True blue power TB-14 Series Document technique
Revision B •
A
pril 28, 2023
1 Manual Number 9019706 • Revision B, April 28, 2023
FOREWORD
This manual provides information intended for use by persons who, in accordance with current
regulatory requirements, are qualified to install this equipment. If further information is required,
please contact:
True Blue Power
c/o Mid-Continent Instrument Co., Inc.
Attn: Customer Service Dept.
9400 E. 34th St. N.
Wichita, KS 67226 USA
Phone 316-630-0101
Fax 316-630-0723
www.truebluepowerusa.com
www.mcico.com
We welcome your comments concerning this manual. Although every effort has been made to
keep it free of errors, some may occur. When reporting a specific problem, please describe it
briefly and include the manual part number, the paragraph/figure/table number and the page
number. Send your comments to:
True Blue Power
c/o Mid-Continent Instrument Co., Inc.
Attn: Technical Publications
9400 E. 34th St. N.
Wichita, KS 67226 USA
Phone 316-630-0101
Fax 316-630-0723
© Copyright 2023
Mid-Continent Instrument Co., Inc.
Download the current
version of this
installation manual
using your
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2 Manual Number 9019706 • Revision B, April 28, 2023
TABLE OF CONTENTS
SECTION 1GENERAL DESCRIPTION 4
1.1INTRODUCTION 4
1.2PHYSICAL ATTRIBUTES 4
1.3UNIT ARCHITECTURE 4
1.4TECHNICAL SPECIFICATIONS 5
1.5IMPORTANT SAFETY INFORMATION 7
SECTION 2PRE-INSTALLATION CONSIDERATIONS 9
2.1COOLING 9
2.2EQUIPMENT LOCATION 9
2.3ROUTING OF CABLES 9
2.4LIMITATIONS 10
2.5MODIFICATION 10
SECTION 3INSTALLATION 11
3.1GENERAL 11
3.2PRE-INSTALLATION INSPECTION 11
3.3PARTS 11
3.4INSTALLATION 12
SECTION 4OPERATION 15
4.1DESCRIPTION 15
4.2CONSTRUCTION AND THEORY OF OPERATION 15
4.3OPERATIONAL MODES 16
4.4BATTERY COMMUNICATION 20
4.5PERFORMANCE 23
SECTION 5CONFORMANCE 24
5.1DISPATCH VERIFICATION AND IN-FLIGHT MONITORING 24
5.2INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 24
5.3SOFTWARE UPDATE 25
5.4COMPONENT SERVICE 28
5.5STORAGE INFORMATION 28
5.6END OF LIFE 29
5.7DISPOSAL 29
5.8DO311-A COMPLIANCE QUALIFICATION FORM 30
5.9ENVIRONMENTAL QUALIFICATION STATEMENT 31
3 Manual Number 9019706 • Revision B, April 28, 2023
REVISION HISTORY
Rev Date Detail Approved
A
02/24/2023 Initial Release WVC
B 04/28/2023 Corrected Ipr (Table 1.4) and hold-down bar p/n (Sec
3.4.2). Provided additional details for Serial
Communications (Sec 4.4.3).Added exhaust gas
temperature (Sec 5.9).
WVC
4 Manual Number 9019706 • Revision B, April 28, 2023
SECTION 1 GENERAL DESCRIPTION
1.1 INTRODUCTION
The TB28-12V and TB14 series Advanced Lithium-ion Batteries, part number(s) 6430014-( ), are
designed to deliver high current capability to start piston and light turbine aircraft engines and
successively provide DC power capacity to the primary electrical bus in the event of generator
function loss. The TB28-12V/TB14 are sophisticated energy storage and power systems that utilize
state-of-the-art lithium-ion iron phosphate battery cell technology which provides improvement in
performance, safety, life and weight when compared to traditional or competing aircraft batteries.
The design of the battery includes detailed focus on key electrical, mechanical and software
elements that combine to provide exceptional performance and safety that meets and exceeds the
latest regulatory and industry standards. The TB28-12V/TB14 are complete battery solutions that
provide significant value and benefit to an aircraft designer, owner and operator.
Key features of the TB28-12V and TB14 batteries include real-time state of charge and state of
health resulting in maintenance-free operation with on-condition end of life. Multiple safety
protections and continuous data monitoring add value, reliability, and reduced cost of ownership
for the life of the product.
The TB28-12V and TB14 batteries require professional use and minimal service to deliver
maximum performance and value as designed. This manual contains information related to the
specifications, installation, operation, storage, scheduled service and other related topics
associated with the proper care and use of this product.
1.2 PHYSICAL ATTRIBUTES
The TB28-12V and TB14 batteries include a single, integrated assembly contained in a metal
enclosure with positive and negative power terminals and a 15-pin D-shell communication
connector. The top of the enclosure supports the use of a hold-down bar for typical aircraft
mounting. There is a 1-inch diameter vent port on top of the unit for an exhaust connection that
directs any released emissions appropriately.
1.3 UNIT ARCHITECTURE
The unit is comprised of two primary functional pieces:
Battery module
BMS (Battery Management System) board; a printed circuit board assembly that serves not
only to manage the battery system, but also controls charging and discharging.
Each battery consists of sixteen (16) cells. The 14 VDC battery (p/n 6430014-1, Model TB28-12V)
cells are arranged as four (4) groups of four (4) parallel cells, connected in series (4S4P); the 28
VDC battery (p/n 6430014-2, Model TB14) cells are arranged as eight (8) groups of two (2) parallel
cells connected in series (8S2P). Both -1 and -2 batteries include multiple temperature monitors to
assure safe operation. The cells are inter-connected with copper busbars and then tied directly to
the BMS board.
The BMS board is a microprocessor-based system that monitors the battery functions and protects
5 Manual Number 9019706 • Revision B, April 28, 2023
against such conditions as short circuit, over-temperature, over-discharge and others. The BMS
also controls enabling and disabling charge and discharge functions depending on the health of
the battery and generates battery status signals that are accessed through the 15-pin
communication connector for cockpit monitoring. An additional Resistance Temperature Detector
(RTD) is included and accessible through the 15-pin connector for external temperature
monitoring, independent from the BMS.
1.4 TECHNICAL SPECIFICATIONS
Electrical Attributes
Power Input:
-1
-2
14.4 VDC Nominal, 56 Amps Max
28.8 VDC Nominal, 28
A
mps Max
Power Output
-1
-2
13.2 VDC Nominal, Continuous Current 200 Amps
Power Peak Current (IPP) 810 Amps
Power Rated Current (IPR) 630 Amps
26.4 VDC Nominal, Continuous Current 100 Amps
Power Peak Current (IPP) 895 Amps
Power Rated Current (IPR) 380
A
mps
Battery Capacity
-1
-2
26 amp hours (Ah) @ 23°C
13 amp hours (Ah) @ 23°C
Table 1.1
Physical Attributes
Weight 10.0 pounds (4.6 kg)
Dimensions (see Figure 1.1)
(not including vent or
connectors)
6.3 x 5.6 x 4.9 inches
[160 x 142 x 124 mm]
Power Terminals M8 x 1.25 x 10mm deep thread, 13mm hex bolt
Communication Connecto
r
15-pin D-shell
Mounting Hold down bar (0.31 inch holes on 7.9 inch centers)
Table 1.2
Qualifications
Certification FA
A
/
TSO-C179b, Class
A
-4B
Performance Qualification RTCA/DO-311A (see section 5.8)
Minimum Operational Performance Standard for
Rechargeable Lithium Batteries and Battery Systems
Environmental Qualification RTCA DO-160G (see section 5.9)
Software Qualification RTCA/DO-178C, Design Assurance Level (DAL) A
Table 1.3
6 Manual Number 9019706 • Revision B, April 28, 2023
Figure 1.1
Unit Outline Drawing
7 Manual Number 9019706 • Revision B, April 28, 2023
1.5 IMPORTANT SAFETY INFORMATION
Read this safety information BEFORE maintaining or servicing the battery.
1.5.1 Symbol Definition
This section describes the precautions necessary for safe operations. The following safety
symbols have been placed throughout the guide.
Warnings identify conditions or practices that could result in personal injury.
Cautions identify conditions or practices that could result in damage to the equipment.
1.5.2 Handling Precautions
The battery’s energy is high enough to sustain an ARC flash. Always wear safety glasses,
fire retardant smocks, and use insulated tools when servicing the battery.
• Remove metal items such as rings, bracelets, and watches when working with battery
packs. A battery could produce a short circuit current high enough to weld jewelry to
metal and cause a severe burn.
• Always use appropriate Electrostatic Discharge (ESD) protection while working with the
battery pack.
• All connections for battery pack testing must include appropriate short-circuit protection.
• The battery pack service area shall be properly ventilated, and egress paths shall be
unobstructed.
• Specialized breathing filters are not required under normal use.
• Always use insulated tools.
• Never smoke or allow a spark or flame near the battery pack.
• Use caution to reduce the risk of dropping a metal tool on the battery. Dropping a tool
could spark or short circuit the battery pack.
• Turn all accessories off before removing the ground terminal.
• Use appropriate lifting devices or equipment for handling batteries; use battery handles
where provided.
CAUTION
W
ARNING
W
ARNING
8 Manual Number 9019706 • Revision B, April 28, 2023
1.5.3 Additional Precautions
The following design and operation factors are required for safe use.
• It is not acceptable to combine or use any battery cells or modules other than those
approved by True Blue Power within this battery pack.
There are no limitations in storing or using this battery in the vicinity of other battery
chemistries. This battery does not emit or absorb any gas during storage, transportation
or during normal operating conditions.
Batteries must not be installed with the output terminals reversed. A reversed battery
could be charged by other batteries in the circuit during discharge; or discharged by the
charging system during charge.
Battery terminals must be covered with non-conductive protective devices to avoid any
possibility of shorting during handling, shipping or storage.
1.5.4 Shipping
True Blue Power lithium-ion cells and batteries are designed to comply with all applicable
shipping regulations as prescribed by industry and regulatory standards. This includes
compliance with the UN recommendations on the Transport of Dangerous Goods, IATA
Dangerous Goods Regulations, and applicable U.S. DOT regulations for the safe transport
of lithium-ion batteries and the International Maritime Dangerous Goods Code. In
accordance with IATA and per UN 3480, PI 965, Section 1A and 1B, the TB14 series
Advanced Lithium-ion Battery will be shipped with a state of charge (SOC) not to exceed
30% of rated capacity. This battery is classified as a Class 9 Dangerous Good. If the
battery requires shipment, please contact the manufacturer for additional instructions on
proper procedures.
NOTE: The unit is shipped with approximately 30% state-of-charge (SOC). Upon receipt
the battery shall be fully charged using the procedures listed in this manual (prior to storage
and again prior to installation/use).
Upon receipt the battery shall be fully charged. Batteries that are stored shall be fully
recharged at a minimum every 6 months, following the procedure set forth in Section 5.2.2.
For more detailed storage instructions refer to Section 5.4.
CAUTION
CAUTION
9 Manual Number 9019706 • Revision B, April 28, 2023
SECTION 2 PRE-INSTALLATION CONSIDERATIONS
2.1 COOLING
No internal or external cooling of the unit is required. The unit is designed to operate over a wide
temperature range and includes internal thermal monitoring and protection circuits. See Section 4
for more details.
2.2 EQUIPMENT LOCATION
The TB28-12V and TB14 Advanced Lithium-ion Batteries are designed for mounting flexibility,
allowing for installation with no requirement for temperature or pressure control. Although not
required, optimum performance and life can be achieved by mounting the battery in a temperature
controlled section of the aircraft. In addition to altitude and temperature tolerance, the unit is
designed to withstand elevated levels of condensing humidity. However, installation locations
where the unit could be subject to standing or direct water exposure should be avoided. The unit
should be mounted in the upright position (vent on top).
Failure mode, effects, and criticality analysis of the TB28-12V and TB14 batteries have shown that
the potential for the release of toxic or flammable gases as a result of any potential condition is
extremely improbable. However, for additional risk mitigation, the unit is designed with a vent
which should be connected and diverted overboard in the event of such an occurrence. Details for
vent installation are provided in Section 3. The unit should not be installed in compartments where
lines, tanks or equipment containing fuel, oil or other flammable fluids are present. Installation near
potential sources of ignition should be avoided.
Consideration should be given to how the status and reporting functions of the battery will be
displayed within the aircraft. At a minimum, critical parameters determined at the time of
certification should be available to the pilot and/or crew. Additionally, existing aircraft systems
which are designed to work with traditional batteries may need alteration in order to accommodate
the slight change in voltage output of this lithium-ion battery and the communication capabilities
available.
2.3 ROUTING OF CABLES
The power terminal wires associated with the unit are heavy gauge wire and carry significant
power. Be aware of routing cables near other electronics or with other wire bundles that may be
susceptible to high energy flow.
Avoid sharp bends in both the power cables and the signal cabling and be cautious of routing near
aircraft control cables. Also avoid proximity and contact with aircraft structures, avionics
equipment, or other obstructions that could chafe wires during flight and cause undesirable effects.
Cables should not run adjacent to heaters, engine exhausts, or other heat sources. The signal
cable bundle wires are recommended to be no smaller than 24 gauge.
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