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High tension leads or high tension cables or spark plug wires or spark plug cables, colloquially referred to as HT leads, are the wires that connect a distributor, ignition coil, or magneto to each of the spark plugs in some types of internal combustion engine. "High tension lead" or "cable" is also used for any electrical cable carrying a high voltage in any context. Tension in this instance is a synonym for voltage. High tension leads, like many engine components, wear out over time. Each lead contains only one wire, as the current does not return through the same lead, but through the earthed/grounded engine which is connected to the opposite battery terminal (negative terminal on modern engines). High tension may also be referred to as HT. [1]
Spark plug wires have an outer insulation several times thicker than the conductor, made of a very flexible and heat-resistant material such as silicone or EPDM rubber. The thick insulation prevents arcing from the cable to an earthed engine component. A rubber "boot" covers each terminal. Dielectric grease can be used to improve insulation; a small amount can be applied in the inside of the rubber boot at each end of each wire to help seal out moisture. Printing on spark plug wires may include a brand name, insulation thickness (in millimeters), insulation material type, cylinder number, and conductor type (suppressor or solid wire).
The wire from each spark plug is just long enough to reach the distributor, without excess. Each end of a spark plug wire has a metal terminal that clips onto the spark plug and distributor, coil, or magneto. There are dedicated spark plug wire pliers, tools designed for removing the terminal from a spark plug without damaging it.
To reduce radio frequency interference (RFI) produced by the spark being radiated by the wires, which may cause malfunction of sensitive electronic systems in modern vehicles or interfere with the car radio, various means in the spark plug and associated lead have been used over time to reduce the nuisance:
Placing spark plug wires back into their separators or holders during replacement helps to keep them in place despite engine vibration, extending their life. A common problem with spark plug wires is corrosion of the metal end terminals. Better-quality spark plug wires usually have brass terminals, which are more resistant to corrosion than other metals used.
Older engines also have a wire connecting the ignition coil to the distributor, known as a coil wire. A coil wire is of the same construction as a spark plug wire, but generally shorter and with different terminals. Some distributors have an ignition coil built inside them, eliminating the need for a separate coil wire, e.g. GM High energy ignition system and some Toyotas and Hondas.
Many modern car engines have multiple ignition coils (one for each pair of cylinders) built into a coil pack, eliminating the need for a distributor and coil wire. Some car engines use a small ignition coil mounted on top of each spark plug, eliminating the need for spark plug wires entirely.
An electrical insulator is a material in which electric current does not flow freely. The atoms of the insulator have tightly bound electrons which cannot readily move. Other materials, semiconductors and conductors conduct electric current more easily. The property that distinguishes an insulator is its resistivity; insulators have higher resistivity than semiconductors or conductors. The most common examples are non-metals.
An ignition magneto, or high-tension magneto, is a magneto that provides current for the ignition system of a spark-ignition engine, such as a petrol engine. It produces pulses of high voltage for the spark plugs. The older term tension means voltage.
In electrical engineering, ground or earth is the reference point in an electrical circuit from which voltages are measured, a common return path for electric current, or a direct physical connection to the earth.
A spark plug is a device for delivering electric current from an ignition system to the combustion chamber of a spark-ignition engine to ignite the compressed fuel/air mixture by an electric spark, while containing combustion pressure within the engine. A spark plug has a metal threaded shell, electrically isolated from a central electrode by a ceramic insulator. The central electrode, which may contain a resistor, is connected by a heavily insulated wire to the output terminal of an ignition coil or magneto. The spark plug's metal shell is screwed into the engine's cylinder head and thus electrically grounded. The central electrode protrudes through the porcelain insulator into the combustion chamber, forming one or more spark gaps between the inner end of the central electrode and usually one or more protuberances or structures attached to the inner end of the threaded shell and designated the side, earth, or ground electrode(s).
An electrical connector is an electromechanical device used to join electrical conductors and create an electrical circuit. Most electrical connectors have a gender – i.e. the male component, called a plug, connects to the female component, or socket. The connection may be removable, require a tool for assembly and removal, or serve as a permanent electrical joint between two points. An adapter can be used to join dissimilar connectors.
An ignition system generates a spark or heats an electrode to a high temperature to ignite a fuel-air mixture in spark ignition internal combustion engines, oil-fired and gas-fired boilers, rocket engines, etc. The widest application for spark ignition internal combustion engines is in petrol (gasoline) road vehicles such as cars and motorcycles.
A contact breaker is a type of electrical switch, and the term typically refers to the switching device found in the distributor of the ignition systems of spark-ignition internal combustion engines.
A distributor is an enclosed rotating shaft used in spark-ignition internal combustion engines that have mechanically timed ignition. The distributor's main function is to route secondary, or high voltage, current from the ignition coil to the spark plugs in the correct firing order, and for the correct amount of time. Except in magneto systems and many modern computer controlled engines that use crank angle/position sensors, the distributor also houses a mechanical or inductive breaker switch to open and close the ignition coil's primary circuit.
Electrical wiring is an electrical installation of cabling and associated devices such as switches, distribution boards, sockets, and light fittings in a structure.
The wasted spark system is an ignition system used in some four-stroke cycle internal combustion engines. In a wasted spark system, the spark plugs fire in pairs, with one plug in a cylinder on its compression stroke and the other plug in a cylinder on its exhaust stroke. The extra spark during the exhaust stroke has no effect and is thus "wasted". This design halves the number of components necessary in a typical ignition system, while the extra spark, against much reduced dielectric resistance, barely impacts the lifespan of modern ignition components. In a typical engine, it requires only about 2–3 kV to fire the cylinder on its exhaust stroke. The remaining coil energy is available to fire the spark plug in the cylinder on its compression stroke.
A power cable is an electrical cable, an assembly of one or more electrical conductors, usually held together with an overall sheath. The assembly is used for transmission of electrical power. Power cables may be installed as permanent wiring within buildings, buried in the ground, run overhead, or exposed. Power cables that are bundled inside thermoplastic sheathing and that are intended to be run inside a building are known as NM-B.
An ignition coil is an induction coil in an automobile's ignition system that transforms the battery's voltage to the thousands of volts needed to create an electric spark in the spark plugs to ignite the fuel. Some coils have an internal resistor, while others rely on a resistor wire or an external resistor to limit the current flowing into the coil from the car's 12-volt supply. The wire that goes from the ignition coil to the distributor and the high voltage wires that go from the distributor to each of the spark plugs are called spark plug wires or high tension leads. Originally, every ignition coil system required mechanical contact breaker points and a capacitor (condenser). More recent electronic ignition systems use a power transistor to provide pulses to the ignition coil. A modern passenger automobile may use one ignition coil for each engine cylinder, eliminating fault-prone spark plug cables and a distributor to route the high voltage pulses.
Capacitor discharge ignition (CDI) or thyristor ignition is a type of automotive electronic ignition system which is widely used in outboard motors, motorcycles, lawn mowers, chainsaws, small engines, turbine-powered aircraft, and some cars. It was originally developed to overcome the long charging times associated with high inductance coils used in inductive discharge ignition (IDI) systems, making the ignition system more suitable for high engine speeds. The capacitive-discharge ignition uses capacitor discharge current to the coil to fire the spark plugs.
A low tension coil is an electrical device used to create a spark across the points of an ignitor on early 1900s gasoline engines, generally flywheel engines, hit and miss engines, and other engines of that era. In modern electronic terms, a low tension coil is simply a large inductor, an electrical device that stores energy for brief periods. The term "low tension" was the terminology of the day used to differentiate it from the term "high tension", and generally meant "low voltage" (tension) as opposed to "high voltage" (tension). High tension coils produce high voltages, generally meant to produce a spark across a spark plug.
A high-voltage cable is a cable used for electric power transmission at high voltage. A cable includes a conductor and insulation. Cables are considered to be fully insulated. This means that they have a full rated insulation system which will consist of insulation, semi-con layers, and a metallic shield. This is in contrast to an overhead line, which may include insulation but not fully rated for operating voltage. High-voltage cables of differing types have a variety of applications in instruments, ignition systems, and alternating current (AC) and direct current (DC) power transmission. In all applications, the insulation of the cable must not deteriorate due to the high-voltage stress, ozone produced by electric discharges in air, or tracking. The cable system must prevent contact of the high-voltage conductor with other objects or persons, and must contain and control leakage current. Cable joints and terminals must be designed to control the high-voltage stress to prevent breakdown of the insulation.
Inductive discharge ignition systems were developed in the 19th century as a means to ignite the air–fuel mixture in the combustion chamber of internal combustion engines. The first versions were low tension coils, then low-tension and in turn high-tension magnetos, which were offered as a more effective alternative to the older-design hot-tube ignitors that had been utilized earlier on hot tube engines. With the advent of small stationary engines; and with the development of the automobile, engine-driven tractors, and engine-driven trucks; first the magneto and later the distributor-type systems were utilized as part of an efficient and reliable engine ignition system on commercially available motorized equipment. These systems were in widespread use on all cars and trucks through the 1960s. Manufacturers such as Ford, General Motors, Chrysler, Citroen, Mercedes, John Deere, International Harvester, and many others incorporated them into their products. The inductive discharge system is still extensively used today.
The Delco ignition system, also known as the Kettering ignition system, is a type of inductive discharge ignition system invented by Charles F. Kettering. It was first sold commercially on the 1910 Cadillac and was manufactured by Delco. Over time, this system was used extensively by all automobile and truck manufacturers until the development of capacitor discharge ignition systems in the 1960s. Delco ignition systems were also used by a number of early aircraft engines.
A magneto is an electrical generator that uses permanent magnets to produce periodic pulses of alternating current. Unlike a dynamo, a magneto does not contain a commutator to produce direct current. It is categorized as a form of alternator, although it is usually considered distinct from most other alternators, which use field coils rather than permanent magnets.
A trembler coil, buzz coil or vibrator coil is a type of high-voltage ignition coil used in the ignition system of early automobiles, most notably the Benz Patent-Motorwagen and the Ford Model T. Its distinguishing feature is a vibrating magnetically-activated contact called a trembler or interrupter, which breaks the primary current, generating multiple sparks during each cylinder's power stroke. Trembler coils were first used on the 1886 Benz automobile, and were used on the Model T until 1927.