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Dual type has one housing, one rotating magnet and single cam the other remaining
parts are two (concession made FAA regulations part 33).
Rotating Armature. When the windings rotates within the permanent magnet’s magnetic field
an AC EMF is induced
Rotating Field: The permanent magnets (field) rotates between fixed transformer windings.
Polar inductor: Soft-iron inductor bars rotate between fixed permanent magnet and
transformer windings.
HT magneto:
Construction: Magnetic circuit, primary coil assembly, secondary coil assembly.
Magnetic Circuit:
It consists of permanent multi pole rotating magnet soft iron core and pole shoe.
Permanent magnet mode of material having high permeability like alnico or alcomax. It
is in cylindrical shape
Core and pole shoe made of soft iron core where both primary and secondary coils are
wound.
Permanent magnet is geared to a/c engine rotates in the gap between the pole shoe.
When magnet rotates in pole shoe the magnetic flux of periodical reversal in nature is
produced, passes through core thus EMF is induced.
Distributor:
It receives high tension current from secondary coil and distribute it in the correct
sequence to appropriate cylinders.
- It consists of two parts. Revolving part is called distributor rotor, rotor may be in the shape
of disc, drum or finger made of insulating material with an embedded conductor.
- Static part of distributor is called distributor of insulating material contained terminals and
terminal receptacles s in to which wiring that connects the distributor and spark plug is
attached.
- The distributor numbers represents magneto sparking order.
- When the high voltage in the distributor flashes across the insulator to ground (in stead of
arcing across the air gaps of distributor ) or this high voltage misdirected to spark plug Other
than one that should be fired called flash over.
- Distributor is a part of magneto, distributor rotor is driven by gear from main
magneto shaft. Some cases distributor rotors are driven by engine gears train separately.
Ignition Harness:
(Ignition leads) made of stranded copper or stainless steel wire enclosed in a rubber or
silicone insulation. This insulation is covered with braided metal shield which is protected by
tough plastic covering. Slick electro inc. produced ignition harness stranded wires are replaced
by continuous spiral of wire impregnated with high voltage silicone rubber insulation.
Two sizes of ignition harness is used 5mm and 7mm. 5mm is used more widely.
Harness testing:
Harness tester is used to test the leakage current the input is 110v 60Hz output is 0-
15000V DC. Two ammeters are used for leakage current 0-100 µamp and 0-1000 µamp.
Check is carried out for 10 seconds excessive leakage reading more than 50 µamps are
break down is indicated by flashing break down indicator.
Ignition leak to be removed put in contact with cylinder for good ground.
Primary breaker points closes at approximately at full register position. Completes the
primary circuit induces primary current. The field produced by primary current is such that it
opposes the cause produce it (flux change reversal in core due to rotation of permanent
magnet (lenz law)).
The primary current holds the resultant flux in core at a high value in one direction until
rotating magnet in neutral position 7°-11° beyond neutral.
As this point the breaker point opens high rate flux change occurs opening of contacts
stops the primary current makes coil core to change the direction of field (reversal of field). This
maximum flux change induces high voltage in secondary, which will be carried to distributor
and to spark plug. So the spark of high voltage intensity jumps through spark plug thus igniting
fuel air in cylinder head.
The breaker points will open beyond neutral position, where greatest change in flux
take place. the angle where it occurs (spark occurs) called "E-gap” angle.
E gap means "Efficiency gap". Where actual spark takes place.
Ignition Switches:
Ignition systems are controlled by an ON-OFF switch in cockpit. When the ignition switch
in OFF position, it completes the circuit by closing its contacts between magneto primary
winding and earth (ground) thus short circuiting the contact breaker. In this condition on
sudden collapse of primary flux even the magneto rotates (Actually in OFF position switch
contacts are made).
When ignition switch in ON position (switch contacts are open actually) breaks the
circuit between primary winding and ground thus normal operation of magneto takes place.
In dual ignition systems, each magneto is controlled by a separate toggle switches or
four position rotary switch controlling both magnetos. The four positions are OFF, LEFT, RIGHT,
BOTH.
The left and right position allow one system to be turned off at a time for carrying out ‘
magneto drop check' (when s/w is OFF RPM drop of engine should not be more than prescribed
valve ) during ground run.
Operation:
When magnet rotates flux is induced in core. This flux induces alternating low voltage by
the rotation of cam operated contact breaker.
Low voltage impulses from magneto induction coil are supplied to distributor via a set of
brushes and segment tracks. The distributor low tension output is supplied to transformer
corresponding in number to the number of spark plugs. The secondary of transformer converts
low tension (LT) to high tension (HT). Thus high voltage impulses provided to spark plug. LT
magnetos are switched ON and OFF similar to HT magneto.
Booster Coil:
Consists of primary secondary coils wound on soft iron core, set of contactor points and
capacitor.
Stationary contact is fitted with +ve terminal of battery. Voltage is applied when
magneto s/w is placed in "Start" position, or automatically applied when the starter is engaged.
This voltage flows through the primary winding via closed contact points to ground. As
the current flows through primary coil sets up flux, magnetizes coil core, coil core attracts
movable contact point against the spring. Thus contact is broken, primary current stops; flux
collapses spring brings back movable contact closed again. Primary current flows flux sets up.
The results of expanding and collapsing magnetic field flux links with secondary which induces
high voltage which is connected to main magneto distributor.
Distributor has
got two electrodes. The
main electrode (main
linger) carries magneto
output. The auxiliary
electrode (finger) carries
booster coil voltage. The
auxiliary electrode is
located such a way that
it always trails the main
electrode thus provides
retarded spark during
starting.
The capacitor prevents arcing between contacts points during collapsing of magnetic
field.
Presently it is not used.
When this rapid succession of battery voltage applied to primary coil of magneto
(primary contact are open). Magnetic field building and collapsing takes place, so EMF is
induced in secondary. Secondary produces “shower of sparks" across selected spark plug.
Impulse Coupling:
Engines having a small number of cylinders (Four or Six), horizontally opposed air craft
engine uses this methods.
Impulse coupling is a
small spring loaded coupling
between the magneto shaft
and the engine drive gear.
When the engine is not
running driven by starter at
slow speed (Low RPM) fly
weights in the impulse
coupling contact a stop pin
in the magneto housing. The
pin holds the magnet shaft
still as the engine continues
to rotate.
By that time engine has rotated far enough for the piston to reach the TDC (Top dead
center). A projection on the body of impulse coupling wedges the fly weight off of the stop pin
and the spring spins the magneto shaft fast enough to produce hot and late spark.
This action takes place for every spark until engine starts running when RPM reaches
high the impulse coupling acts as straight coupling for magneto.
BAT +ve - closed contact R4 - starter motor gets supply starts rotating. When engine
reaches normal advance firing main breaker opens still the interrupted supply flow to ground
through retard breaker points. Which, do not open till the retard firing position of the engine is
reached. Which is 20° more travel retard points open the magneto primary coil not shorted and
current produces in T1.
Each time V1 open current through V1 interrupted collapsing the field about T1 cuts
through secondary and induces a high voltage surge used to fire the spark plug.
V1 Opens and closes very rapidly a shower of sparks furnished to cylinder when both
main and retard points are open.
When engine beings to accelerate the spring loaded starter s/w released. L1L3 de
energized, vibrator and retard breaker points in operative. Opens contact R3 making right
magneto connected. Both magnetos fires normal running piston position.
Spark plug:
The function of spark plug in ignition system is to conduct a short impulse of high
voltage current through the wall of combustion chamber. Inside the cylinder.
It provides an air gap across which this impulse can produce an electric spark to ignite
the fuel / air mixture.
The three main components of spark plug are electrode, Insulator and out shell.
Electrode is made up of Nickel-clad copper electrode.
Outer shell threaded to fit in cylinder made of finely mechanized steel. Outer
shell plated to prevent corrosion form engine gasses.
Copper gasket prevents cylinder gas pressure from escaping around the plug.
Insulator provides electrical insulation which is made of ceramic. Protective core
around the electrode. It also transfers heat from ceramic tip or nose to the
cylinder.
Reach:
The length of the threads on the outer shell classifies the spark plug. Short reach 1/2
inch thread. Long reach 13/16 inch.
Heat Range:
The heat range of spark plug refers to the ability of the insulator and center electrode to
conduct heat away from its tip.
Hot spark plug has long insulator path/nose: Long heat path and tip operates at high
temperatures used in engines whose temperatures are relatively low.
Clod spark plug has short path for heat used hot running high compression engines. It
transfers heat rapidly to cylinder head.
Capacitance effect of shield of ignition harness prolong the duration of spark. A 1500 Ω
resistor is installed in spark plug insulator between spark plug lead and center electrode
reduces the duration of spark without affecting the initial spark production.
Magneto Timing:
Ignition timing must be adjusted such a way that the following four conditions occur at
same instant.
1. The position in No. 1 cylinder must be in a position, a prescribed degrees before the top
dead center (TDC) on compression stroke.
2. The rotating magnet of magneto must be in "E" gap position.
3. The breaker points must be just opening on the No. 1 cab lobe.
4. The distributor finger must be aligned with the electrode serving No. 1 cylinder.
1 Joule = 10 watts ×.1 sec ¿ 100 w atts × .01 sec¿ 1000 watts ×.001 sec
Induction Coil:
It consists of primary winding and secondary winding, both wound on soft iron core.
Primary is connected to ground through trembler mechanism. Primary induces the pulsating
flux with trembler mechanism. So that in secondary alternating voltage will be induced.
Trembler Mechanism:
It consists of breaker point, capacitor connected across breaker points. Breaking and
making of breaker points are achieved by a cam or with permanent magnet, which can be
pulled when current flows through primary so breaker is open or transistor type.
Trembler mechanism functions in conjunction with primary winding of induction coil.
Breaker points operate for 200 times per second. So that battery DC voltage converted to
pulsating DC in primary. So the EMF is induced in secondary. The purpose of capacitor is to
reduce arcing across contacts.
Rectifier:
Selenium rectifiers to allow the current to flow in one direction. Rectifier does not allow
current to flow from - ve of secondary up to capacitor top side of secondary. It allows current
vice versa.
Reservoir Capacitor:
The successive pulses of voltage produced in secondary charges reservoir capacitor.
Through rectifier. When the voltage of reservoir capacitor reaches the predetermined value
2000volts is sufficient to breakdown the discharge gap by ionization so that capacitor
discharges through igniter plug.
Choke:
Discharge is conducted through choke. It extends the duration of discharge through a
high tension ignition lead to igniter plug where energy is released.
The discharge is in the order of 12 joules with in 50 micro seconds of very high energy
capable of vaporizing globules of fuel and overcoming carbonaceous deposits.
Discharge Resistors:
There are fitted to ensure that any residual stored energy in reservoir capacitor is
dissipated within ONE minute after unit being switched off. It also protect the ignition unit from
overheating when ignition unit turn ON with igniter plug isolated or no igniter plug is
connected.
Safety Resistors:
These are fitted to enable the unit to operate safely even when high tension lead is
disconnected or isolated by dissipating the spark through it.
Operation:
Primary of induction coil operated by trembler mechanism induces high voltage in
secondary. This high voltage charges the reservoir capacitor through high voltage rectifier.
When the voltage in reservoir capacitor is equal to the breakdown value of sealed
discharge gap the energy is discharged across the face of the igniter plug.
AC operated HEIU:
AC Supply 115V 400Hz single phase is applied to the step up transformer Tl through
noise filter.
The trigger spark which occurs by the action of trigger transformer T1 and capacitor
creates the low resistance path and allows both trigger capacitor and storage capacitor fully
discharges at the igniter plug.
Bleeder resistors R3 & R4 provides the means of dissipating energy of the circuit in the
event that the output of igniter unit is open circuited. They also serve to bleed off any residual
charge on capacitor €4 between successive flash over and so provides constant level of
triggering voltage from the secondary of winding of transformer T1.
Filter Circuit:
Consists of reactor (power choke) and feed through capacitors. It prevents high speed
frequency feed back in to A/C electrical systems. Power choke limits spark rate variations over
input voltage frequency range. The voltage is applied to primary winding of power transformer
from filter.
Doubler Circuit:
It consists of two solid state rectifiers, two capacitors (double capacitors) and resistors.
High voltage induced in secondary fed to doubler circuit. Each change in polarity of
pulse of DC voltage sent to storage capacitor, with successive pulses the storage capacitor
assumes a greater and greater charge at increasing voltage.
The purpose of resistors in doubler circuit is to limit the current passing through the
rectifiers during those intervals of discharge of the storage capacitor when the voltage has
reversed.
When the charge of storage capacitor reaches the predetermined value, Set by spark
gap in discharger tube. Storage capacitor's charge breaks down the gap. Current flows through
primary winding of HT transformer and trigger capacitor. This flow of current induces high
voltage in secondary enough to ionize the air gap in igniter plug. Thus plug becomes conductive,
remaining charge in storage capacitor delivered to igniter plug as high current low voltage spark
across the air gap. This high energy spark produce ignition under adverse conditions.
Bleeder resistor is provided to dissipate the energy in the circuit if the ignition plug is
absent or fails to fire; it provides path to ground for any left out charge on the trigger capacitor
between cycles.
When stored capacitor discharges all its accumulated energy next cycle of energy
commences.
Ignition cable assembly consists of electrical lead contained in flexible metal braiding,
coupling nuts at each end to facilitate the connections to ignition exciter and spark igniter plug.
Igniter Plug:
Insulator made of aluminum oxide ceramic with a diamond like hardness. That
provides mechanical strength, high voltage insulation and rapid heat
conductivity.
Electrodes are of inconel chromel D, tungsten or any of Nickel alloys.
Shell body made of extremely high quality of stainless steel or inconel to resist
bums in combustion chambers.
Internal seals are made of ceramic materials.
System provides current to a hot coil element in each glow plug, which makes the plug
glow red hot. The glow plug reaches an extremely high temperature very rapidly and ignites the
fuel spray in combustion section during starting.