEf8va1S7Sw&feature=related
INTAKE
COMPRESSION
POWER [IGNITION]
EXHAUST
http://www.youtube.com/watch?v=sEf8va1S7Sw&feature=related
Fig 8-105
 MAGNETO IGNITION

1 - hotter spark at high engine speeds

2 - self-contained unit

not dependent on any external

source of electric energy

Pg - 167
 TYPES OF MAGNETOS

low-tension or high-tension

rotating-magnet

single or double

flange-mounted or base-mounted

Pg - 168
Fig 8-106
We offer complete Slick factory upgrade/conversion kits
for virtually all general aviation aircraft. These kits
include two factory new Slick magnetos, a complete Slick
ignition harness, and conversion information. A $150.00
factory rebate is available for these kits. Add $300 core
charge to the kit prices which is refundable upon return of
the two old magnetos to Aircraft Spruce. Specify aircraft
and engine make and model when ordering. As of 2001
most Slick Upgrade Kits now incl. 2 mags., complete
harness and 8 Unison spark plugs. Prices of kits vary
depending on whether or not kits incl. spark plugs.
Kit 4315 3/4“ All Weather Sparkplugs & Ignition Leads

Lycoming: 0-235-C1C, C2C, E2B, F1, G2B, J2B, N2C, 0-320-

A1A, B1A, B2A, C1A, C2A, C2B, C2C, C3A, C3B, C3C, D1D,
D2G, D2H, D3G, E1J, E2D, E2E, E2G, E3D, 0-320-B1B, E1B,
A10-320-A2B, AE10-320-E1B, E2B 0-360-A1NG, A2H, A4K,
B1A, C1E,C1F,C2B,C2E,D1A 10-360-B1F6 A10-360-A2B
AE10-360-A2B, B1F6, B2F6, H1A

$1,182.00
 THREE CIRCUITS:
1 - magnetic
permanent magnet;
coil core;
pole shoes & extensions

Pg – 168;169
 THREE CIRCUITS:
2 - primary
primary winding;
breaker points;
capacitor/condenser

Pg – 8-74
 THREE CIRCUITS [continued]:
3 - secondary
secondary winding;
distributor & rotor;
high-tension ignition lead;
spark plugs
 MAGNETIC CIRCUIT
permanent magnet - alnico
pole shoes & primary core
soft-iron laminations
[reduces eddy currents]
[allows for ease of flux reversal]
[reduces hysteresis losses]
cast into the aluminum housing
Fig 8-111
 FULL REGISTER
Fig 8 – 7;-8

NEUTRAL
Fig 8-112
Points & PERMANENT
Dist Gear MAGNET
DE [drive
end]

SEALED BALL
BEARINGS
 PRIMARY-CIRCUIT
Coil assembly
primary winding
few turns of heavy wire
#18 - 180 turns
secondary winding
many turns of fine wire
20,000 to 30,000 turns

Pg – 8-73
Fig 8-114
primary & secondary circuits
insulated between each & core
three contacts:
ground lead;
high tension terminal;
primary/points circuit lead
 PRIMARY / PRIMARY /
SECONDARY SECONDARY
GROUND LEAD
COILS

PRIMARY - SECONDARY
POINTS/CAPACITOR HIGH-TENSION
LEAD LEAD
Breaker Assembly
- contact points
platinum-iridium
heat & wear resistant
- cam follower
lubricating oil
Breaker Assembly
- contact points
platinum-iridium
heat & wear resistant

points in series with the primary coil

points close - max flux linkage
points open - after neutral
greatest flux change

Pg – 173; Lt col, 2nd line, 1st word

CAPACITOR
connected across the points;
"opposes any changes in voltage"
absorbs the sudden rise of voltage
self-induced from the primary
when points "begin" to open
part of the series LRC
Fig 8-115
Electrical circuit of the primary coil:

coil -- case ground --

points -- capacitor across the points

 N S

CAPACITOR

CONTACT
POINTS
points closed
- coil current builds up
- magnetic field increases

points open
- current build up stops
- primary coil is in series with
the capacitor
- L R C circuit
 Charging -
current does not rise instantly - 63.2% of
its current flows within
1 time constant
 Discharging -
collapsing field causes a “surge” in the
current flow of 63.2% within 1 time
constant
 Charging - current
immediately flows
electrons pushed on
to the negative plate
and pulled from the
positive plate voltage
rises 63.2% in one
time constant
 Discharging - loses
63.2% of its charge in
one time constant -
[milliseconds]
Time Constant is
dependent upon
Resistance &
Capacitance within the
circuit
COLLAPSIN
G
MAGNETIC
FIELD

CHARGING
OF THE
CAPACITO
R
N S
N S
N S
N S
N S
N S
N S
N S
N S
N S
 Electrical circuit
for the
primary coil of the magneto:

coil => case ground =>

capacitor
[when the points open] =>

coil
CURRENT INDUCED IN A COIL

PROPORTIONAL TO THE
RATE OF CHANGE
OF FLUX LINKAGE

1. adding more turns to the coil

2. stronger magnet having more
lines of flux
3. the speed of flux change

Pg – 170
LENZ' LAW

an induced voltage always operates in such a

direction as to oppose the source of its
creation

change in flux linkage occurs:

direction of current in the coil is such that its
magnetic field opposes the change in flux
linkage
Fig
8-3 FULL REGISTER
Maximum flux from the magnet
Contacts are open
No current in the primary Pg – 173
Fig MAGNET JUST PAST FULL REGISTER
8-3 Contact points close
Current & flux increase in the primary
Pg – 173
Fig Magnet at NEUTRAL
8-3 Contacts closed
High current & flux in the primary
Pg – 173
 E-GAP
Fig Magnet 5-17 deg past neutral
8-3 Contacts just opening
Primary current & flux collapsing
Pg – 173
 PRIMARY CAPACITOR
TroubleShooting
- points open
primary current would
arc across points
burning the contacts;
inc resistance;
dec current through primary;
decrease flux links to secondary

Pg – 173
 PRIMARY CAPACITOR [cont]
Point arcing results in:
reduced rate of field collapse
weak spark from the secondary
weak spark at the plugs

When points "begin" to open

part of the series LRC
 CAPACITOR T/S [continued]
capacitance -
too low
arcing of points;
weaken the spark
too high
mismatch coil/capacitor
reduce the voltage developed
weaken the spark
STATIC FLUX CURVE

RESULTANT FLUX CURVE

primary coil - opposes changes in
flux strength

E-GAP
# of degrees of rotation between the neutral
position [magnet] and the position where the
contact points "just" open :: 5 - 17 degrees

Fig 8-14

Pg – 174
STATIC - FLUX CURVE

without windings attached

direction of the flux & concentration of flux
neutral - twice
greatest change passing through the neutral
position
 4 POLE MAGNET ROTOR
FULL
REGISTER

Fig 8-14
 4 POLE MAGNET ROTOR
NEUTRAL
 4 POLE MAGNET ROTOR

STATIC
FLUX
CURVE --
AC SINE
WAVE
 4 POLE MAGNET ROTOR

POINTS
CLOSED

PRIMARY
COIL
CURRENT

POINTS
OPEN
 4 POLE MAGNET ROTOR

RESULTANT
FLUX
Fig 8-113
 4 POLE MAGNET ROTOR

1 3
MAGNETO
FIRING
ORDER -
Rev 1 & 2 2 4
 4 POLE MAGNET ROTOR

1 3
MAGNETO
FIRING
ORDER -
Rev 3 & 4 2 4
Fig
8-42 Pg – 177
 DOUBLE-TYPE MAGNETO
[common]

Single Housing
One rotating magnet
Two sets of:
breaker points
coil assemblies
distributor assemblies
 DUAL MAGNETO
single driveshaft &
rotating magnet
two INDEPENDENT
ignition circuits

Fig 8 - 43

Uses retard contacts for the LEFT magneto to retard the

spark to just before TDC
The RIGHT magneto p-lead is grounded during starting

Pg - 189
LOW TENSION IGNITION

problems encountered in the production

& distribution of HIGH-VOLTAGE
electricity used to fire the spark plugs

High-voltage causes
corrosion of metals
deterioration of insulating materials
tendency to escape from the routes
provided
Pg – 192; 193
Fig 8-109
 HIGH-VOLTAGE Corona

condition of stress across any insulator

[dielectric] exposed to high voltage

difference of potential between

conductor of an insulated lead & any
metallic mass near the lead

repeated applications results in

insulation failure
 Principle Problems for
HIGH-VOLTAGE Ignition Systems

FLASHOVER - jumping of the high-

voltage inside a distributor

altitude increases - dielectric or

insulating strength decreases
 Low Tension Ignition: High voltage
confined to small area near the plug
Capacitance – the ability of a shielded
conductor to store electrons

** high-tension shielded ignition

leads store a portion of the electric
charge BEFORE the sparkplug can
fire
Pg – 193
 *** AFTER ignition the gases between
the electrodes ionizes & the gap’s resistance
is greatly reduced

mag

**** the electrical ENERGY stored by the capacitance of the leads is

discharged as a relatively low voltage & high current
## the result is the electrodes are eroded [worn] by the high
current flow & the spark plug’s operating life is greatly reduced
 Advantages

failure of the primary or secondary

of ONE transformer:

will affect only ONE spark plug

reduction of "flashover"
DISTRIBUTOR
ASSEMBLY Distributor Gear
Distributor Block
Brass Electrode Carbon Brush
Posts
Bronze Oilite
Bushing
Rotor
Distributor Gear &
Electrode Finger Gear
Distributor
Carbon Brush Block Electrode Finger
Rotor Gear

Pg – 175
Rotor Gear drives the Distributor Gear

Ratio between gears is ALWAYS =>

Distributor Gear is driven at ½ engine crankshaft speed

720o of crankshaft rotation means the Distributor Gear

must rotate 360o

Distributor Assembly distributes the high voltage current

from the coil secondary terminal to the various ignition

wire connection of the distributor block

Pg – 176
Construction & Other Characteristics of Magnetos
Case – aluminum allow
light weight
Vents – ventilation & cooling
Distributor assembly
Dielectric material – Formica, Bakelite
Must be able to withstand
high engine temps; moisture resistant;
high “electric stresses”

Pg – 176
Magneto Speed
The number of poles & lobes on the cam are the same
each revolution of the magnet will produce the
same number of sparks as it has poles

No. of Cylinders magneto shaft speed

--------------------- = ------------------------------
2 x No. of Poles engine crankshaft speed

Magneto shaft speed = the speed of the magnet

BUT the speed of the distributor rotor MUST always
be ½ of the engine crankshaft speed

Pg – 177
 Polarity or Direction of Sparks

AC AC –[low]
Step-Up
ENGINE GEN Transformer

AC –[high]

DISTRIBUTOR

Pulse DC

SPARKPLUG
to Engine
BEARING BAR – 2nd Bronze
Oilite Bushing
 Electrode Posts
normal transfer of
electrical-metal with
the electrode finger
[wiper] is NOT cause
for rejection

SLICK MAINT MANUAL

INSPECT for: cracks; brass electrode posts for wear;

bushing for gumming oil & contaminates
Lubricate - Exxon Teresstic 100 oil/ Slick P/N M-
3306; USE NO OTHER
 INSPECT:

gear teeth for wear

electrode for looseness

[use "light“ finger

pressure]
SLICK MAINT MANUAL

HIGH-VOLTAGE COMPONENTS MUST NOT

RETAIN CLEANING FILMS or IT COULD CAUSE

Pg – 192; 204 "flashover" & carbon tracking Pg – 195

Distributor Block Assembly
clean all surfaces - free of dirt, oil, carbon dust,
contaminants
bearing bar -
non-filming non-conductive cleaner
gear -
soapy water & rinse

CAUTION - DO NOT PUT CLEANER IN EITHER

BRONZE OILITE BUSHING
 Principle Problems for
HIGH-VOLTAGE Ignition Systems
Pg – 175

FLASHOVER - jumping of the high-

voltage inside a distributor

altitude increases - dielectric or

insulating strength decreases

FLASHOVER – any time the high-voltage pulse

leaves the secondary but goes to ground before
it reaches the spark plug electrodes.
Magneto Maintenance & Inspection

100hrs or Annual

Adjust timing to engine

Inspect
wiring connections & conditions
vent holes
P-lead attachment

Pg 194-196
 500 hr Inspection:
All the above – [100hr]
Cleaning
Ball bearing assembly
Coil
Contact Points
Condenser
Carbon brush - secondary
Lubrication
OVERHAUL when:

engine is o/h

operating conditions are unusual

[sudden stopage]

after 4 years regardless

Overhaul

disassembly

cleaning

inspection

repair/replacement

reassembly

testing
Items to be replaced at overhaul:

capacitor ball bearings

coil impulse coupling

oil seat

contact-point assembly

rotor gear Self-Locking Screws

distributor block & gear assembly

felt strips & washers

gaskets Lockwashers
Tungsten oxide on the Breaker Points
dielectric
stops all current flow through the closed contacts

Remove oxide with stiff clean paper

Lubrication of Points

A DROP OR TWO OF ENGINE OIL ON THE

OILER FELT [old] – CAM FOLLOWER [new]

CAUTION – no oil must get on the points

excess oil may cause points to burn black

Pg – 195; 172; Rt Col; last sentence
PRIMARY CAPACITOR [CONDENSER]
TESTER

MFD – microfarad

Capacitance Tester tests the ELECTRICAL

INTEGRITY of the dielectric by placing it under

“stress” using a HIGH VOLTAGE.

DO NOT HANDLE THE TESTER LEADS

EXCEPT WHEN THE SELECTOR SWITCH IS

IN THE OFF POSITION. THE HIGH

VOLTAGE CAN CAUSE A SEVERE SHOCK.

Capacitor / condenser
visual inspection - 10x
glass bead end seals
condenser wire - chafing, frayed
insulation or exposed wires
capacitance tester -
CAUTION HIGH VOLTAGE
400v DC; 35microfarad +- 10%
leakage - failure of the dielectric
resistance - 10Mohms
P-lead stud & Capacitor
Seal

twisting
pulled condition
corrosion
bad threads

DO NOT MAKE
ANY SOLDERING
OR CRIMPING OF SLICK MAGNETO MAINTENANCE MANUAL

CONDENSER WIRES
 - CARBON TRACKING -
Distributor rotor; distributor block;

Dark Lines – carbon track

due to flashover or leakage through the dielectric

material

dust build up absorbs moisture to make it conductive

high-tension current uses the conductive dust as a

bridge to ground

the burned path becomes more conductive as current

flows continues & eventually becomes a short circuit

Jeppesen Pg 8-69 Glencoe Pg 195

Air Vents – magneto

prevents build up of a “corrosive atmosphere” and cools

the magneto during operation

Corrosive Atmosphere – due to arcing in the

DISTRIBUTOR & subsequent CORONA GENERATION

Arcing causes OZONE which interacts with carbon based

oils & grease to form NITRIC ACID

Results in decrease life expectancy for internal

components & poor magneto performance

Pg – 196
 Contact Points
Inspection

pitting/discoloration
blue – excessive arcing

proper: white, frosty surface

around the edges

Pg – 195; 196
BOTH SETS OF POINTS
Build up on one contact & a “hole” on the other from
material being removed
Wear of breaker contacts:
timing will “drift” early
advance timing
Wear of Cam follower:
timing will “drift” late
retard timing
Poor spring tension:
floating or drifting
prevents normal induction buildup
 ROTOR
SHAFT
Inspection SEAL

Magnet
soft-iron keeper bar
prevent loss of
magnetism
shaft check for
dimples

Slick Maintenance Manual

ROTOR
SHAFT
OIL
SEAL

E
N
G
I
N

ENGINE SIDE
E
Inspection -
radial cracks
corrosion
wires &
contacts

Resistance checks: Slick Maintenance Manual

grounding - megohms range

primary - 0.50 - 1.2 ohms
secondary - 13,000 - 20,500 ohms
 Slick Maintenance Manual

Proper High Tension Lead adjustment for

SPRING LOADING of the carbon brush on the
Distributor Gear
94110195
4373
20 L
 L or R slots on the
Magnet

Slick Maintenance Manual

INTERNAL TIMING OF THE MAGNETO –

setting E-Gap
Pg 191-192
 ALIGNMENT OF
L OR R

Distributor Gear with

alignment pin

Rotor Gear with mark

on the distributor block

Sets up Electrode Finger

to #1 ignition lead

Slick Maintenance Manual

 POINTS ADJ

CAUTION

Slick Maintenance Manual

Condenser lead to points assembly must NOT touch magneto frame - GND
Severe example of Carbon Arc Tracking damage to magneto
When the pilot did the magneto check on run-up, what did this magneto do?
Answer: Magneto exhibited normal rpm drop during the engine magneto check prior to
takeoff.
However, magneto  misfired with a resultant loss of engine power at full power. 
As power increases the voltage required to jump the spark plug gap increases. In this
example the spark plug would fire at lower engine power settings but at higher power
settings the voltage arc'd within the magneto causing the destruction you see.
 8554.If it is found that a
MAGNETO FILTER
by LONESTAR
shielded ignition system
AVIATION
P/N 07-00713 ­$42.850 does NOT adequately
reduce ignition noise, it
Eliminate magneto noise with this
FAA/PMA approved ignition filter.
Easily connects to the primary lead may be necessary to install
& ground at the magneto. Dims:
1"x1.8". 1 year limited warranty. Not
for use with Slick Magnetos.
SPECIFICATIONS: 8555.A second layer of shielding
 Heavy duty
 1000 VDC working voltage,
mounting clamp
5000VDC break down voltage
 Capacitance: .05 uf-self
 Advanced feed 8556.A
2. filter
A filter betweenthe
between themagneto
through design
healing technology
 Temp. range: -35°C
 Braided cable is shielded,
silver plate over copper,
to +80°C magneto
and and magneto
magneto switch.
 Max. current: 20
supplied in 8 inch lengths.
amps
switch.

8557.Bonding wires from the

shielding to ground.
25kv
 AB-349276 Magneto capacitor

MF-3 A/C MAGNETO FILTER

MAGNETO TEST STAND

coming-in speed
good indication of the magneto's performance

too high RPM -

magnet is weak;
internal timing is not correct;
capacitor is defective
INSTALLATION & TIMING:
Mag to Engine

Remove all ignition leads

Pull top spark plug #1 cylinder

Find the compression stroke on the #1

cylinder positive pressure
Sets distributor rotor to #1
ignition lead

Sets magnet to E-gap

Sets points up to just begin

to OPEN

Slick Maintenance Manual

 ENGINE TIMING
REFERENCE
MARKS

TC - alignment
#1 piston is at
TDC

24/32 - are
Before TDC
Starter
ring gear

Starter
Housing
Exterior engine
plugs:

reduction gear
housing

crankshaft
flange

inside
TIMING LIGHTS

used to determine the exact instant at which the

magneto points open

Center lead - Ground

Outer leads for Left and Right P-leads

 PTS
CLOSED
MAGNETO CHECK
Run engine to specified RPM
From the BOTH position
Move to L
Manufacturer will designate min &
max change in RPM -- "mag drop"
Back to BOTH then repeat for R

Example: @ 1,650 RPM for BOTH

L - 1,500 RPM
R - 1,500 RPM
IGNITION SWITCH CHECK
EXCESSIVE MAG DROP

Magneto to engine timing

incorrect
Internal mag timing incorrect
Weak breaker point spring
Weak condenser
Weak magnet [low speed miss]
Defective coil [may break down
under load]
 IGNITION SWITCH CHECK

At IDLE, low RPM, turn ignition

switch to OFF

Engine should stop

Fig 3-15
 PRESSURIZED
MAGNETOS
reduces "flashover"-
jumping of high voltage
outside of its intended
path
altitude increases -- air is
Slick Maintenance Manual less dense & lower
resistance to arcing
Approx: 18,000 ft
Pg - 192