True blue power TB40 Series Installation Manual And Operating Instructions
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True blue power TB40 Series Installation Manual And Operating Instructions

Advanced lithium-ion battery
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Revision C • May 21, 2020

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Summary of Contents for True blue power TB40 Series

  • Page 1 Revision C • May 21, 2020...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 GENERAL DESCRIPTION 1.1 INTRODUCTION 1.2 PHYSICAL ATTRIBUTES 1.3 UNIT ARCHITECTURE 1.4 TECHNICAL SPECIFICATIONS 1.5 IMPORTANT SAFETY INFORMATION SECTION 2 PRE-INSTALLATION CONSIDERATIONS 2.1 COOLING 2.2 EQUIPMENT LOCATION 2.3 ROUTING OF CABLES 2.4 LIMITIATIONS 2.5 MODIFICATION SECTION 3 INSTALLATION 3.1 GENERAL 3.2 PRE-INSTALLATION INSPECTION 3.3 PARTS...
  • Page 4 REVISION HISTORY Date Detail Approved 08/02/2019 Initial release. Revised EQF, added DO-311A Compliance Qualification 10/01/2019 Form and provided additional limitation details (sec 2.5) Updated style and brand to meet Marketing and Engineering guidelines. Added downloadable event log feature and instructions to 05/21/2020 load/download custom configuration parameters.

  • Page 5: Section 1 General Description

    SECTION 1 GENERAL DESCRIPTION INTRODUCTION The TB40 series Advanced Lithium-ion Battery, part number 6430040-( ), is designed to deliver high current capability to start piston and light turbine aircraft engines and subsequently, provide power to the aircraft electrical bus in the event of generator function loss. The TB40 is a ®...

  • Page 6: Unit Architecture

    UNIT ARCHITECTURE The unit is comprised of two primary building blocks: • Battery cell modules with on-board monitoring, logic, and protections • Battery Management System (BMS) with control and communication functions Each battery module consists of thirty-two (32) cells arranged as eight (8) groups of four (4) parallel cells, connected in series.

  • Page 7: Technical Specifications

    TECHNICAL SPECIFICATIONS Electrical Attributes Power Input 28.8 volts DC Nominal, 400A Max Power Output 26.4 volts DC Nominal, Continuous Current 525A; Power Peak Current (I ) 1390A (at 18.5V CV discharge); Power Rated Current (I ) 1125A (at 18.5V CV discharge) Battery Capacity 40 amp hours (Ah) @ 23°C (Beginning of Life)
  • Page 8 13.0 13.8 14.7 12.1 Figure 1.1 Outline Drawing Manual Number 9019288 • Revision C, May 21, 2020...

  • Page 9: 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 10 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, applicable U.S.

  • Page 11: Section 2 Pre-Installation Considerations

    EQUIPMENT LOCATION The True Blue Power Advanced Lithium-ion Battery is 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.

  • Page 12: Limitiations

    LIMITIATIONS The conditions and tests for TSO approval of this article are minimum performance standards. Those installing this article, on or in a specific type or class of aircraft, must determine that the aircraft installation conditions are within the TSO standards. TSO articles must receive additional installation approval prior to being operated on each aircraft.

  • Page 13: Section 3 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 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 14: Installation

    INSTALLATION WARNING DO NOT SHORT TERMINALS AT ANY TIME! Extreme care and caution should be applied 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 15 1-½ inch Vent Port Quick Disconnect Receptacle per MS3509 (MIL-PRF-18148/3) ¼ -20 Threaded Ground Lug 18-pin Data Communication USB Access Cover Figure 3.1 Connection Features Figure 3.2 Connection Locations Manual Number 9019288 • Revision C, May 21, 2020...
  • Page 16 Communication Connector (18-pin) Description Analog SOC Battery Disable Input Heater Disable Input RTD-1A RTD-1B RTD-2A RTD-2B Figure 3.3 Communication Connector ARINC 429 (A) Service Discrete Fault Discrete Heating Discrete Min Capacity Discrete Analog Ground Spare Spare ARINC Shield Engine Start Discrete ARINC 429 (B) Table 3.2 Communication Connector Pinout...
  • Page 17 3.4.2 Securing the Unit The battery is designed to be secured in the aircraft using hold-down rods. The hold-down features are integrated into the lid of the battery. The hold-down consists of a slot for the hold-down rod, open to the outboard sides, and two perpendicular slots on each side to keep the rod vertical using an alignment washer.
  • Page 18 A Vent Kit is available that includes a high temperature vent hose and hose attachment hardware (see Section 3.3.2). Contact True Blue Power for potential alternatives. The vent tube should be properly and securely attached to an aircraft exit point which would allow any gaseous emissions to be vented overboard.
  • Page 19 (see Section 5.2.2). A fixed file format and file name with valid data parameters is required to be loaded onto the battery. Invalid file formats or data will be rejected and not allowed to load. Contact True Blue Power to coordinate parameter and file creation for your application.
  • Page 20 Control Mode (see Section 4.3.2). To download the event log onto a USB flash drive, follow instructions in Section 5.2.4. Contact True Blue Power for further details with respect to the event log. Manual Number 9019288 • Revision C, May 21, 2020...

  • Page 21: Section 4 Operation

    SECTION 4 OPERATION DESCRIPTION The True Blue Power TB40 Advanced Lithium-ion Battery is designed to supply power for starting an aircraft engine and providing emergency backup power to aircraft systems in the event of primary power generation loss. It utilizes rechargeable Nanophosphate lithium-ion cells in a parallel and series configuration to provide the specified voltage, power and total energy capacity.
  • Page 22 Switch Board The Switch board incorporates high-power transistors used to enable and disable charging or discharging of the unit. This allows for the unit to take action based on its own monitoring and protections to prevent damage to the product. The Switch board also contains the current limiting functionality.
  • Page 23 4.2.5 Case and Hardware The mechanical construction plays a key role in the design to specifically support optimal functionality, mitigate and contain any potential failure, and withstand the expected aircraft environment. Material selections, component design, assembly processes and test all contribute to the performance and safety of the product.

  • Page 24: Operational Modes

    OPERATIONAL MODES The battery has three basic modes of operation: Sleep Mode, Control Mode, and Active Mode. These modes, and associated functionality, are explained below. 4.3.1 Sleep Mode Sleep Mode is used to disable the power output of the battery and reduce internal energy consumption to preserve resting state of charge.
  • Page 25 4.3.3 Active Mode In Active Mode, the battery is fully functional and available to provide power barring no protections are being enforced and the battery is operating properly. In Active Mode, the battery continuously monitors all cells and battery conditions to manage operation and mitigate exceedances as needed through its various protection methods.
  • Page 26 Engine Start The TB40 battery can provide a peak current of 1500A for the purpose of aircraft engine starting. It will provide a maximum of 1120A for up to 15 seconds and below 525A continuously. The low internal impedance of the Nanophosphate lithium-ion chemistry allows extremely high current delivery while maintaining higher voltage than traditional battery types.
  • Page 27 Heating The battery is designed to support an engine start from as low as -5°C (23°F), depending upon the engine start profile without pre-heat required. Below this temperature, the performance of the unit begins to decrease in current and energy delivery as the electrolyte in the cells begins to thicken and the internal impedance increases to retard ion flow.
  • Page 28 Battery Protections The TB40 series Advanced Lithium-ion Battery has built-in protections for conditions that may exceed specified operating limits: Protection Parameter(s) Action Recovery Under Voltage If discharge current < 160A and Discharging Battery Voltage > 20VDC and (low current) battery voltage < 16VDC or cell disabled Cell string voltage >...

  • Page 29: Battery Communication

    BATTERY COMMUNICATION When in Active Mode, the Advanced Lithium-ion Battery presents multiple status indications and data to the aircraft for display and monitoring on appropriate systems. These are supplied as either serial, discrete, or analog signals. The various outputs and their definition are supplied in Sections 4.41 through 4.43.
  • Page 30 4.4.2 Discrete Communication Signals Discrete signals are available to provide both basic battery status and simplified indication of battery readiness specific to the aircraft’s requirements. In some cases, where serial data cannot be integrated with the aircraft’s avionics or other messaging systems, the discrete battery status signals can be used to meet minimum regulatory annunciation requirements for lithium batteries.
  • Page 31 4.4.3 Serial Communication Signals The battery generates a sophisticated array of situational status and data available for real- time reporting and awareness. This is provided to the aircraft in the form of serial data using the ARINC 429 protocol. Below is the definition of the data the battery provides. Contact the manufacturer to receive additional details associated with the format of the data provided for each label.
  • Page 32 ARINC 429 Label Format Definition Transmit Interval (ms) Label Parameter Name Data Type Range Units Resolution Bits Battery Discrete DISCRETE Outputs DC Current ± 4096 0.125 DC Voltage 0.001953 Battery Temperature ± 512 0.125 1000 2000 Deliverable Energy 0.0625 1000 2000 Capacity 0.0625...
  • Page 33 4.4.4 On-board Status Indicator The on-board Status Indicator can provide active or on-demand health status and state of charge. It can also be used to manually transition the battery from Sleep Mode to Active Mode by pressing the STATUS button. This can be used to check status, state of charge, or to initiate the heaters to pre-heat the battery (if the battery is cold).

  • Page 34: Performance

    PERFORMANCE 4.5.1 Capacity Capacity is the measurement of the energy stored in the battery and most often is used to determine the length of time a particular electrical load can be operated. A standard measure of rechargeable battery capacity is the current-over-time performance (measured in amp- hours) called the “C”...
  • Page 35 4.5.2 Temperature Performance The TB40 incorporates cell technology that performs well over temperature extremes. It can support an engine start from as low as -5°C (23°F), depending upon the engine start profile. Cold temperature performance is extended to as low as -40°C (-40°F) when using the internally powered heater and allowing the appropriate pre-heat time.

  • Page 36: Section 5 Conformance

    SECTION 5 CONFORMANCE DISPATCH VERIFICATION AND IN-FLIGHT MONITORING The main ship battery typically serves two primary purposes: engine start and emergency backup power. • Engine Start: In order to attempt an engine start, the user should verify that the FAULT signal is not active.
  • Page 37 Update Status Light Status Idle White Reading / Writing USB Storage Blue Operation In Progress Yellow Operation Successful Green Operation Error Table 5.1 Service Light Status 5.2.1 Software Update A. Download the approved software update file from https://www.truebluepowerusa.com/software-updates/ to the root directory of a standard FAT formatted USB 2.0 compatible flash drive, ensuring the filename is exactly update.muf.
  • Page 38 A. To verify custom programmable parameters or the currently loaded software version, place an empty text file named getcfg.cmd onto the root directory of a standard FAT formatted USB 2.0 compatible flash drive. Contact True Blue Power if you have questions regarding creation of the getcfg.cmd file.
  • Page 39 G. The USB flash drive will now have a file named installer.txt that can be viewed with any text editor. In addition to validating the custom programmable parameters, the installer.txt file also provides a timestamp when the installer.txt file was created and also displays the battery software version.

  • Page 40: Optional Service

    OPTIONAL SERVICE The True Blue Power Advanced Lithium-ion Battery is a maintenance-free product. No scheduled maintenance is required once installed. The procedures described in this section are included for verification of battery performance only on an as-needed, or on-condition, basis. Note, however, that the battery MUST be recharged every six (6) months when not in use.
  • Page 41 Alternate Method: A. Using a Christie RF80-K, set the Mode Switch to “CHARGE” and the Charge Method Switch to 12 (CONSTANT POTENTIAL / CELLS LEAD ACID). Adjust charge current to 40A. B. With this method, the voltage will start at approximately 26VDC and a current of 40A. It will rise to approximately 28.8VDC as the current drops.

  • Page 42: Component Service

    Manual Capacity Check If there is any reason to suspect the accuracy of the reported capacity, a manually measured capacity check can be performed. Ensure that the unit is charged per Section 5.3.2. Apply a constant current load of 40A to discharge the battery pack. (Capacity check should be conducted at 23°C ±3°C (68-79°F) for best results.) Monitor the time (in minutes and seconds) from initially applying the constant current load in Step B until the unit the battery is nearly depleted and turns off...
  • Page 43 Rechargeable lithium-ion batteries must be stored in a dry, well-ventilated area. They must not be kept in the same area as highly flammable materials. The unit can be stored in the same area as other battery chemistries. The battery does not emit or absorb any gas during storage, transportation, or during normal operating conditions.

  • Page 44: End Of Life

    END OF LIFE Estimated life for the True Blue Power Advanced Lithium-ion Battery is expected to exceed six (6) years. The unit has reliably demonstrated over 20,000+ simulated engine starts and subsequent charge cycles. The cells themselves are designed for a useful life of up to ten (10) calendar years.

  • Page 45: Do-311A Compliance Qualification Form

    MODEL NUMBER: TB40 _ PART NUMBER: 6430040-( ) DESCRIPTION: Advanced Li-Ion Main Ship Battery CERTIFICATION: FAA TSO-179b MANUFACTURER: True Blue Power, a division of Mid-Continent Instrument Co., Inc. ADDRESS: 9400 E. 34 St. North, Wichita, KS 67226, USA SPECIFICATION: Test Specification (TS) 713 Test Data Sheet (TDS) 713...

  • Page 46: Do-160 Environmental Qualification Form

    PART NUMBER: 6430040-( ) DESCRIPTION: Advanced Li-Ion Main Ship Battery CERTIFICATION: FAA TSO-179b MANUFACTURER: True Blue Power, a division of Mid-Continent Instrument Co., Inc. ADDRESS: 9400 E. 34 St. North, Wichita, KS 67226, USA. SPECIFICATION: Test Specification (TS) 713 Test Data Sheet (TDS) 713...

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