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Revision E • December 3, 2021
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1 Manual Number 9019049 • Revision E, December 3, 2021
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. 34th St. N.
Wichita, KS 67226 USA
Phone 316-630-0101
Fax 316-630-0723
© Copyright 2017
Mid-Continent Instrument Co., Inc.
Download the current
version of this
installation manual
using your
smartphone or tablet.
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2 Manual Number 9019049 • Revision E, December 3, 2021
TABLE OF CONTENTS
SECTION 1 GENERAL DESCRIPTION 4
1.1 INTRODUCTION 4
1.2 TECHNICAL SPECIFICATIONS 5
SECTION 2 PRE-INSTALLATION CONSIDERATIONS 6
2.1 COOLING 6
2.2 EQUIPMENT LOCATION 6
2.3 ROUTING OF CABLES 6
2.4 LIMITATIONS 6
2.5 MODIFICATION 8
SECTION 3 INSTALLATION 9
3.1 GENERNAL INFORMATION 9
3.2 UNPLACKING AND INSPECTING EQUIPMENT 9
3.3 CABLE HARNESS 9
3.4 MOUNTING 12
3.5 INSTALLATION COMPLETION 14
3.6 INSTALLATION CAUTION 14
SECTION 4 OPERATION 15
4.1 ELECTRICAL PERFORMANCE 15
4.2 PROTECTIVE FEATURES 15
SECTION 5 CONFORMANCE 16
5.1 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 16
5.2 ENVIRONMENTAL QUALIFICATION STATEMENT 16
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REVISION HISTORY
Rev
Date
Detail
Approved
A
12/28/2017
Initial release
BAW
B
01/26/2018
Corrected formatting issues. Incorporated FAA
comments.
BAW
C
03/08/2018
Changed paragraph 3.3.2.3 pin ‘E’ to pin ‘A’. Added note
page 5 on ground regulatory requirements.
JRC
D
05/07/2020
Updated style and brand to meet Marketing and
Engineering guidelines.
DLR
E
12/03/2021
Changed paragraph 3.2. …mating connector from
9018550-2 to 9018993-3
MEK
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4 Manual Number 9019049 • Revision E, December 3, 2021
SECTION 1 GENERAL DESCRIPTION
1.1 INTRODUCTION
The model TC2000 Series Static Electrical Power Converter is a lightweight power converter that
translates an aircraft alternating current (AC) input of 115 volts at 360-800 Hertz to a 28 volt direct
current (DC) output. Additionally the TC2000 can be bench operated on AC Mains with 115 or 230
volts at 47-65 Hz input and provide a 28 volt direct current (DC) output (see Note 1 below).
The wide input operating voltage and frequency make the TC2000 suitable for nearly any common
business or commercial aircraft which provides 100-125 VAC between 360-800 Hertz. The output
of 71 amps @ 28 VDC produces 2000 watts of power to supply avionics, instrumentation, seating,
personal charging, lighting, and many other applications. The TC2000 Series Static Converter is
FAA certified to TSO-C71 and tested to rigorous environmental standards and levels of RTCA DO160G. The small size and light weight in conjunction with its installation flexibility (inside or outside
the pressure vessel) make it an ideal choice for aircraft power needs while reducing the challenges
associated with other similar products.
Highlighted features include short circuit protection, overload capability, low voltage shut-down,
temperature monitoring, a self-resettable over-temperature disable and a remote on/off function.
The TC2000 Series has a robust Military-rated circular connector, and the rugged extrusion that
houses the unit is designed to help dissipate heat and provide mechanical strength against
vibration or other possibilities of damage. Two independent fans allow for a smaller unit and quiet
operation, and keep the internal components cool extending the life of the unit.
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1.2 TECHNICAL SPECIFICATIONS
Electrical Attributes
Input Voltage
Aircraft: 115VAC nominal, 360-800 Hz.
AC Mains: 115VAC or 230VAC, 47 to 65 Hz. (Note 1)
Input Current (full load)
22 Amps nominal; 28 Amps max
Input Current (unit off)
2 Amps
Recommended Input Circuit Breaker
30 Amps (for 115VAC aircraft use)
Output Voltage
28VDC ± 0.5 VDC
Output Power
2000 watts (28VDC @ 71 Amps rated)
Efficiency
88% nominal
Table 1.1
Physical Attributes
Weight:
9.9 lbs [4,49 kg]
Dimensions:
(not including connector mate)
14.00 inches x 6.32 inches x 3.46 inches (LxWxH)
[35,5 x 16,1 x 8,8 cm]
Mating Connector (and cable clamp):
MCI P/N 9018993-1 and 9018550-2
Mounting:
Base mount – orientation not critical
Table 1.2
Note 1: The TC2000 has not been tested to UL, CE, or other ground regulatory requirements.
Powering from AC mains is intended for testing or temporary use only.
Qualifications
Certification:
FAA TSO-C71
Environmental Qualification:
RTCA DO-160G Environmental Category; See Section 5.2
Altitude:
35,000 feet
Temperature:
-55°C to +70°C (-67°F to + 158°F)
Table 1.3
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SECTION 2 PRE-INSTALLATION CONSIDERATIONS
2.1 COOLING
No external cooling is required. The unit is equipped with two internal DC fans that are
thermostatically controlled. The fans normally run at a slow speed, but depending upon load and
ambient temperature one or both fans may operate at a higher speed.
Restriction to airflow can cause overheating of the unit and limit performance or reduce the
expected life of the product. Make sure to provide adequate clearance on both ends of the unit with
the hexagonal openings to allow for proper circulation. In general, four to six inches of clearance
on both ends of the unit should be acceptable. Mounting the unit to a metal surface can also help
reduce the effects of temperature within the unit but is not required.
2.2 EQUIPMENT LOCATION
The TC2000 Series is designed for mounting flexibility, allowing for installation inside or outside the
pressure vessel with no requirement for temperature control within the temperature specifications.
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 can be mounted in any orientation. Clearance should be provided for the mating
connector and may require as much as five inches past the unit connector to allow for back shell
access to the connector.
2.3 ROUTING OF CABLES
The wires and cable bundle associated with the unit are heavy gauge wire and carry significant
power. Be aware of routing cables near other electronics or with other wire bundles that may be
susceptible 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.
2.4 LIMITATIONS
The TC2000 contains an internal DC-to-DC conversion function to produce the rated output as
specified. This function meets the requirements of FAA TSO-C71. The TC2000 also creates an
initial translation of an alternating current (AC) input to the intermediate DC voltage, which then
gets converted to the rated output. This initial translation of AC-to-DC power is considered a nonTSO function. This is due to the lack of an available AC-to-DC Technical Standard Order.
However, the AC-to-DC function is fully tested and verified per the equipment requirements and
design as well as the stated environmental requirements. The data to support the non-TSO
function has been submitted to and reviewed by the FAA along with the TSO-C71 requirements
and functionality.
Additionally, there are limitations associated with a derating of the maximum continuous power
available at the high end of the rated temperature and altitude specification. For more details, see
Figures 2.1 and 2.2 below.
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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. The article may be installed only
according to 14 CFR Part 43 or the applicable airworthiness requirements.
Figure 2.1 – Derated Output Power versus Altitude
Figure 2.1 – Derated Output Power versus Temperature
0
500
1000
1500
2000
2500
0 5000 10000 15000 20000 25000 30000 35000 40000
Output Power (watts)
Altitude (feet)
Output Power vs Altitude
0
500
1000
1500
2000
2500
-60 -40 -20 0 20 40 60 80
Output Power (watts)
Temperature (°C)
Output Power vs Temperature
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8 Manual Number 9019049 • Revision E, December 3, 2021
2.5 MODIFICATION
This product has a nameplate that identifies the manufacturer, part number, description,
certification(s) and technical specifications of the unit. It also includes the “MOD” or modification
number representing notable changes in the hardware design of the unit.
Modification (MOD) 0 is the initial release of the product 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 2.2 for
examples). MODs do not have to be sequentially inclusive and may be applied independent of
each other.
For additional details regarding specific changes associated with each MOD status refer to the
product published Service Bulletins at www.truebluepowerusa.com.
Figure 2.2
Nameplate and MOD Status Example
MOD 0
MOD 1
MOD 1
& MOD 2
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9 Manual Number 9019049 • Revision E, December 3, 2021
SECTION 3 INSTALLATION
3.1 GENERNAL INFORMATION
This section contains interconnect diagrams, mounting dimensions and other information
pertaining to the installation of the TC2000 Series Static Converter. After installation of cabling and
before installation of the equipment, ensure that power is applied only to the pins specified in the
interconnect diagram.
3.2 UNPLACKING AND INSPECTING EQUIPMENT
When unpacking this equipment, make a visual inspection for evidence of any damage that may
have incurred during shipment.
The following parts should be included:
A. Static Converter MCIA P/N 6432001-1
B. Installation Manual MCIA P/N 9019049
Available Equipment:
A. Mating Connector (& cable clamp) MCIA P/N 9018993-1 and 9018993-3
Equipment not provided:
A. Mounting Hardware four (4) ¼-20 pan head screws
¼” lock washers (optional)
B. Cable Harness Wire See Section 3.3 for specifications
3.3 CABLE HARNESS
Construct the cable harness with regards to the instructions below, and using Figures 3.3 – 3.5,
and Wiring Diagram of Table 3.3.
Refer to Section 2: Pre-Installation Considerations in regards to routing precautions.
Wire Gauge Selection
Use of PTFE, ETFE, TFE, Teflon, or Tefzel insulated wire is recommended for aircraft use.
Use the following wire gauges for each of the pins in the connector. For the higher current
input and output wires, use the larger wire size listed if the wire run is long to avoid voltage
drop.
Pins C and D – 4 to 6 AWG stranded wire
Pins B and E – 8 to 10 AWG stranded wire
Pins A, G, and F – 16-22 AWG stranded wire
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Figure 3.3 Table 3.3
Pinout View of Unit Connector Connector Pinout
Pin Assignment Information
3.3.2.1 Converter Input Power:
AC Line input – Pin B – 115 VAC. Connect to the aircraft 115 VAC bus using a 30
Amp circuit breaker.
AC Neutral input – Pin E – Connect to the aircraft 115VAC Return Bus.
3.3.2.2 Converter DC Output:
The TC2000 DC Output is isolated from the incoming 115VAC and the inverter
chassis. This allows the TC2000 to provide 28V DC output independent and
isolated from other aircraft DC power sources if desired.
DC +28V Output – Pin C – Positive 28 volt output from the converter. Use of one or
more circuit breakers is optional.
DC -28V Output – Pin D – Negative 28 volt output from the converter. In typical
aircraft, the negative 28V is connected to the airframe. However with the TC2000
converter the 28V negative can be connected to an isolated return bus if it is
desirable to have a 28V DC bus independent and isolated from the aircraft DC bus.
Note: Use of a circuit breaker on the DC output is optional. For the full output
of 2000W, a single circuit breaker current of 75 Amp maximum is
recommended. If multiple branching circuits are connected to the output, then
the total rating of all circuit breakers should not exceed 75 Amps.
3.3.2.3 Converter Remote Enable Control: (see section 4.2.1)
Remote ENABLE (ON/OFF Control) – Pin A – Connecting this pin to the converter
DC -28V Output turns-ON the 28V output of the Converter. If the Converter DC-28V
Output is connected to the airframe then a remote ENABLE switch only needs to
connect this pin to the airframe to turn ON the output of the converter. When
unconnected (output is OFF) this pin will have approximately 28 VDC present,
internally limited to a few milliamps. If the Converter is to be enabled at all times, pin
A is to be connected to pin D.
MS3102A32-10P Connector Pinout
A
Enable
B
AC IN Line
C
+28 VDC Output
D
28VDC Return
E
AC IN Neutral
F
Parallel
G
Chassis Ground
A
D
B
E
C
F
G
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3.3.2.4 Converter Chassis Ground
Chassis Ground – Pin G – Typically the converter chassis is grounded when the
converter is mounted to the aircraft structure. This pin provides an additional
chassis ground connection independent from the mounting. It is recommended that
a wire of less than 18 inches in length be connected to this pin to provide additional
grounding for the Converter.
3.3.2.5 Converter Parallel Operation
Parallel – Pin F – More than one TC2000 can be connected in parallel to provide
more than 2000 Watts of power conversion to 28 VDC. Contact Mid-Continent
Instruments, True Blue Power for additional information on this feature. If the
parallel operation feature is not being used, this pin should remain unconnected.
Example Wiring Diagrams
See Figures 3.4 and 3.5 for examples of potential wiring diagram options for installation
purposes.
Harness Verification
With the TC2000 Series Static Converter disconnected, activate the aircraft power bus that
supplies the unit and use a multi-meter to verify that aircraft power and ground with
appropriate voltage is on the pins within the mating harness.
TC2000
B B
E E
A A
C C
D D
115 VAC INPUT
30A CIRCUIT
BREAKER
CASE ATTACHED
TO AIRFRAME
28 VDC OUTPUT
G G
F
Figure 3.4: Typical TC2000 Aircraft Wiring Installation – Constant On
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TC2000
B B
E E
A A
C C
D D
115 VAC INPUT
30A CIRCUIT
BREAKER
OFF
ON
CASE ATTACHED
TO AIRFRAME
ENABLE
75A CIRCUIT
BREAKER
28 VDC OUTPUT
G G
F
Figure 3.5: Typical TC2000 Aircraft Wiring Installation – Remote On/Off
3.4 MOUNTING
Refer to Section 2: Pre-Installation Considerations in regards to equipment location.
The TC2000 Series Static Converter is designed for base mounting only (in any orientation). Four
¼-20 mounting holes should be provided in the aircraft in accordance with Figure 3.6. Secure the
unit with four ¼-20 pan head screws, or equivalent. A lock-washer under the head of each screw is
recommended.
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3.75
5.50
13.25
11.75
14.00
(4X) Ø
0.281
Mounting Holes
3.45
6.32
Figure 3.6
TC2000 Series Static Converter Outline Drawing
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14 Manual Number 9019049 • Revision E, December 3, 2021
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 best not to attach the output
to other equipment or power busses prior to verification. Verify the output of the unit at the
terminating end of the cable with a multi-meter to ensure proper voltage and polarity. Once
verified, installation can be completed and functionality of the remote on/off feature (if used) should
be checked.
3.6 INSTALLATION CAUTION
Do not connect the output of the TC2000 Series Static Converter to the output of any other
Converter or damage will result. Under no circumstance allow the output of the Converter to be
connected to ground utility AC power or damage will result.
CAUTION
CAUTION
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15 Manual Number 9019049 • Revision E, December 3, 2021
SECTION 4 OPERATION
4.1 ELECTRICAL PERFORMANCE
The TC2000 Series Static Converter converts an alternating current (AC) voltage input to a
regulated VDC output. See Table 4.1 specific output and input frequency.
Model
Input
Frequency
Output
TC2000
115 VAC
360-800 Hz
28 VDC
Table 4.1
TC2000 Series Electrical Performance
The unit is capable of providing 2000 watts to power a variety of aircraft accessories including
lights and onboard systems.
4.2 PROTECTIVE FEATURES
Remote On/Off
The TC2000 Series Static Converter incorporates a remote on/off feature that allows the
user to enable or disable the output of the unit. By providing a ground on the appropriate
pin (See Table 3.3) the user, via a remote mounted switch, can enable the output of the
unit. The unit can be similarly disabled by removing the ground signal (open circuit) to the
same pin.
Over-Temperature
The TC2000 Series Static Converter incorporates an internal temperature sensing device
that continually provides monitoring and feedback to the control circuits. When the unit
senses an internal condition that exceeds maximum temperature ratings, the output is
disabled and the internal cooling fans cease to operate. The unit output will be enabled
when the temperature returns to within acceptable limits. This over-temperature reset
occurs automatically without external intervention required.
Short Circuit and Over-Current
The TC2000 Series Static Converter is capable of surviving a short circuit or over-current
event without permanent damage or effect to long-term reliability. Under standard
conditions, the unit can provide over its rated power output up to 2200 watts for over 5
minutes (until over-temperature shutdown occurs).
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SECTION 5 CONFORMANCE
5.1 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
No periodic scheduled maintenance or calibration is necessary for continued airworthiness of the
TC2000 Series Static Converter. 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: TC2000 PART NUMBER: 6432001-( )
DESCRIPTION: Static Electrical Power Converter 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.
SPECIFICATION: Test Specification (TS) 714 Test Data Sheet (TDS) 714
STANDARD: RTCA DO-160, Rev G, dated 12/08/10
CONDITIONS
SECTION
DESCRIPTION OF TEST
Temperature and Altitude
4
Category C3
Temperature Variation
5
Category S2
Humidity
6
Category B
Operational Shock and Crash Safety
7
Category B
Vibration
8
Category R; Curve C, C1
Explosion
9
Category X
Waterproofness
10
Category X
Fluids
11
Category X
Sand and Dust
12
Category X
Fungus
13
Category X
Salt Spray
14
Category X
Magnetic Effect
15
Category A
Power Input
16
Category A(CF)
Voltage Spike
17
Category A
Audio Frequency Conducted Susceptibility
18
Category R(CF)
Induced Signal Susceptibility
19
Category X
Radio Frequency Susceptibility
20
Category X
Emission of Radio Frequency Energy
21
Category B
Lightning Induced Transient Susceptibility
22
Category X
Lightning Direct Effects
23
Category X
Icing
24
Category X
ESD
25
Category A
Flammability
26
Category X
Remarks:
Section 4: Category C3 with excursions as declared by the manufacturer:
• 4.5.1 Ground Survival and Short-Time Operating Low Temp: -55°C
• 4.5.3 Ground Survival and Short-Time Operating High Temp: +70°C
• 4.5.4 Operating High Temp: +70°C
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