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INSTALLATION MANUAL AND
OPERATING INSTRUCTIONS
TB44-( ) Series
Advanced Lithium-ion Battery
®
True Blue Power
is a division of Mid-Continent Instrument Co., Inc.
Mid-Continent Instrument Co., Inc.
dba Mid-Continent Instruments and Avionics
th
9400 E. 34
Street N.
Wichita, KS USA 67226
Manual Number 9018041
PH (800) 821-1212
FX (316) 630-0723
Revision A, April 29, 2014
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Summary of Contents for True blue power TB44 series
- Page 1 INSTALLATION MANUAL AND OPERATING INSTRUCTIONS TB44-( ) Series Advanced Lithium-ion Battery ® True Blue Power is a division of Mid-Continent Instrument Co., Inc. Mid-Continent Instrument Co., Inc. dba Mid-Continent Instruments and Avionics 9400 E. 34 Street N. Wichita, KS USA 67226...
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Page 2: Foreword
Phone 316-630-0101 Fax 316-630-0723 All products produced by Mid-Continent Instruments Co., Inc., including those identified as Mid-Continent Instruments and Avionics or True Blue Power, are designed and manufactured in Wichita, Kansas, USA. ©Copyright 2014 Mid-Continent Instrument Co., Inc. Rev A, April 29, 2014... -
Page 3: Revision History
REVISION HISTORY Date Detail 04/29/2014 Initial release Rev A, April 29, 2014 3 of 27 Manual Number 9018041... -
Page 4: Table Of Contents
TABLE OF CONTENTS FOREWORD REVISION HISTORY SECTION 1 GENERAL DESCRIPTION INTRODUCTION PHYSICAL ATTRIBUTES UNIT ARCHITECTURE TECHNICAL SPECIFICATIONS IMPORTANT SAFETY INFORMATION ... - Page 5 PERFORMANCE 4.4.1 CAPACITY 4.4.2 TEMPERATURE PERFORMANCE 4.4.3 LIFE EXPECTANCY SECTION 5 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DISPATCH VERIFICATION IN‐FLIGHT MONITORING ROUTINE MAINTENANCE 5.2.1 VISUAL INSPECTION ...
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Page 6: General Description
GENERAL DESCRIPTION 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 ®... -
Page 7: Technical Specifications
TECHNICAL SPECIFICATIONS Physical Characteristics Weight 52.7 pounds Dimensions 10.9 L x 10.5 W x 10.2 H inches (see Figure 1.1) (not including vent, handles and connectors) [276 x 266 x 258 mm] COMM/Service Connector 18-pin per MS3114E14-18P RTD Temperature Connector 4-pin per MS3114E8-4P Quick Disconnect Receptacle 2-pin per Mil-PR7-1814148/3 form factor... -
Page 8: Important Safety Information
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. *** WARNING *** Warnings identify conditions or practices that could result in personal injury. CAUTION Cautions identify conditions or practices that could result in damage to the equipment. -
Page 9: Additional Precautions
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. -
Page 10: Pre-Installation Considerations
SECTION 2 PRE-INSTALLATION CONSIDERATIONS 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. EQUIPMENT LOCATION The TB44 Advanced Lithium-ion Battery is designed to allow for installation without requirements for temperature or pressure control. -
Page 11: Installation
SECTION 3 INSTALLATION GENERAL This section contains mounting, electrical connections and other information required for installation. These instructions represent a typical installation and are not specific to any aircraft. PRE-INSTALLATION INSPECTION Unpacking: Carefully remove the TB44 battery from the shipping container. The shipping container and packing are designed specifically for the transit of lithium batteries and approved by international transportation agencies. -
Page 12: Harness Preparation
Install the TB44 in the aircraft in accordance with the aircraft manufacturer’s instructions and the following steps: 3.4.1 HARNESS PREPARATION Prepare aircraft wiring with mating connectors in accordance with the proper Wire Size and Type Recommendations (Table 3.1), Wiring Diagram (Figure 3.1), Connector Locations (Figure 3.2) and Pin Identification Diagrams (Figures 3.3, 3.4 and 3.5) Use of PTFE, ETFE, TFE, PVDF, Teflon or Tefzel insulated wire is recommended for aircraft use. - Page 13 Quick Disconnect Negative/ Positive/ Power Receptacle Ground Pin (-) Power Pin (+) RTD Temp Connector Heater Enable Switch Label Nameplate Power Receptacle (2-pin) Communications/ Service Connector Pin Pin Function + 28VDC power in aircraft ground Figure 3.2 Figure 3.3 Connector Locations Power Connector Comm/Serv ice Connector (18-pin) RTD Temp Pin Pin Function...
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Page 14: Securing The Unit
1.0 inch tall. It is recommended to use the vent tube and attachment hardware as provided in the TBP Vent Kit, P/N 9018043. (Contact True Blue Power for potential alternatives) The vent tube must be properly and securely attached to an aircraft exit point which would allow any gaseous emissions to be vented overboard. -
Page 15: Operation
OPERATION DESCRIPTION The True Blue Power TB44 Battery is designed to supply power for starting an aircraft engine and provide emergency backup power to aircraft systems in the event of primary power generation loss. It utilizes rechargeable Nanophosphate lithium-ion cells to provide approximately 26 volts DC and 44 Ampere-hours (Ah) of capacity (see Performance 4.4). -
Page 16: Resistance Temperature Devices
4.2.4 RESISTANCE TEMPERATURE DEVICES There are two Resistance Temperature Devices (RTDs) in the unit that supply direct analog resistance through the 4-pin connector for independent temperature monitoring. Each RTD uses two pins of the connector (see Figure 3.5) and are characterized with a resistive (Ohms) output. The RTD has a resistance of 200.5 ohms at 60°C. -
Page 17: Engine Start
4.3.2 ENGINE START The TB44 Battery is rated for up to a 1500 amp discharge peak for the purpose of engine starting. The low internal impedance of the Nanophosphate lithium-ion chemistry allows extremely high current delivery while maintaining higher voltage than traditional battery types. This equates to a higher total power delivery, producing quicker starts, more start attempts as needed and a higher remaining battery capacity following engine start. -
Page 18: Performance
Fault Contact Name Normal Independent Fault Conditions BATT OK Contact closed Contact open Battery voltage is below 16V Battery voltage is or over 30V for 10 seconds More than three faulted modules BATT FAIL signal is active BATT MAINT Contact open Contact closed One or more faulted modules Heater or heater control fault... -
Page 19: Temperature Performance
linearly at higher C-rates. As an example, a 44Ah battery rated at 0.1C may typically only support a 44A load for 45 minutes, not a full hour. The capacity for these types of batteries is generally defined by a logarithmic function of load versus time. So, when doubling the load, the battery will typically last significantly less than half the time. -
Page 20: Instructions For Continued Airworthiness
SECTION 5 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS DISPATCH VERIFICATION AND IN-FLIGHT MONITORING The TB44 typically serves two primary purposes on an aircraft: engine start and emergency backup power. Availability for Engine Start: In order to attempt an engine start, user must verify that the “BATT OK”... -
Page 21: Create A Log File
D. Visually inspect the battery connectors, including the power terminals, RTD Temp connector and Comm/Service connector. Verify that no connectors are loose and there are no signs of damage, wear or corrosion. E. If any of the above conditions are present, the unit must be evaluated and tested for repair or replacement by an authorized repair facility. - Page 22 iii. Configure PuTTY using the following steps and parameters: a. Select “Serial” under the “Connection” items from the navigation list on the left b. For “Serial line to connect to”, enter: COM1 NOTE: If you are using a USB connection, the serial input may not be COM1. Review the Ports category in the computer’s Device Manager to verify.
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Page 23: Torque Verification 213
CONDUCTIVE TOOL (plastic or wood) to press the button and reset the fault. If the fault reappears, contact True Blue Power for further instruction. It is recommended to record the module number and fault reset action in the aircraft maintenance log for future reference. -
Page 24: Charging
5.2.4 CHARGING *** WARNING *** The power terminals of the TB44 are always active and energized. DO NOT SHORT TERMINALS AT ANY TIME! Extreme care and caution should be used when handling and connecting to the unit. Danger of short circuit and subsequent arc flash, electrical burns or equipment damage can occur if not handled properly. -
Page 25: Capacity Update
The cells, electronics, and other components that comprise the TB44 battery are not user replaceable items. Therefore, data is not available from the manufacturer to conduct field repairs. Contact True Blue Power for return to manufacturer for service. Rev A, April 29, 2014... -
Page 26: Storage Information
End of life is determined when the unit fails to meet the minimum capacity requirement of the aircraft as tested during the capacity verification per Section 5.2.5. In the event that the unit exhibits failure, insufficient capacity or expired life, contact an authorized True Blue Power maintenance provider for repair, exchange or replacement. Visit www.truebluepowerusa.com... -
Page 27: Appendix 1
PART NUMBER: 6430044-( ) NOMENCLATURE: Advanced Lithium-ion Aircraft Battery TSO APPROVALS: C179a MANUFACTURER: True Blue Power division of Mid-Continent Instrument Co., Inc. ADDRESS: 9400 E. 34 St. North, Wichita, KS 67226, USA MANUFACTURERS SPECIFICATIONS: Minimum Performance Specifications: TS502 , TDS502...
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