True blue power 6430202-1, 6430202-4, 6430202-2, 6430202-3, 6430202-5 Installation Manual And Operating Instructions

Installation Manual and Operating Instructions

TA202 Series

High Power USB Charging Port

True Blue Power

Mid-Continent Instrument Co., Inc.
dba Mid-Continent Instruments and Avionics
9400 E. 34
Wichita, KS 67226 Manual number 9017899
PH [phone] FX [phone] Revision G, June 6, 2019

th

®

is a division of Mid-Continent Instrument Co., Inc.

Street N.

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 Street N.

Wichita, KS 67226 USA

PH [phone]
FX [phone]

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 reference and the page
number. Send your comments to:

True Blue Power

c/o Mid-Continent Instrument Co., Inc.

Attn: Technical Publications

9400 E. 34th Street N.

Wichita, KS 67226 USA

PH [phone]
FX [phone]

All products produced by Mid-Continent Instrument, Co., Inc., including those identified as Mid­Continent Instruments and Avionics or True Blue Power, are designed and manufactured in
Wichita, KS, USA.

© Copyright 2019

Mid-Continent Instrument Co., Inc.

Rev G, June 6, 2019 2 Manual Number 9017899

REVISION HISTORY

Rev. Date Approved Detail

A 03/14/16 BAW Initial release.
B 04/25/16 CAS Updated formatting, added AEH statement to table 1.3
C 05/10/16 BAW Added single port unit mounting options, removed

configurations table.
D 06/23/16 ScH Added two screws (1/4”) to included connector kit.
E 01/04/17 BAW Updated to include new mounting option. Added 1.2.4.
F 05/07/19 VAA Added single rear mount with cover plate option.
G 06/06/19 VAA Updated figure 3.9 and added rear mount with circular cover

plate options.

Rev G, June 6, 2019 3 Manual Number 9017899

TABLE OF CONTENTS

SECTION 1 GENERAL DESCRIPTION

1.1 INTRODUCTION

1.2 TECHNICAL SPECIFICATIONS

1.2.1 ELECTRICAL ATTRIBUTES

1.2.2 PHYSICAL ATTRIBUTES

1.2.3 QUALIFICATIONS

1.2.4 CONFIGURATIONS

SECTION 2

PRE-INSTALLATION CONSIDERATIONS

2.1 COOLING

2.2 EQUIPMENT LOCATION

2.3 ROUTING OF CABLES

2.4 LIMITATIONS

2.5 MODIFICATIONS

SECTION 3

INSTALLATION PROCEDURES

3.1 GENERAL INFORMATION

3.2 UNPACKING AND INSPECTING

3.3 CABLE HARNESS

3.3.1 WIRE GAUGE SELECTION

3.3.2 PIN ASSIGNMENT INFORMATION

3.3.3 HARNESS VERIFICATION

3.4 MOUNTING

3.5 INSTALLATION COMPLETION

SECTION 4

OPERATION

4.1 ELECTRICAL PERFORMANCE

4.2 PROTECTIVE FEATURES

4.2.1 SHORT CIRCUIT PROTECTION

4.2.2 OVER-CURRENT PROTECTION

4.2.3 LOW INPUT VOLTAGE SHUTDOWN

4.2.4 OVER-TEMPERATURE

SECTION 5

CONFORMANCE

5.1 CONTINUED AIRWORTHINESS STATEMENT

5.2 ENVIRONMENTAL QUALIFICATION STATEMENT

Rev G, June 6, 2019 4 Manual Number 9017899

SECTION 1 GENERAL DESCRIPTION

1.1 INTRODUCTION

The TA202 Series High Power USB Charging Port is a certified accessory that converts 10 to 32 volts of
DC electrical input from the aircraft to standard 5 volt power for any electronic product that charges using
a USB connector. The TA202 provides one or two Universal Serial Bus-A or C (USB-A or USB-C) ports
and can be rear mounted or front mounted in a variety of locations throughout the aircraft. The new
“Type-C” USB port design is a smaller port that accommodates the latest consumer electronic devices on
the market. Among other features, the Type-C connector accepts reversible cable plugging with no ‘up’ or
‘down’ requirement for cable orientation. The unit is certified to FAA TSO C71 and qualified to multiple
RTCA DO-160 requirements, providing confidence and allowing installation in the cockpit or cabin.

This High Power USB Charging Port is designed as a DCP (Dedicated Charging Port) to industry­standard protocol per the USB Battery Charging 1.2 Compliance Plan. It also complies with the higher
power requirements of USB Power Delivery 2.0. Newer electronics, such as the Apple iPad
and larger devices can accept or may require 2.1 amps or more to charge and operate. As a high power
DCP, the TA202 can provide up to 3.0 amps of power to charge USB devices, including the higher
demand products. Most dual USB chargers typically provide 1.0 amp on one port and 2.1 amps on the
second port, but the TA202 can provide 3.0 amps to both ports simultaneously (for dual port units). The
unit has built-in protections for short circuit, over-current, and low voltage conditions. It is designed to
protect against reverse polarity installation and has temperature monitoring and shutdown capability,
allowing the unit to handle unforeseen conditions safely.

Small, compact and powerful, with plenty of installation flexibility, the TA202 is an ideal choice as a highly
useful and effective addition to any aircraft.

®

, other tablets

Rev G, June 6, 2019 5 Manual Number 9017899

1.2 TECHNICAL SPECIFICATIONS

1.2.1 Electrical Attributes

Input Voltage: 10-32 VDC
Input Power: 35 watts max; 2.5 amps @ 14 VDC / 1.25 amps @ 28 VDC

Output Voltage: 5 VDC ±0.25 per port
Output Power: 3.0 amps max per port
Efficiency: ~90% nominal

Table 1.1

1.2.2 Physical Attributes

Weight: 1.3 oz. (38 g) (dual port), 0.8 oz. (23 g) (single port)
Dimensions (Dual Port Units): (not
including connector)
Dimensions (Single Port Units): (not
including connector)
Charging Ports Type: USB Standard-A or USB Standard-C
Connector Kit: MCIA P/N 9017960
Mounting: Panel mount; rear or front

1.50 inches wide X 1.03 inches high X 1.25 inches deep

1.50 inches wide X 0.52 inches high X 1.25 inches deep

Table 1.2

1.2.3 Qualifications

Certification: FAA TSO-C71

EASA ETSO-C71

Environmental Qualification: RTCA DO-160G Environmental Category

F1S2BB[(RCC1)(UG)]XXXXXXY[B(XX)]BRXXMXXXAX

Airborne Electronic Hardware: RTCA DO-254, Design Assurance Level E

Table 1.3

1.2.4 Versions

Part Numbers

Non Lighted Lighted

6430202-1 6430202-11 Rear
6430202-2 6430202-12 Bottom
6430202-3 6430202-13 Rear
6430202-4 6430202-14 Bottom
6430202-5 6430202-15 Rear
6430202-6 6430202-16 Bottom
6430202-7 6430202-17 Rear
6430202-8 6430202-18 Bottom
6430202-9 6430202-19 Rear

6430202-10 6430202-20 Bottom

Table 1.4

Power Input

Location

USB Connector

Dual: Type A+Type C

Dual: Type C+Type C

Dual: Type A+Type A

Single: Type C

Single: Type A

Rev G, June 6, 2019 6 Manual Number 9017899

SECTION 2 PRE-INSTALLATION CONSIDERATIONS

2.1 COOLING

No external cooling is required. The unit will become warm when in use. This is normal and within
operational parameters. No special mounting considerations are required; however, mounting to a metal
surface can help dissipate any heat generated and extend the life of the product.

2.2 EQUIPMENT LOCATION

The TA202 High Power USB Charging Port is designed for mounting flexibility, allowing for installation in
the cockpit or in the cabin. It is designed for panel mounting and can be installed in a rectangular
configuration or, with an available installation kit, can be front mounted with a cosmetic cover plate. An
instrument mounting adapter bracket is also available to easily mount the unit in a standard 2-inch round
instrument opening that may already exist in the cockpit panel. There are two versions to choose from
which allow the input connector to be located either on the rear of the unit or from the bottom.

The unit can be mounted in any orientation. Clearance should be provided for the mating connector which
may require an additional inch beyond the rear of the unit.

2.3 ROUTING OF CABLES

Avoid sharp bends in cabling and routing near aircraft control cables. Avoid close proximity and contact
with aircraft structures, avionics equipment or other obstructions that could chafe wires during flight and
cause undesirable effects.

2.4 LIMITATIONS

Environmental qualifications were verified per RTCA DO-160, Revision G in lieu of those identified within
the minimum performance standards (MPS) of the TSO.

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, specification of the article and deviations as listed above. TSO
articles must have separate approval for installation in an aircraft. The article may be installed only
according to 14 CFR part 43 or the applicable airworthiness requirements.

The USB Type-C interface is an exciting new connector for electronic devices. Beyond the physical
format of the Type-C connector, it also allows for a variety of interface options when communicating with
compatible devices. This device-to-charger communication is defined within the USB 3.1 Specification
and Power Delivery 2.0 standards. However, manufacturers of consumer electronic devices and/or cables
may choose to implement proprietary versions or modifications of the USB standards to operate
specifically with their own charging equipment. The TA202 has been tested with and supports a wide
variety of devices now emerging on the open market. However, compatibility with all devices may not be
guaranteed. True Blue Power continues to be proactive in evaluating new devices and strives to
continually improve the product as needed to serve the vast majority of USB Type-C electronic products.

Rev G, June 6, 2019 7 Manual Number 9017899

2.5 MODIFICATIONS

Each TA202 series High Power USB Charging Port (part number 6430202-( )) has a nameplate that
identifies the manufacturer, model, part number, description, certifications and technical specifications of
the unit. The nameplate also includes the “MOD” or modification status representing notable changes in
the design of the unit. The following identifies each “MOD” or modification.

Modification (MOD) 0 is the initial release of the TA202 series High Power USB Charging Port and is
identified on the nameplate by the lack of marking on the MOD numbers 1 through 9 (i.e. 1-9 are visible).

All subsequent modifications are identified on the nameplate by the marking/blacking out of that particular
MOD number (i.e. for MOD 1, the number 1 is not visible and 2-9 are visible). See Figure 2.1 for examples.

For additional details regarding design changes to the TA202 series High Power USB Charging Port,
refer to individual Service Bulletins associated with each MOD.

MOD 0 MOD 1

Figure 2.1

Nameplate and MOD Status Examples

Rev G, June 6, 2019 8 Manual Number 9017899

SECTION 3 INSTALLATION PROCEDURES

3.1 GENERAL INFORMATION

This section contains interconnect diagrams, mounting dimensions and other information pertaining to the
installation of the TA202 Single and Dual USB Charger. After installation of cabling and before installation
of the equipment, ensure that power and ground are applied to the proper pins specified in Section 3.3.2,
Pin Assignment Information.

3.2 UNPACKING AND INSPECTING EQUIPMENT

When unpacking this equipment, make a visual inspection for evidence of any damage that may have
occurred during shipment. The following parts should be included:

a. High Power USB Charging Port MCIA P/N 6430202-( )
b. Installation Manual MCIA P/N 9017899
c. Connector Kit MCIA P/N 9017960

i. Mating Connector, 2-pin

ii. Pins (4) (2 required, 2 spares)
iii. Screws, #4-40 x 1/4 flat-head (2)
iv. Screws, #4-40 x 5/16 flat-head (2)

Optional Equipment Available:

a. Front Mount Installation Kit MCIA P/N 9017897
b. Instrument Mount Adapter Kit MCIA P/N 9017947
c. Dual Rear Mount Installation Kit MCIA P/N 9017958
d. Single Rear Mount Installation Kit MCIA P/N 9019351-1
e. Dual Rear Mount Circular Cover Plate MCIA P/N 9019384-2
f. Single Rear Mount Circular Cover Plate MCIA P/N 9019384-1

Equipment Not Provided:

3.3 CABLE HARNESS

Construct the cable harness following the instructions outlined below and per Figure 3.1.
Refer to Section 2: Pre-Installation Considerations, for routing precautions.

3.3.1 Wire Gauge Selection

Note: Pins should be crimped using Molex Hand Crimp Tool 63819-0000 (Preferred), 63811-2800
(obsolete) or 11-01-0200 (obsolete). See the Molex Hand Crimp Tool User Manual for crimp
procedures.

a. Cable Harness Wire See Section 3.3.1 for specifications
b. Circuit Breaker Recommendation 3 amp (2 amp may be sufficient for 28V aircraft)

Use of PTFE, ETFE, TFE, Teflon or Tefzel insulated wire is recommended for aircraft use.
The wire harness should utilize 20-24 AWG stranded wire. Refer to table 3.1 below.

Wire Gauge Wire Length
20 AWG stranded wire 35 ft
22 AWG stranded wire 22 ft
24 AWG stranded wire 14 ft

Table 3.1

Wire Gauge and Length

Rev G, June 6, 2019 9 Manual Number 9017899

3.3.2 Pin Assignment Information

INPUT POWER:

Pin A (keyed) – Positive DC input +10 to 32 VDC power

Pin B – Negative DC input / ground

3.3.3 Harness Verification

Note:

The TA202 has built-in reverse polarity protection for the
power connector. If Pins A and B are swapped, the unit will not
be damaged, but will also not function.

Once the cable harness is prepared, prior to connecting the
TA202, activate the aircraft power bus and use a multimeter to
verify that aircraft power and ground is supplied with appropriate
voltage on the proper pins within the mating harness.

Pin A

(rear input versions)

Pin B

3.4 MOUNTING

The TA202 can be installed in one of five ways:

 rear mount, rectangular

1 2 3

 instrument mount
 front mount, decorative cover plate
 rear mount, decorative cover plate
 rear mount, circular cover plate

1

Installation kit required. See Section 3.2, Optional Equipment Available for part

number reference

2

Dual port units only

3

Black anodized

4

Brushed aluminum, bare (appropriate for additional plating/finish)

1 2 4

1 4

1 3

Pin A

(bottom input versions)

Figure 3.1

Power Input

Pin B

Prepare the panel cutout as shown in Figures 3.4 thru 3.11 per the selected mounting option.

 Countersinks shown in the panel cutouts for flat head screws are optional. However, flat head

screws are provided for flush appearance. For Rear Mount Cover Plate Installations, countersinks in
the panel are required.

 For Rear Mount Installations:

Mounting screws length MUST be between (PT +0.150”) and (PT +0.210”). [PT = panel thickness]
Mounting screws provided with the unit are 0.24” and 0.31”. (accommodates 0.030” to 0.160” PT)
For PT greater than 0.125, the USB connector will be below the surface of the panel (below flush).



For Front Mount Installations: Minimum panel thickness is 0.04”. Maximum panel thickness is 0.20”.

 For Rear Mount Installation with Cover Plate: Panel thickness greater than 0.065 will cause the USB

connector to be below the surface of the Cover Plate (below flush).

3.5 INSTALLATION COMPLETION

Prior to operating the unit in the aircraft, it is recommended to verify the output and functionality of the
unit. In order to prevent accidental damage to other systems, it is not recommended to attach the output
to other equipment prior to verification. Verify the output of the unit at the terminating end of the cable with
a multimeter to ensure proper voltage and polarity. Once verified, installation can be completed and
functionality should be checked.

Rev G, June 6, 2019 10 Manual Number 9017899

TA202 Outline Drawing

(dual port, rear input version shown)

Figure 3.2

Figure 3.3

TA202 Outline Drawing

(single port, rear input version shown)

Panel Cutout Detail

Figure 3.4

Dual Port Rear Mount Installation

Rev G, June 6, 2019 11 Manual Number 9017899

g

Step 1: attach adapter

plate to unit

Step 2: attach adapter plate to

Step 1: install

grommets

Step 2: place screw through

mounting plate (x4) with front

recess set to panel thickness

(see Gap Set detail view)

panel

Figure 3.5

Dual Port Instrument Mount Installation

Step 3: loosely attach mounting plate to unit

screws included with unit

usin

Gap Set Detail

Step 4: twist unit through

Step 5: Insert top and bottom screws

panel cutout.

Tighten screws (x2)

Step 6: Apply adhesive backing, align pins

on rear of cover plate into holes on

mounting plate and press firmly

Figure 3.6

Dual Port Front Mount Installation

Rev G, June 6, 2019 12 Manual Number 9017899

Step 1: install

grommets

Latch and front of unit - flush

Step 2: place screw through

mounting plate (x4) with front

latches set flush to front of unit

(see detail view)

Flush Detail

Step 4: place adhesive on

panel (x2) in locations

shown and remove backing

Figure 3.7

Dual Port Rear Mount Installation with Cover Plate

Step 5: align pins on rear

of cover plate into holes on

panel and press firmly

Step 3: place unit in panel

cutout and secure with
screws (x2)

provided with unit

Circular Cover Plate is
Ø1.50

Note: screws provided

with unit

Figure 3.8

Dual Port Rear Mount Installation with Circular Cover Plate

Rev G, June 6, 2019 13 Manual Number 9017899

Port protrusion
toward top

Figure 3.9

Single Port Rear Mount Installation

Step 4: place adhesive on

Step 2: Place mounting

plate over port
protrusion

panel (x2) in locations

shown and remove

backing

Step 3: place unit in panel cutout

and secure with screws (x2)
provided with unit

Step 1: Insert grommets

Step 5: align pins on rear of cover

Figure 3.10

Single Port Rear Mount Installation with Cover Plate

Note: screws provided

Figure 3.11

with unit

Single Port Rear Mount Installation with Circular Cover Plate

Rev G, June 6, 2019 14 Manual Number 9017899

plate into holes on panel
and press firmly

Circular Cover
Plate is Ø1.35

SECTION 4 OPERATION

4.1 ELECTRICAL PERFORMANCE

The TA202 Series High Power USB Charging Port converts an aircraft (DC) input voltage within the range
specified to a 5V (DC) output. This output power is applied to a single or dual USB-A or USB-C connector
in accordance with the USB Implementers Forum.

The USB D+ and D- data lines communicate with the USB portable device to tell the device it is a
dedicated charging port (DCP), capable of a higher current than a standard USB port. This allows the
USB portable device to draw up to 3.0 Amps.

The unit is designed as a DC-to-DC converter with a series switch on each output to regulate current
applied to that output. Each series switch independently reduces the output current to a safe level if the
USB portable device draws excess current, is shorted or has a fault.

If the temperature of the TA202 becomes elevated due to a fault or excessive load, the device will
seamlessly communicate with the USB portable device to lower the charge current. This allows the device
to continue charging while the unit returns to a temperature within designed limits. When the temperature
returns to a safe level the TA202 will automatically reestablish the higher charge current level with the
device and continue charging.

4.2 PROTECTIVE FEATURES

4.2.1 Short Circuit Protection

The TA202 is capable of surviving a short circuit event without permanent damage. The unit
goes into an over-current condition so that the average current is significantly reduced and
the device is protected.

4.2.2 Over-Current Protection

The TA202 monitors the current draw individually on each port. During an over-current
condition the voltage is reduced. If the voltage falls below 3.8 VDC the output is turned off for
a period of 12 seconds. The output is then checked for continued over-current conditions
every 16 milliseconds. This condition is referred to as a hiccup mode. The device stays in this
mode until the over-current condition is removed, then returns to normal operation.

4.2.3 Low Input Voltage Shutdown

If the input voltage applied to the TA202 drops below 10 VDC the unit will shut down until the
applied voltage returns to a level within range.

4.2.4 Over-Temperature

When the internal temperature of the TA202 exceeds designed thresholds, the unit will shut
down and stop providing power. When the temperature returns to an acceptable level the unit
will automatically begin providing power as required, up to a full charge of 3.0 amps.

Rev G, June 6, 2019 15 Manual Number 9017899

SECTION 5 CONFORMANCE

5.1 CONTINUED AIRWORTHINESS STATEMENT

No periodic scheduled maintenance or calibration is necessary for continued airworthiness of the TA202
series Single and Dual USB Charger. If the unit fails to perform to specifications, the unit must be
removed and serviced by Mid-Continent Instruments and Avionics or their authorized designee.

5.2 ENVIRONMENTAL QUALIFICATION STATEMENT

MODEL NUMBER: TA202 Series PART NUMBER: 6430202-( )
NOMENCLATURE: Single and Dual USB Charger
CERTIFICATION: FAA TSO-C71
MANUFACTURER: True Blue Power, a division of Mid-Continent Instrument Co., Inc.
ADDRESS: 9400 E. 34th St. North, Wichita, KS 67226, USA.

MANUFACTURERS SPECIFICATIONS:

Minimum Performance Specifications: TS365 (03/14/2016), TDS365 (03/14/2016)_______________
Qualification Test Reports: QTR2604-2608, QTR2615-2618, QTR2621, QTR2625___________________

RTCA DO-160: Rev G, dated 12/08/10 DATES TESTED: 02/2016-03/2016

CONDITIONS SECTION DESCRIPTION OF TEST

Temperature and Altitude
Low Temperature
High Temperature
High Temperature
Altitude
Temperature Variation 5 Category S2
Humidity 6 Category B
Operational Shock and Crash Safety 7 Category B
Vibration 8 Fixed Wing: Category R, Curves C, C1
Explosion 9 Category X
Waterproofness 10 Category X
Fluids 11 Category X
Sand and Dust 12 Category X
Fungus 13 Category F
Salt Spray 14 Category X
Magnetic Effect 15 Category Z
Power Input 16 Category B(XX)
Voltage Spike 17 Category B
Audio Freq Conducted Susceptibility 18 Category R
Induced Signal Susceptibility 19 Category X
Radio Frequency Susceptibility 20 Category X

Emission of Radio Frequency Energy 21 Category M
Lightning Induced Transient Susceptibility 22 Category X
Lightning Direct Effects 23 Category X
Icing 24 Category X
ESD 25 Category A
Fire, Flammability 26 Category X

REMARKS:

Sections 4: Normal operating low temperature was tested to and complies with -40°C. (Category F1 Continuous Operating
Low Temperature requirement is -20°C.)

4

4.5.1

4.5.3

4.5.4

4.6.1

Category F1

Operating Low Temp = -40°C

Short Time Operating High Temp = +70°C

Normal Operating High Temp = +55°C

Altitude = 55K feet

Rev G, June 6, 2019 16 Manual Number 9017899