Ignition switch failure.

[Graham Pukallus]

Went to start, when selected to switch power on, no go ! Went to next next start position which connected power to panel and thus pump and started engine but stopped providing no continueing power to panel on return to initial stage of switch position. Shut down and investigated fuses/circuit breakers and connections with multimeter and finally traced problem back to ignition switch. Replaced with new item, all good. Somewhat disappointing with only 140 hours and relieved it happened at home with appropriate tools etc. Graham.

 

 

[damkia]

Went to start, when selected to switch power on, no go ! Went to next next start position which connected power to panel and thus pump and started engine but stopped providing no continueing power to panel on return to initial stage of switch position. Shut down and investigated fuses/circuit breakers and connections with multimeter and finally traced problem back to ignition switch. Replaced with new item, all good. Somewhat disappointing with only 140 hours and relieved it happened at home with appropriate tools etc. Graham.

More info? Reported to aircraft manufacturer/switch supplier? Cause of failure? Could this happen to anyone else?

 

This is the sort of thing we should be all over like a rash.

 

 

[Ultralights]

The exact same thing happened to my savannah yesterday, but inflight, all avionics went dead, pretty much the master turned off, jiggled the key again and all came back to life, once on the ground we couldn't turn the key to the off position, once mags were off the engine shut down as usual, but key could not be moved to off position, or start position, couldn't even remove the key!

 

So after borrowing a car, some of a fellow instructors electrical tools, we now have installed a new independent master switch, and nice big red led push to start button. Switch, like the aircraft is 819 hrs old.

 

Though thinking back on it, the electrical system would randomly cut out for a millisecond leaving us with a WTF moment, but this would only happen every 50 hrs or so. I'm certain now with the U/S switch removed, it won't happen again.

 

 

[Kyle Communications]

Switch life is determined by the amount of operations not hours. but most switches are usually good for 50,000 to 100,000 operations. All savannah switches seem to be the same from I have seen so it is looks like ICP gets them from the same supplier from the beginning

 

 

[Ultralights]

I don't think the issue was with the switches, but the key barrel part of it. Testing with multimeter proved the switch worked ok, just the key was jammed, and once removed, could not be used again to operate the switch.

 

 

[Hadyn Bell]

A common problem in a high salt air environment and not just aircraft. A small spray with ACF50 or corrosion block keeps the barrel lubed and working well. This will be going on my maintenance check list.

 

 

[Graham Pukallus]

Thanks for all your help,

 

dankia, I notified Reg Brost.

 

Ultralights, great idea will see how new switch progresses and will incorporate your idea next time round re independant switch, and no ! the key did not jam but rotated and was removable as normal, but no connection.

 

Mark - according to the log book the switch would not have exceeded 250 starts to date.

 

Hayden Bell - the aircraft and equipment has shown no sign of corrosion but the auto elect informed me that failure of ignition switches is not that uncommon.

 

Flew today with no problems.

 

 

[Alasdair]

My ignition switch failed at 100 hours and led to the wiring heating to the extent that I had excessive smoke in the cockpit. Switched off everything and did a dead stick landing. All OK

 

 

[facthunter]

Perfectly good motor but a stupid switch makes it dead or puts smoke in the cockpit. A dose of reality. I like individual toggle switches none of the fancy stuff. Stuck solenoids and switches can cause very serious situations. Take them seriously. Any sign of intermittent operation or bad feel REPLACE. I have experienced life threatening situations because of stuck switches. IF it is a critical operation Like a starter, consider an "energised" indicator light. Simple to fit and tells you what is going on. Nev

 

 

[cscotthendry]

My ignition switch failed at 100 hours and led to the wiring heating to the extent that I had excessive smoke in the ....

LOL, excessive smoke? Is there an amount of smoke in a cockpit that's NOT excessive?

 

 

[facthunter]

Pipes and cigarettes in the old days. You had to calm the nerves. High pressure stuff you know. Nev

 

 

[Graham Pukallus]

Alastair, have had no further problems with auto key switch supplied and recommended by local auto electrician, currently at total of 360 hours and approx 80 + starts since switch replacement at 140 hours in Savvy.

 

Suggest what ultralights did to rectify his switch problem by quote, (install a new independent master switch, and nice big red led push to start button) otherwise replace with a high quality auto switch, take your old one in to a reputable auto electrician for a suitable easy install replacement.

 

Let me know how you get on.

 

GPuk

 

 

[fly_tornado]

you can buy premade ignition switch blocks for boats that have all the switches you could ever need. probably look a lot more professional than a random selection of switches

 

 

[Graham Pukallus]

Yes, that's why I went the simple way of using a quality ignition switch block, but everyone is different as to their preferences of aircraft electrical and avionics installations.