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IS 14380 (1996): Automotive vehicles - Ignition coils for magneto ignition systems [TED 11: Automotive Electrical Equipment]

“ान एक न भारत का नमण” Satyanarayan Gangaram Pitroda “Invent a New India Using Knowledge”

“ान एक ऐसा खजाना जो कभी चराया नह जा सकताह ै”ै Bhartṛhari—Nītiśatakam “Knowledge is such a treasure which cannot be stolen”

IS14380:1996

Indian Standard AUTOMOTIVE VEHICLES - IGNITION COILS FOR MAGNETO IGNITION SYSTEMS - SPECIFICATION

ICS 43.060.50

0 BIS 1996

BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002

September 1996 Price Group 5 . Automotive Electrical Equipment Sectional Committee, TED 11

FOREWORD This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Automotive Electrical Equipment Sectional Committee had been approved by the Transport Engineering Division Council. In petrol/gasoline engines, combustion takes place due to an electric spark and this spark is provided by energy transfer ignition coils which are pulse transformers that transforms voltage from a low tension source such as battery or generator into a high tension voltage with suflicient energy to produce an electrical spark across a fixed gap of spark plug electrodes.

Ignition coil for battery coil ignition system has been covered separately by IS 2325 : 1981 ‘Specification for ignition coils for a battery-coil ignition systems for automobiles’. Since this standard did not cover energy transfer ignition coils for magneto ignitionsystem used primarily with two and three wheelers, the need for preparing the present standard was felt by the sectional committee. Ignition coil for magneto ignition system is an important fitment for the automotive vehicle and to facilitate interchangeability, overall and mounting dimensions besides the performance requirement and methods of test have been laid down in the standard. The committee responsible for preparation of this standard is given in Annex B. For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )‘, The number of significant places retained in the rounded off value should be the Same as that of the specified value in this standard.

PS 14380 : 1996 Indian ~~a~~a~~ AUTOMOTIVE VEHICLES MAGNETO IGNITION SYSTEMS -

1 SCOPE 3.5 Routine Tests

1.1 This standard covers the basic mechanical and Tests carried out on each ignition coil to check whether electrical requirements and methods of test for energy the ignition coil is satisfactory with regard to certain transfer ignition coils along with their mounting essential requirements which are likely to vary during dimensions for use with automotives with magneto as production. source of power supply for magneto ignition syste%n 3.6 Primary Terminals used by two/three wheelers and stationary vehicles. Terminals providing means of connection of the 1.2 It does not cover ignition coils for battery assisted ignition coil to generator and contact breaker. and also electronic ignition systems. 3.7 Three Point Spark Gap 2 REFERENCES The adjustable air gap between three electrodes as The following Indian Standards are necessary adjuncts shown in Fig. 1. to this standard: 4 CONSTRUCTION Title 4.1 Materials Cables for motor vehicles ( .second revision ) All materials used in the construction of ignition coils shall be of good quality conforming to the relevant 9000 Basic environmental testing Indian Standards. (Part 16) : 1983 procedures for electronic and 4.2 An ignition coil generally consists of the electrical items : Part 16 Driving rain test following: a) Primav winding, 3 TERM~NOL6bGY b) Sccondarv winding, For the prlrpose ‘of this standard, the following c) L~aminations, definitions shall apply. d) Primary and secondary terminals, e) Insulated body, and 3.1 Ignition Coil I) InsulNing medium in which the coil winding A pulse transformer designed to step up the low is placed inside the outer body.

primary voltage as available from generator to the high 4.3 Dimensions tension voltage~required to jump the spark plug gap located in the com’bustion chamber. A typical ignition coil is shown in Fig. 2. The mounting dimensions of ignition coil shall be as agreed to 3.2 Mounting between the manufacturer and the purchaser.

The means of fixing the ignition coil. 4.4 Terminals

3.3 Type Tests 4.4.1 Primary (Low Tension ) Terminals

Tests carried out to prove conformity with the Ignition coil may be provided with connectors of specification. These are intended to prove the general suitable and reliable type. qualities and design of a given type of ignition coil. 4.4.2 Secondary (High Tension ~- WI’) Terminals 3.4 Acceptance Tests 4.4.2.1 A self tapping screw or sharp pointed terminal Tests carried out on samples taken from a lot for the shall be provided in the coil for fixing HT cable or purpose of acceptance of the lot. cables and shall be moulded in th~c coil.

IS 14380 : 1996

MOBILE POINT

ISATION POINT

All dimensions in millimetres. Fro. 1 SPARKGAP WITHIONISATION POINT

4.4.2.2 The terminal fitted on cable for connecting 5 SAMPLING the spark plug shall be as agreed to between the 5.1 Sampling Criteria for Approval manufacturer and the purchaser. Nine samples selected at random shall be submitted 4.5 HT Ignition Cable for the Coil for testing with the relevant data. These shall be tested according to the sequence of tests~given in Annex A. 4.5.1 The HT cables, if fitted, shall conform to the The testing authority shall issue a type approval requirements of ignition cables specified in IS 2465 : certificate if the ignition coils are found to comply 1984. with requirements of the tests given in 6.1. 4.6 Insulating Cap 5.1.1 In case of failure in one or more type tests the testing authority, may at its discretion, call for fresh If fitted, the insulating cap provided on HT cable and samples not exceedingtwice the number of original coil shall be either waterproof or watertight. samples and subject them to test(s) in which failure NOTE ~ A sleeve on the HT cable pulled over the HT has occurred. If in repeat test(s) no failure occurs, terminal nose prevents direct entry of water into the HT the product may be considered to have passed the type terminals. approval tests. In case of failure of the sample during

7

IS 14380 : 1996

END OF PRIMARY WINDING +p

nm+ ‘\i- ‘VIEW FROM Y

*p kg Y

INSUL ATING CAP TO HAVE INTER1 :ERENCE FITMENT ON COI L AS WELL AS SECONDARY WIND!& ^. ^._._ TO SPARK PLUG /’

SECTION B-B SECTION C-C /PRIMARY WINDING SECTlbN A-A ALTERNATE METHODSOF R ELECTRIC DIAGRAM

All dimensions in miUmctres. Fro. 2 IGNITIONCOIL -TYPICAL retest, the product shall be rejected and may be 6.2 Acceptance Tests subjected to fresh type of approval tests after carrying out the necessary improvements in the product. The following shall constitute acceptance tests:

6 TESTS a) V?sual examination,

6.1 ‘Qpe Tests b) Dimensional check, c) Performance test, The following shall constitute the type tests: d) Water spray test. and a) Visual examination (see 6.4) c) Test for performance at high temperature b) Dimensional check (see 6.5) NOTE - The number of samples for acceptance shall he as c) Insulation test (see 6.6) agreed between the purchaser and the manufacturer. 4 Performance tests (see 6.7), 6.3 Routine Tests e) Open circuit test (see 6.8), The following shall constitute the routine tests 0 Water spray test (see 6.9) a) Visual examination, and b) lnsulatron resistance. k9 Test for moisture resistance (humidity test) (see 6. lo), 6.4 Visual Examination h) Test for operation at high temperature The ignition coil assembly shall be examined visually (see 6.11) for correct assembly and finish and shall be free from injurious flaws or defects. j) Temperature cycling test (see 6.12), 6.5 Dimensional Check k) Vibration test (see 6.13) and It shall be carried out on all parts and the mountmg ml Endurance test (see 6.14). dimensions shall be as specified in 4.3,

3

IS 14380 : 1996

6.6 Insulation Test a) Test for operation at low speed ( see 6.7.1 ),

The input of the primary of HT coil shall be so adjusted b) Test for operation at normal speed ( see from ac power supply with the help of variac -and 6.7.2 ), voltmeter to get the secondary output of coil on c) Test for operation at high speed ( see 6.7.3 ), oscilloscope at l-10 percent of the maximum voltage developed by a coil on the vehicle or 20 kV, whichever d) Polarity test for HT pulse ( see 6.7.4 ), and is more. The coil shall be tested for 10 seconds in open circui&conditions without any load. e) Test for spark duration ( see 6.7.5 ).

6.6-l No internal leakage shall be observed on the 6.7.1 Test for Operation at Low Speed oscilloscope ~c;re~n at the test voltage specified in The test shall be carried ott at the site atmospheric F1g. 3 temperature and humidity under the following conditions: TIME ( pm) a) Power supply Suitable magneto mounted Q on the test bench

5 b) Speed for 500 rev/min (approx) magneto (may be fired by mutual agreement between the purchaser and the manulracturer)

c) Three point gap 5 mm

6.7.1.1 The product shall be considered lo have passed the test if the spark does not miss by more than 30-1 15 percent. OPEN CIRCUIT VOLTAGE 6.7.2 Test for Operation at Normal Speed

The test shall be carried out at the site atmospheric TIME ( pm) temperature and humidity under the following conditions:

a) Power supply Suitable magneto mounted on the test bench b) Speed of magneto 2 500 rev/min (may be fired by mutual agreement between the purchaser and the manufacturer )

c) ‘IThree pomt gap 8.5 mm

d) Duration of test 5 minutes

6.7.2.1 The coil shall be considered to have passed the BRAKE DOWN ( INTERNAL SPARKING ) test if there is continuous spark during the duration of OF H.T. COIL test without any break.

Frt;. 3 VOLTAGESFORINSULATJON TEST 6.7.3 Test jbr Operation at High Speed

6.7 Performance Tests The test shall be carried out at the site atmospheric temperature and humidity under the following The performance tests consist of the following tests conditions: and these tests shall be carried out in conjunction with the typical magneto coil of the vehicle: a) Power supply Suitable magneto mounted on rhe test bench 4 IS 14380 : 1996

b) Speed of 6 000 revimin ( may be magneto fired by mutual agreement where between the purchaser and SE = spark energy in micro-semiens, and the manufacturer ) R = resistance in mega-ohms. c) Three point gap 8.5 mm The spark energy ofthe coil shall be as agreed between d) Duration of test 5 minutes the manufacturer and the purchaser. However a value of 5 micro-seimens higher than the minimum value is ~6.7.3.1 The coil shall be considered to have passed recommended The minimum valrre specified for this the test if there is continuous spark during the duration test is 5 micro-seimens. of test without any break.

6.7.4 Polarrt): of H. 7: Pulse TIME (us)

The spark gap in the three point gap shall be adjusted to 5 mm. The coil shall be tested with associated magneto at 1 500 rev/min or any other agreed speed. 2-K The polarity of H.T. pulse shall be checked on oscilloscope and it shall be negative with respect to common ground. (see Fig. 4).

TIME (m s) 120 160 _ o- LO 80

121 3- v v I,“- Fm.5 SPARKDURATIONAT1500rev/min 9- 6.8 Open Circuit Test

The coil shall be run in open circuit condition (no spark between three point gap) at 1 WC1 rev/mm or any other FIG.~ H.T. RJLSETRAINATSPARKGAPELEC-FRODE agreed speed for one hour. The coil shall pass insulation test as outlined in 6.6. 6.7.5 Spark Duration 6.9 Water Spray Test The spark gap in the three point gap shall be adjusted to 5 mm. The coil shall be tested with associated The test shall be conducted in the manner specified in magneto at 1 500 rev/min or any other agreed speed. IS 9000 (Part 16) : 1983. The spark duration shall be checked with the help of 6.9.1 There shall be no missing spark under following oscilloscope and high tension probe. concIitions of testing: The spark duration shall be greater than I 000 micro a) Three pomr spark gap 5 mm seconds (see Fig. sj or shall be as agreed between the mantiacrurer ana the purchaser. b) Magneto speed 1 SO0 rev/min or any other agreed 6.7.6 Spark Enetg$Loaded Performance Test value ‘The three pomt spark gap shall be adjusted to 5 mm. c) Duration of water shower One hour The associated magneto shaI1 be run at I 500 rev/min or any other agreed speed. The spark energy shall be NGTE - ‘Lhc revoiving rable of the unit shall be kept checked by conrlectmg MIerent resistances in shunt stationary. with spark gap eiectrodes. Thevalue of resistance shall 6.10 Test for Moisture Resistance (Humidity Test) be adjusted till a continuous spark is achieved. The spark energy ( SE ) shall be calculated as follows: The coil shaIl be kept in atmosphere of air, water, vapour and droplet mixture with water temperature of 6O”C, for a mimmum penod of one hour. After the

IS 14380 : 1996 test the external surface of the coil shall be wiped off 6.14 Endurance Test and it shall be subjected to the spark energy test specified in 6.7.6 and shall pass the test. The coil shall run continuously at 1 500 rev/r&r or any other agreed speed of magneto with a spark gap of 6.11 Test for Operation of High Temperature 5 mm for the period to 250 h. After the test the coil The coil shall be kept in air at 9O’C for not less than shall be subjected to spark energy test specified in 6.7.6 one hour. Immediately after removal from the oven and shall pass the test. the coil shall be subjected to spark energy test 7 MARKING specified in 6.7.6 and shall pass the test.

6.12 Temperature Cycling Test 7.1 Each ignition coil shall be legibly and indelibly marked with the following: The coil shall be kept in 100’ -f 5°C air for one hour. After this the coil shall be kept at minus 20°C f 5°C a) Manufacturer’s name or trade-mark, if any; air for 1 h. The temperature cycle shall be repeated b) Batch number; and four times. After the test the coil shall be subjected c) Month and year of manufacture. to spark energy test specified in 6.7.6 and shall pass the test. 7.2 IBIS Certification Marking

6.13 Vibration Test The product may also be marked with the Standard Mark. The test piece with mounting bracket, after being rigidly mounted on a suitable vibrating machine 7.2.1 The use of the Standard Mark is governed by the constructed to produce simple harmonic motion ( a provisions of the Bureau of” Indian Standards Act. total lift of 1.5 mm ) shall be subjected to vibration 1986 and the Rules and Regulations made thereunder. through a frequency range of 10-55-10 Hz for a period The details of conditions under which the licence for of 1 min at room temperature. With continuously the use of Standard Mark may be granted to the varying frequencies. the vibration shall be applied for manufacturers or producers may be~obtained from the not less than 1 h with the coil fitted vertically and the Bureau of Indian Standards. terminals facing upwards. At the end of the test, the coil shall be examined for any evidence of damage and 8 PACKING shall be subjected to spark energy test according to 6.7.6. There shall be no damage to the coil and it 8.1 The ignition coils shall be packed as per best shall pass the spark energy test. prevalent trade practice.

6

IS 14380 : 1996

ANNEX A ( (q/au.re 5. 1 )

SEQUENCE OF TESTS FOR TYPE APPROVAL

Test Sequence

fi /cII---- I---\ I 2 3 4 5 6 7 8 9 9 Vrsual examination x x x x x x x x x ii) Dimensional check x x x X x x x x x iii) Insulation test x x x X X x x x X

iv) Performance tests x x x x x x x x x a) Operation at low speed b) Operation at normal speed c) Operation at high speed d) Polarity test e) Spark duration test VI Open circuit test vi) Water spray proof test x x vii) Test for moisture resistance X viii) Test for operation at high temperature x x

ix) Temperature cycling X x) Vibration test X xi) Endurance test X

___. ---__--____I_____

ANNEX B ( Foreword ) COMMITTEE COMPOSITION Automotive Electrical Equipment Sectional Committee, TED 11

( ‘hairman Represerr f ing

SHRI K. R. /WhNDAKUiMARrUVMAiR Lucas TVS I,imited, Madras

h4embers

SHKI C. RANcAN~~HAN (Alternate to Shri K. R. Anandakumaran Nair ) SHKI ANIL. AHAND Lumax Industries Pvt Ltd, New Delhi SHKL S. A. LATIF SHKI A. BANtlHoPAnHYhY DCSSI, New Delhi SHKI TAPAN BASLc Ltd, Pune SHRI T. M. RALARAMAN ( Aliernate ) SHKI G. K. BINANI Ltd, Calcutta SHKi V. CHANDRASEKARAN Tractors and Farm Equipment Ltd. Madras SHKI R. RANGANATHAN ( Alternate j .SHKIS. K. (;ilLATI DTDP ( Air ), Ministry of Defence, New Delhi SHRI D. GANGOPADHYAYA( Alternate ) SHKI K. C. JAIN Escorts Ltd, Faridabad SHKI R. K. GU~A (Alternate ) SHKI R. K. JAIN HMT Ltd. Distt Ambala SHRI K. K. SEHCAL ( Alternate ) SHHI R. M. KANITKAH Bajaj Tempo Ltd, Pune SHRI S. B. DIJGAL ( Alte.rnate ) SHKI R. K~MAR Tractor Components Group Escorts Ltd, Faridahad SHRI A. JINDAL ( Alternate ) SHFI V. A. KALGAONKAR Tata Engineering and Locomotive Co Ltd, Pune SHKi I). R. YADAV ( Ah-nare ) SHK! R. KH 4NiFLWAL Indian Society for Liphting Engine~ern, Mumbai SHKI A. R. KIILKAHNI C 0 A V, Ahmednapar L-r COI. R. K. MALHOTRA ( Alrernare ) SHRI C. R. S. MENON Ltd, Madras SHRI A. J. SIIRIYAPRAKASH ( Alternate ) SHRI 0. M:iyl~Epp~ Sahney Paris-Rhone Ltd. Hyderahad SHK! V. C. MarIluR DGTD, New Delhi SHRI C. P. MATHI’R Motor Industries Company Ltd, Bangalore SHKI V. BALXIPRASAD ( Alcernafe ) SHRI S. K. MUKHERJEE Mahindra and Mahindra Ltd. Mumhai SHRI S. MOHAN Best and Crompton Engineering Ltd, Madras SAKI S. JOHN AUGUSTINE ( Alternate ) SHRI R. K. MANKAO Punjab Tractors Ltd, Ropar SHRI ANAND SWARUP ( Alrernhre ) SHRI K. NARA~ANAN SRF Nippon Denso Ltd. P. 0. Tilpatta SHRI N. RAMANATHAN ( Alternate ) SHRI P S. PA~ABHIKAMAN FIEM Industries (P) Ltd, Kundli SHRI C. B. P~NDLIK Finolex Cables Ltd, Pune SHRI E. M. PITHAMBARAN Ministry of Defence, Ahmednagar (L)RLX)) SHRI S. K. CH~ERIEE ( Alternate ) SHRI G. N. PARAD Maharashtra State Road Transport Corporation, Ratnagiri DR S. B. ROY Chloride India I,td, Calcutta SHRI I. V. RAO Maruti Udyog Ltd, Gurgaon SHXI K. C. HALLONE (Alternate ) SHRI A. K. RARAI Vehicle Factory, Jabalpur SHRI B. L. PATHARIYA ( Alternate ) SHRI R. K. SARINE Auto Ignition Pvt Ltd, Faridabad SHRI U. S. PRABHU (hernufe )

( (‘ontrnued on page 9 )

8

Is 14380 : 1996

( Contmued from page 8 )

Members Representing

SHRI I. SONDHI J. M. A. Industries Ltd. New Delhi SHRI KULDIPSINGH ( Alrernafe ) SHRI SADHU SINGHSIDHU Pepsu Road Transport Corporation, Patiala SHRI S. S. SANDHU Automotive Research Association of India, _@ne SHRI P. N. RANGAN ( Alternufe ) SHRI S. N. SRINIVASAN Automobiles Ltd. Mumbai SHRI H. S. DAVE ( Alternute ) SHRI K. E. SANATHKUMAR National Test House, Madras SHRI U. S. Smx ( Ahmate ) SHRI S. V. SRINNASA International Instruments Ltd. Bangalore SHRI JAIPAL( Alternate ) SHRI N. V. SRIDHARAN Addon, Bangalore SHRSDIUP F? Pa ( titertie ) SHRI S. R. TAFADE Central Institute of Road Transport, Ptme SHRI P C. BARJKITA( Alternate ) SHRI 0. p. TIWARI DCM Daewoo Motors, New Delhi Sm A. A. V~YAYAN ( Alternate ) Sm UMA SHANKAR India Nippon EhctxicalsLtd, Dhrampuri SHRI P. R &VINDAN ( Alternote ) SHRI V. S. VENKATESAN Brakes India Ltd, Madras SHRI M. V. R-s RACI( Alternate ) SHRI A. R GULA~, Director General, BIS ( Ex-o@io Member ) Director (Transpott Engineering )

SHRIM. V. S. D. WADA R,UI Joint Director ( Transport E!agineering ), BIS

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Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of ‘BIS Handbook’ and ‘Standaras : Monthly Additions’.

This Indian Standard has been developed from Dot :-No. TED 11 ( 513 5 ).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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