True Blue Power TC240 Installation Guide

Revision E • May 7, 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 2016

Mid-Continent Instrument Co., Inc.

th

St. N.

Download the current
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1 Manual Number 9018640 • Revision E, May 7, 2020

TABLE OF CONTENTS

SECTION 1 GENERAL DESCRIPTION 4

1.1 INTRODUCTION 4

1.2 TECHNICAL

SECTION 2 PRE-INSTALLATION CONSIDERATIONS 6

2.1 COOLING 6

2.2 EQUIPMENT

2.3 ROUTING

2.4 LIMITATIONS 7

2.5 MODIFICATION 8

SECTION 3 INSTALLATION 9

SPECIFICATIONS 5

LOCATION 6

OF CABLES 6

3.1 GENERAL INFORMATION 9

3.2 UNPACKING

3.3 CABLE

AND INSPECTING EQUIPMENT 9

HARNESS 9

3.4 MOUNTING 13

3.5 INSTALLATION

3.6 INSTALLATION

CAUTION 13
COMPLETION 13

SECTION 4 OPERATION 14

4.1 ELECTRICAL PERFORMANCE 14

4.2 PROTECTIVE

FEATURES 14

SECTION 5 CONFORMANCE 16

5.1 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 16

5.2 ENVIRONMENTAL

QUALIFICATION STATEMENT 16

2 Manual Number 9018640 • Revision E, May 7, 2020

REVISION HISTORY

Rev Date Detail Approved

A 05/23/2016 Initial release SHO

Corrected typo, page 12, 4.2.3, ‘maximum.’

5.2 Environmental Qualification Statement:
Section 4, changed from F2 to F1;

B 06/22/2016

Section 4.5.1 Operating Low Temp changed from -55C to

KJW

-40C
Section 4.5.3 Operating High Temp changed from +70C to
+55C.
Corrected description, Figure 3.3. Revised the

C 12/02/2016

Environmental Qualification Statement table for

KJW

Temperature and Altitude, Section 4.

D 10/24/2017

Changed Environmental Qualification Statement to add
helicopter vibe levels.

KJW

E 05/07/2020

Updated style and brand to meet Marketing and
Engineering guidelines.

DLR

3 Manual Number 9018640 • Revision E, May 7, 2020

SECTION 1 GENERAL DESCRIPTION

1.1 INTRODUCTION

The model TC240 DC/DC Power Converter is a lightweight power converter that translates a direct
current (DC) input of 28 volts to an adjustable 5 to 18 volt direct current (DC) output.

The input operating voltage (24–32VDC) makes the TC240 suitable for nearly any common
general, business, or commercial aviation application and provides an adjustable DC output
voltage of 5 to 18VDC. The unit is rated for a nominal output of 240 watts to power avionics,
instrumentation, personal charging, lighting, and many other applications. The TC240 DC/DC
Converter is FAA certified to TSO-C71 and tested to rigorous environmental standards and levels
of RTCA DO-160G. 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 input voltage shut­down, temperature monitoring, reverse polarity protection, a self-resettable over-temperature
disable and an optional remote enable (on/off) feature.

The TC240 DC/DC converter has a robust Military-rated circular connector and a rugged aluminum
case which dissipates heat and provides excellent mechanical strength. It is engineered to require
no external cooling and contains no internal fans or cooling methods, which saves energy, reduces
weight and allows more flexible installation locations. At only 0.70 pounds, it is lighter and smaller
than any other certified solution in the aviation market today.

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1.2 TECHNICAL SPECIFICATIONS

Electrical Attributes

Input Voltage Rated 28VDC nominal, Operating 24 – 32VDC.
Input Current (full load) 10 amps max at nominal input voltage
Output Voltage 5 – 18VDC adjustable
Output Power 240 watts nominal
Efficiency 95% nominal

Table 1.1

Physical Attributes

Weight 0.70 lbs (0.32 kg)
Dimensions
(not including connector mate)

Mating Connector Kit

2.75 inches long x 3.75 inches wide x 1.29 inches high
(69.9 mm long x 95.3 mm wide x 32.8 mm high)
6430240-1 MCIA P/N 9018654
6430240-2 MCIA P/N 9018655

Mounting Base mount – orientation not critical

Table 1.2

Qualifications

Certification FAA TSO-C71

Environmental Qualification

RTCA DO-160G Environmental Category;

See Section 5.2
Altitude -15,000 feet to +55,000 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

The TC240 product does not require external cooling or contain internal active cooling. Cooling of
the unit occurs exclusively through passive conduction through the base or radiated cooling across
the metal case. Additional cooling can be realized through convection (exposure to free moving air)
or conduction (mounting to a thermally conductive metal surface). These methods are not required
to achieve rated performance but can help prevent potential overheating and extend life when the
unit is operated at full power or during overload conditions. Specifically, mounting the unit to a
metal surface is preferred, but not required.

2.2 EQUIPMENT LOCATION

The TC240 is designed for mounting flexibility, allowing for installation inside or outside the
pressure vessel with no requirement for temperature control. In addition to altitude and
temperature resistance, 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.

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2.4 LIMITATIONS

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.

The TC240 is designed to operate at full rated load (per Figure 4.1) throughout the specified
environmental temperature range (per section 5.2). Note that when operating at full power, the unit
case can be hot to the touch. Reference the following examples of selected conditions when

operating at maximum rated load of 240 watts (stabilized after 20 minutes):

 At an ambient test temperature of +23°C when not mounted to a metal surface, the

maximum case temperature can reach +62°C. (+42°C when mounted to a metal surface)

 At an ambient test temperature of +70°C when not mounted to a metal surface, the

maximum case temperature can reach +87°C. (+68°C when mounted to a metal surface)

Caution and consideration should be taken with respect to aircraft installation and operation.

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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 2.1 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.

MOD 0

MOD 1

MOD 1
& MOD 2

Figure 2.1

Nameplate and MOD Status Example

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SECTION 3 INSTALLATION

3.1 GENERAL INFORMATION

This section contains interconnect diagrams, mounting dimensions and other information
pertaining to the installation of the TC240 DC/DC 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.

The following two versions of the unit are available. See Section 4.2.1 for additional details of the
remote enable (on/off) feature and installation details within Section 3.

Part Number Remote On/Off

6430240-1 No (output always enabled)
6430240-2 Yes (enable signal required)

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. DC/DC Converter MCIA P/N 6430240-( )
B. Connector Kit

i. 6430240-1 MCIA P/N 9018654

ii. 6430240-2 MCIA P/N 9018655

C. Installation Manual MCIA P/N 9018640

Equipment not provided:

A. Mounting Hardware Four 6-32 x 1” (min) pan head screws

#6 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 Connector Pinout of
Table 3.1 or 3.2 and referencing Typical Wiring Diagrams of Figures 3.3 or 3.4, as applicable.

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:

Pins A and B – 16 AWG stranded or solid
Pins C – 14 AWG or 16 AWG stranded or solid
Pins D (for -2) – 24 AWG stranded or solid

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Pin Assignment Information

Positive DC input – (24-32 VDC). Connect pin B to aircraft positive 28 VDC bus.
(20 Amp circuit breaker recommended)
DC Output – Connect pin C as the positive output voltage (adjustable)
DC Return – Connect pin A to input power return or aircraft ground.

Enable – 6430240-1: Not available
6430240-2: Pin D to be grounded to enable power output
(via switch or other means. See section 4.2.1 and figure 3.4 for related details)

Connector Pinout

A DC Power Return

B DC Power Input

Figure 3.1 Table 3.1

C DC Power Output

Pinout View of 6430240-1 Unit Connector 6430240-1 Connector Pinout

Connector Pinout

A DC Power Return

B DC Power Input

Figure 3.2 Table 3.2

Pinout View of 6430240-2 Unit Connector 6430240-2 Connector Pinout

C DC Power Output

D Enable

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Harness Verification

With the TC 240 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.

Output Voltage Adjustment

The output voltage can be set to any value between 5 and 18VDC.
NOTE: The default output voltage is initially set to approximately 13.8VDC at the factory.

The output voltage can be adjusted while the TC240 DC/DC Power Converter is connected
to the mating harness and aircraft power, but disconnected from the output load. Use a
multi-meter at the load end of the harness to measure output voltage.

The adjustment trimmer can be accessed by removing the screw near the label as shown
in Figure 3.5. After removing the screw, a flat screwdriver (2mm) will fit into the hole and
the trimmer. Turn the trimmer carefully either clockwise to increase voltage or counter­clockwise to decrease voltage. Replace the screw after adjustment is complete.

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5-18 V OUTPUT
ADJUSTMENT POT

TC240

A

B

C

DC RETURN

DC INPUT

DC OUTPUT

6430240-1

Figure 3.3: Typical 6430240-1 Aircraft Wiring Installation – Constant On

A

5-18V OUTPUT
ADJUSTMENT POT

B

DC RETURN

DC INPUT

TC240
6430240-2

D

Figure 3.4: Typical 6430240-2 Aircraft Wiring Installation – Remote On/Off

12 Manual Number 9018640 • Revision E, May 7, 2020

DC OUTPUTC

ON/OFF

ON

ENABLE

OFF

3.4 MOUNTING

Refer to Section 2: Pre-Installation Considerations in regards to equipment location.

The TC240 DC/DC Converter is designed for base mounting only. Four 6-32 mounting holes
should be provided in the aircraft in accordance with Figure 3.5. Secure the unit with four 6-32 pan
head screws, or equivalent. A lock washer under the head of each screw is recommended.

3.38

2.75

2.40
Output voltage adjustment

4X Ø0.15 Mounting Holes
for #6-32 X 1.0" (min)

0.75

3.75

1.29

Connector per
MS3102A-16-10P

Figure 3.5

TC240 DC/DC Converter Outline Drawing

Connector per
MS3102A-16-9P

3.5 INSTALLATION CAUTION

Under no circumstances should the output of the Converter be connected to another power output
source or damage will occur to the unit or the connected power source.

3.6 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.

13 Manual Number 9018640 • Revision E, May 7, 2020

SECTION 4 OPERATION

4.1 ELECTRICAL PERFORMANCE

The TC240 is designed as a non-isolated, buck topology, solid-state switch-mode power supply.
The unit converts a direct current voltage (VDC) input to a regulated 5-18 VDC output. It is capable
of providing up to 240 watts of power to a variety of aircraft accessories including lights and
onboard systems or portable consumer product power. Rated output current, and thus power, is a
function of the user-selected output voltage. See Figure 4.1 for maximum current vs. voltage.

TC240OutputCurrentPerformance

Maximum Continuous

28

26

24

22

20

18

16

OutputCurrent(A)

14

12

10

5 7 9 11131517

TC240 Output Current Performance

4.2 PROTECTIVE FEATURES

Remote On/Off

The TC240 DC/DC Converter (6430240-2 only) 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, the user can enable the output of the unit via a remote mounted switch.
(See Figure 3.4)

OutputVoltage(V)

Figure 4.1

Input Voltage Limit

If the input voltage exceeds the over-voltage threshold (34VDC), the output will be
disabled.

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Over-Temperature

The TC240 DC/DC 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.
The Converter will continue to remain shut-down until the temperature returns to within
acceptable limits. This over-temperature reset occurs automatically without external
intervention required.

Short Circuit and Over-Current

The TC240 DC/DC Converter is capable of surviving a short circuit or over-current event
without permanent damage or effect to long-term reliability. The unit can provide over its
rated power output up to 277 watts for over 120 minutes (until over-temperature shutdown
occurs).

The Converter monitors the DC output on a pulse-by-pulse scenario to determine a short ­circuit or over-current situation. If detected, the output is limited by limiting the current
output to less than 20A. If the short-circuit or over-current situation is removed, the unit will
return to normal operation.

15 Manual Number 9018640 • Revision E, May 7, 2020

SECTION 5 CONFORMANCE

5.1 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

No periodic scheduled maintenance or calibration is necessary for continued airworthiness of the
TC240 DC/DC 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: TC240 PART NUMBER: 6430240-( ) Series

DESCRIPTION: DC/DC 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) 688-P Test Data Sheet (TDS) 688-P
STANDARD: RTCA DO-160, Rev G, dated 12/08/10

CONDITIONS SECTION DESCRIPTION OF TEST

Temperature and Altitude 4 Category F1 and F2
Temperature Variation 5 Category S2
Humidity 6 Category B
Operational Shock and Crash Safety 7 Category B
Vibration 8 Fixed Wing: Category R; Curve C, C1

Rotorcraft: Category U; Curve G

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 Frequency Conducted Susceptibility 18 Category R
Induced Signal Susceptibility 19 Category X
Radio Frequency Susceptibility 20 Category X
Emission of Radio Freq 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
Flammability 26 Category X

REMARKS:

16 Manual Number 9018640 • Revision E, May 7, 2020