True Blue power TB 17 User Manual

Revision J • September 21, 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 [phone]

Fax [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 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

Wichita, KS 67226 USA

Phone [phone]

Fax [phone]

© Copyright 2017

Mid-Continent Instrument Co., Inc.

th

St. N.

Download the current
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1 Manual Number 9018047 • Revision J, September 21, 2020

TABLE OF CONTENTS

SECTION 1 GENERAL DESCRIPTION 4

1.1 INTRODUCTION 4

1.2 PHYSICAL

1.3 UNIT

1.4 TECHNICAL

1.5 IMPORTANT

SECTION 2 PRE-INSTALLATION CONSIDERATIONS 9

2.1 COOLING 9

2.2 EQUIPMENT

2.3 ROUTING

2.4 LIMITIATIONS 10

2.5 MODIFICATION 10

ATTRIBUTES 4

ARCHITECTURE 4

SPECIFICATIONS 5

SAFETY INFORMATION 7

LOCATION 9

OF CABLES 9

SECTION 3 INSTALLATION 11

3.1 GENERAL 11

3.2 PRE-INSTALLATION

INSPECTION 11

3.3 PARTS 11

3.4 INSTALLATION 12

SECTION 4 OPERATION 16

4.1 DESCRIPTION 16

4.2 OPERATIONAL

4.3 ACTIVE

MONITORING 18

MODES 16

SECTION 5 CONFORMANCE 19

5.1 DISPATCH VERIFICATION AND IN-FLIGHT MONITORING 19

5.2 ROUTINE

5.3 COMPONENT

5.4 STORAGE

5.5 END

MAINTENANCE 19

MAINTENANCE 21

INFORMATION 21

OF LIFE 22

5.6 DISPOSAL 22

5.7 ENVIRONMENTAL

QUALIFICATION STATEMENT 23

2 Manual Number 9018047 • Revision J, September 21, 2020

REVISION HISTORY

Rev Date Detail Approved

A 10/17/2013 Initial release. BAW
B 12/10/2013 Miscellaneous revisions to grammar and content. BAW
C 10/23/2015 Updates for MOD 1 monitoring signal definitions and other

BAW

miscellaneous revisions.

D 03/21/2016 Updates for MOD 2 battery operational characteristics;

BAW
added QTR 1727 and DO-160 Sections 10, 12 to Appendix
1 EQF.

E 04/22/2016 Added Modifications section (2.6). WVC
F 06/23/2017 Added 6430017-2 and associated references; revised

WVC
weight to 16.0 lbs; clarified battery storage charge interval.

G 11/01/2017 Removed technical content not required for Installation and

WVC
Operating Instructions.

H 05/04/2020 Updated style and brand to meet Marketing and

DLR
Engineering guidelines. Section 1.5.1, updates to title and
symbols. Inserted Section 5.7, Environmental Qualification
Statement.

J 09/21/2020 Added 6430017-3 and -4 and associated references. VAA

3 Manual Number 9018047 • Revision J, September 21, 2020

SECTION 1 GENERAL DESCRIPTION

1.1 INTRODUCTION

The TB17 series Advanced Lithium-ion Battery, part numbers 6430017-( ), is 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 TB17

®

is a sophisticated power system that utilizes state-of-the-art Nanophosphate

lithium-ion battery
cell technology which provides improvements in performance, safety, life and weight when
compared to traditional or competing aircraft batteries. Consideration given to key electrical and
mechanical design principles yield compliance with regulatory standards and meet or exceed
industry expectations. The TB17 is a complete battery solution that provides significant value and
benefit to an aircraft designer, owner and operator.

The TB17 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 PHYSICAL ATTRIBUTES

The TB17 is a single, integrated component contained in a metal enclosure with positive and
negative power terminals and a 7-pin circular 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 three primary functional pieces:

 Battery modules
 “Switch” board; a printed circuit board assembly to control charging and discharging
 “Control” board; a printed circuit board assembly to serve as the battery management

system

Each battery module consists of twenty-eight (28) cells, arranged in four strings of seven parallel
cells connected in series. Two modules are connected in series to provide the total battery output.
The modules are designed identically and each includes multiple temperature monitors and a
heater. The cells are connected with welded bus bars which contain an individual fuse for each cell
in the module.

The Switch board incorporates the ability to enable and disable charging or discharging depending
on the health of the battery and associated conditions. It also contains a charge limiting function
and current monitoring.

4 Manual Number 9018047 • Revision J, September 21, 2020

The Control board is the battery management system. The discrete logic circuitry monitors the
battery functions and protects against such conditions as short circuit, over-temperature, over­discharge and others. The Control board also generates the battery status signals that are
accessed through the 7-pin communication connector for cockpit monitoring and heater
functionality control.

Additional components in the unit include Resistance Temperature Detectors (RTDs) that produce
analog electrical signals accessible through the 7-pin connector for redundant temperature
monitoring. There are two RTDs in the 6430017-1/-3 units and one in the 6430017-2/-4 units
(hereafter referred to as -1, -2, -3, and -4, respectively).

1.4 TECHNICAL SPECIFICATIONS

Electrical Attributes

Software / Complex Hardware None
Power Input 28.8 volts DC Nominal, 34A Max
Power Output 26.4 volts DC Nominal, Continuous Current 500A;

Power Peak Current (I
Power Rated Current (I

) 840A;

PP

) 600A

PR

Battery Capacity 17 amp hours (Ah) @ 23°C

Table 1.1

Physical Attributes

Weight

Dimensions (see Figure 1.1)
(not including vent and
connectors)

16.0 pounds (7.2 kg) -1 and -2 configurations

17.1 pounds (7.5 kg) -3 and -4 configurations

7.22 x 7.37 x 6.01 inches -1 and -2 configurations
[183 x 187 x 153 mm]

7.22 x 9.33 x 6.01 inches -3 and -4 configurations

[183 x 237 x 153 mm]
Power Terminals (for -1 and -2) M8 x 1.25 x 10mm deep thread, 13mm hex bolt
Quick Disconnect Power

Receptacle (for -3 and -4)

2-pin per MIL-PRF-18148/3 form factor (MS3509)

Communication Connector 7-pin circular
Mounting Hold down bar (0.31 inch holes on 7.9 inch centers)

Table 1.2

Qualifications

Certification FAA/TSO-C179a; EASA/ETSO-C179a
Performance Qualification RTCA/DO-311 Minimum Operational Performance

Standard for Rechargeable Lithium Battery Systems

RTCA/DO-347 Certification Test Guidance For Small

and Medium Sized Rechargeable Lithium Batteries and
Battery Systems (partial)

Environmental Qualification RTCA DO-160G; See Section 5.7

Table 1.3

5 Manual Number 9018047 • Revision J, September 21, 2020

6.56

7.22

Figure 1.1

-1 and -2 Unit Outline Drawing

6.01

7.37

7.22

6.01

9.33

Figure 1.2

-3 and -4 Unit Outline Drawing

6 Manual Number 9018047 • Revision J, September 21, 2020

W

W

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.

ARNING

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.

Handling Precautions

ARNING

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.

7 Manual Number 9018047 • Revision J, September 21, 2020