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Rotax 912 Eating Ignition Modules

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Guy Buchanan

Joined: 16 Jul 2006
Posts: 1204
Location: Ramona, CA

Posted: Fri Sep 18, 2020 6:18 pm Post subject: Rotax 912 Eating Ignition Modules

A friend has a 912uls in a Kitfox that seems to be eating ignition modules. He's gone through three. Yes they were all old. Yes new ones work, but we're worried that maybe his plane is producing electrical noise detrimental to the modules. We did some testing using an oscilloscope looking for voltage spikes in the ground wire during start up and shutoff. For various reasons we weren't able to capture any voltage spikes during start and stop, but did capture some very messy noise signatures while running. Picture 1 shows one module's ground wire while "open". Note +/- 30V peaks and a regular 30hz sawtooth. Picture 2 shows the same ground "grounded". We did some further testing of the input and output to the voltage regulator and those voltages appeared relatively clean. Question: is it possible the ignition module is being damaged by the voltage noise, regardless of source? Should we apply some caps to the ground wires to kill the noise?



Thanks,

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_________________
Guy Buchanan
Deceased K-IV 1200
A glider pilot too.

williamtsullivan(at)att.n
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Posted: Fri Sep 18, 2020 6:27 pm Post subject: Rotax 912 Eating Ignition Modules

My gut instinct says clean and tighten all grounds.  If a component grounds through it's base, take off the unit and clean and ground the contact area.  Good luck!



                                                                                       Bill Sullivan

            

                                                                                        On Friday, September 18, 2020, 10:21:35 PM EDT, Guy Buchanan <gebuchanan(at)cox.net> wrote:                

                



                



                --> RotaxEngines-List message posted by: "Guy Buchanan" <gebuchanan(at)cox.net (gebuchanan(at)cox.net)>



A friend has a 912uls in a Kitfox that seems to be eating ignition modules. He's gone through three. Yes they were all old. Yes new ones work, but we're worried that maybe his plane is producing electrical noise detrimental to the modules. We did some testing using an oscilloscope looking for voltage spikes in the ground wire during start up and shutoff. For various reasons we weren't able to capture any voltage spikes during start and stop, but did capture some very messy noise signatures while running. Picture 1 shows one module's ground wire while "open". Note +/- 30V peaks and a regular 30hz sawtooth. Picture 2 shows the same ground "grounded". We did some further testing of the input and output to the voltage regulator and those voltages appeared relatively clean. Question: is it possible the ignition module is being damaged by the voltage noise, regardless of source? Should we apply some caps to the ground wires to kill the noise?



Thanks,



--------



Guy Buchanan



K-IV 1200 / 912Uls / Warp / 500 hours and flying again.



Now a glider pilot too.



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Griffo

Joined: 18 Mar 2021
Posts: 70
Location: The Oaks, NSW, Australia

Posted: Sat May 08, 2021 9:16 pm Post subject: Re: Rotax 912 Eating Ignition Modules

I concur with William Sullivan - would go further to suggest making sure all ground/earth wires have continuity.

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