True blue power TB44 series Document technique
Revision F • May 15, 2020
1 Manual Number 9018041 • Revision F, May 18, 2020
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. 34
th
St. N.
Wichita, KS 67226 USA
Phone 316-630-0101
Fax 316-630-0723
© Copyright 2019
Mid-Continent Instrument Co., Inc.
Download the current
version of this
installation manual
using your
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2 Manual Number 9018041 • Revision F, May 18, 2020
TABLE OF CONTENTS
SECTION 1GENERAL DESCRIPTION 4
1.1INTRODUCTION 4
1.2PHYSCIAL 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 16
4.1DESCRIPTION 16
4.2CONSTRUCTION 16
4.3OPERATIONAL MODES 17
4.4PERFORMANCE 20
SECTION 5CONFORMANCE 22
5.1DISPATCH VERIFICATION AND IN-FLIGHT MONITORING 22
5.2ROUTINE MAINTENANCE 22
5.3COMPONENT MAINTENANCE 28
5.4STORAGE INFORMATION 29
5.5END OF LIFE 30
5.6DISPOSAL 30
5.7ENVIRONMENTAL QUALIFICATION STATEMENT 31
3 Manual Number 9018041 • Revision F, May 18, 2020
REVISION HISTORY
Rev Date Detail Approved
A 04/29/2014 Initial release BAW
B 10/26/2015 Minor revisions to content BAW
C 01/14/2016 Correct mating connector number in sec. 5.2.2.B
Update weight to 51.7 in sec. 1.4 WVC
D 06/29/2018 Updated to include -3 version and various
comments/corrections. BAW
E 03/25/2019 Updated shipping information and recharge interval to 3
months, EQF to add in helicopter vibration. WVC
F 05/18/2020 Updated style and brand to meet Marketing and
Engineering guidelines. DLR
4 Manual Number 9018041 • Revision F, May 18, 2020
SECTION 1 GENERAL DESCRIPTION
1.1 INTRODUCTION
The TB44 series Advanced Lithium-ion Battery, part number 6430044-( ), is designed to provide
high current capability to start turbine or piston aircraft engines and subsequently, provide DC
power capacity to the primary electrical bus in the event of generator function loss. The TB44 is a
sophisticated power system that utilizes state-of-the-art Nanophosphate® lithium-ion battery cell
technology which provides improvements to the performance, safety, life and weight when
compared to traditional or competing aircraft batteries. Consideration given to key electrical and
mechanical design principles provide adherence to regulatory standards and meet or exceed
industry expectations. The TB44 is a complete battery solution that provides significant value and
benefit to an aircraft designer, owner and operator.
The TB44 requires professional use and maintenance to deliver maximum performance and value
as designed. This manual contains information related to the specifications, installation, operation,
storage, scheduled maintenance, and other related topics associated with the proper care and use
of this product.
1.2 PHYSCIAL ATTRIBUTES
The TB44 is a single, integrated component contained in a metal enclosure with multiple interface
connections. There is a primary 2-pin, industry standard military-specification power receptacle, an
18-pin circular communications and service connector, a 4-pin circular temperature monitoring
connector and a heater enable push-button with LED indicator. The lid of the enclosure includes
two hold-down features on either side to support typical aircraft mounting. Handles on each side
provide ease of lifting and carrying for installation, removal and transport. There is a 1.50 inch
diameter vent port on top of the lid to provide an exhaust connection for directing any released
emissions in the rare event of a battery failure.
1.3 UNIT ARCHITECTURE
The unit is comprised of two primary building blocks: the Battery Modules with integrated Module
Management System (MMS) and a Central Monitoring System (CMS). Additional components
include power and communication interconnects, heaters, temperature sensors, container and
hardware.
Each Battery Module consists of eight (8) cells, connected in series, with the MMS electronic
protections and battery control logic contained within each module. There are 19 modules
arranged in three banks, all connected in parallel through a network of bus bars to provide
combined power to the main connector and thus the aircraft. There is an integrated heater in each
module as well that improves cold weather performance.
The CMS monitors individual signals provided by each MMS and reports status information to the
aircraft. It also employs hardware to manage heater functionality, and software for diagnostic
information and storing data that contains operating information.
There are two Resistance-Temperature Devices (RTDs) in the unit that provide analog electrical
signals through the 4-pin connector for independent temperature monitoring.
5 Manual Number 9018041 • Revision F, May 18, 2020
1.4 TECHNICAL SPECIFICATIONS
Electrical Attributes
Power Input 28.5 volts DC Nominal, 400A Max Charge Current
Power Output 26.4 volts DC Nominal, 750A Continuous Max, 1500A Pulse Max
Rated 1C Battery Capacity 44 amp hours (Ah) @ 23°C
Table 1.1
Physical Attributes
Weight 51.7 pounds
Dimensions
(not including vent,
handles and connectors)
10.9 L x 10.5 W x 10.2 H inches (see Figure 1.1)
[276 x 266 x 258 mm]
COMM/Service Connector
RTD Temperature
Connector
Quick Disconnect
Receptacle
18-pin per MS3114E14-18P
4-pin per MS3114E8-4P
2-pin per Mil-PRF-18148/3 form factor
Mounting See Section 3.4.2
Table 1.2
Table 1.3
Qualifications
Certification FAA TSO-C179a
Performance Qualification RTCA DO-311 Minimum Operational Performance Standard for
Rechargeable Lithium Battery Systems
Environmental
Qualification
See Appendix 1
Software Qualification RTCA DO-178B, Design Assurance Level (DAL) C
6 Manual Number 9018041 • Revision F, May 18, 2020
1.1
3.5
5.0
4.8
8.2
10.1
11.0 RTDTemp
Connector
Communications/
ServiceConnector
10.0
0.6
10.5
11.7
10.9
Label
Nameplate
Label
4.8
QuickDisconnect
PowerReceptacle
Heater
Enable
Switch
Vent
Figure 1.1
7 Manual Number 9018041 • Revision F, May 18, 2020
1.5 IMPORTANT SAFETY INFORMATION
Read this safety information BEFORE maintaining or servicing the battery.
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.
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.
The battery does not include any serviceable internal components. Do not remove the
lid or loosen the lid screws. Tampering with the lid could compromise the battery’s
ability to contain failure events.
Remove metal items such jewelry and watches when working with batteries. 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, including grounding of an aircraft to reduce static electricity when working with
the battery on-board.
All connections for battery testing must include appropriate short-circuit protection.
The battery service area shall be properly ventilated and egress paths shall be
unobstructed.
o Specialized breathing filters are not required under normal service and
operation.
Always use insulated tools.
Never smoke or allow a spark or flame near the battery.
Use caution to reduce the risk of dropping a metal tool on the battery. Dropping a tool
could spark or short circuit the battery.
Turn off all attached loads before connecting/disconnecting the battery power harness
plug.
CAUTION
W
ARNING
W
ARNING
8 Manual Number 9018041 • Revision F, May 18, 2020
If using a DC power supply or a battery charger, use equipment manufacturer’s
instructions to prevent the potential for arc discharge during connection. Arc discharge
may cause damage to the battery receptacle’s pins. Specifically, be aware of whether
the power supply or charger should be on or off prior to connecting to the battery.
Do not stack more than 120 lbs. on top of the battery.
SDS info can be found on website at truebluepowerusa.com.
Additional Precautions
The following design and operation factors are required for safe use.
There are no limitations in storing or using this battery in the vicinity of other battery
types/chemistries (i.e. lead acid, nickel cadmium (ni-cad), etc.). 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. Verify the correct polarity of any harness or equipment
prior to connecting to the battery.
Battery terminals must be covered with non-conductive protective devices to avoid any
possibility of shorting during handling, shipping, or storage.
Precautions should be applied if the battery is damaged or fails in such a way that
produces liquid or gaseous emissions. Consult the Safety Data Sheet and contact the
manufacturer for more information.
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, when shipped by air,
the TB44 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.
The unit may be shipped at approximately 30% state of charge (SOC). Upon receipt, the
battery MUST be fully charged using the procedures listed in this manual (prior to storage
and again prior to installation/use).
Batteries that are stored or not in use MUST be fully recharged at a minimum every 3
months, following the procedure set forth in Section 5.2.3. For more detailed storage
instructions refer to Section 5.4.
CAUTION
9 Manual Number 9018041 • Revision F, May 18, 2020
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 with internal thermal monitoring and protection circuits. See Section 4 for
details.
2.2 EQUIPMENT LOCATION
The TB44 Advanced Lithium-ion Battery is designed to allow for installation without requirements
for temperature or pressure control. Although not required, optimum performance and life can be
achieved by mounting the TB44 in a section of the aircraft that reduces exposure to high
temperatures. In addition to altitude and temperature tolerance, the unit is also designed to
withstand high levels of condensing humidity. However, installation locations where the unit could
be subject to standing or direct water exposure should be avoided. The unit shall be mounted in
the upright position (vent on top).
Failure mode, effects, and criticality analysis of the TB44 has shown that the potential for multiple
cells to release 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.
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 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 wires associated with the battery are heavy gauge wire and carry significant power. Be
aware of routing cables near other electronics or wire bundles that may be exposed to high energy
flow.
Avoid sharp bends in cabling and 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. The interconnect cables should not run adjacent to
heaters, engine exhausts, or other heat sources. Interconnect cable wire is recommend to be no
smaller than 24 gauge. There are no length restrictions in regard to the interconnect cable wiring.
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