True Blue Power TS 835 User Manual

Revision Q • Oct 6, 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 2015

Mid-Continent Instrument Co., Inc.

th

St. N.

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1 Manual Number 9016798 • Revision Q, October 6, 2020

TABLE OF CONTENTS

SECTION 1 GENERAL DESCRIPTION 4

1.1 PURPOSE 4

1.2 PHYSICAL

1.3 FUNCTIONAL

1.4 TECHNICAL

SECTION 2 PRE-INSTALLATION CONSIDERATIONS 6

2.1 COOLING 6

2.2 EQUIPMENT

2.3 ROUTING

2.4 LIMITATIONS 7

2.5 MODIFICATIONS 7

DESCRIPTION 4

DESCRIPTION 4

SPECIFICATIONS 5

LOCATION 6

OF CABLES 6

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 21

4.1 DESCRIPTION 21

4.2 THEORY

4.3 INSTALLED

OF OPERATION 21

OPERATION 24

4.4 MAINTENANCE 25

4.5 PERFORMANCE 27

SECTION 5 CONFORMANCE 30

5.1 TEST AND VERIFICATION INTERVALS 30

5.2 COMPONENT

5.3 STORAGE

MAINTENANCE MANUAL 30

INFORMATION 30

5.4 DISPOSAL 31

5.5 ENVIORNMENTAL

QUALIFICAION STATEMENT 32

2 Manual Number 9016798 • Revision Q, October 6, 2020

REVISION HISTORY

Rev Date Detail Approved

1 04/30/2009 Preliminary release. BAW
2 12/02/2009 Updated information. BAW
A 03/11/2010 Production release. BAW
B 04/15/2010 Revised Figure 3.3 Installation Diagram. BAW

Added MCI P/N 54-2007-1 to diode options in

C 05/18/2010

Section 3.3.2. Add Section 4.3.5 and related

information regarding MD835-2 version.
D 10/12/2010 Update unit picture with True Blue Power label. MKN
E 01/13/2011 Updated to include optional annunciator switch. JDS
F 04/14/2011 Added 9017201 5V Module as an optional part. BAW

G 07/27/2011

Added additional installation instructions for

9017201 5V Module.

Update manual to add references to True Blue

Power division of Mid-Continent Instrument Co.,

Inc. Identify new model number “TS835-( )” while
H 07/06/2012

maintaining unit part number references as

“MD835-( )”. Added information associated with

new -5 version and Mod 1 improvements. Updated

certification from FAA TSO C179 to C179a.

Add ETSO to Table 1.2. Updated Section 2.2 and

J 11/15/2012

2.4 for equipment location limitations. Removed

4.2.6. Updated 4.2.7. Add 4.2.8 regarding

software/complex hardware.

K 01/6/2014

L 02/26/2015

Updated document for vented version that applies

to all 835 units.

Add Mod 3: Extended filtering for high-transient

load current.

Change Environmental Qualification table: For

M 12/06/2016

CONDITION “Lightning Induced Transient

Susceptibility” change DESCRIPTION OF TEST to

A3H3L3.

Update 3.2 and 5.3 with information regarding state

N 11/22/2017

of charge for shipping and recharge intervals for

storage. Added cold test clarification. Minor format

and reference updates.

P 05/14/2020

Q 10/06/2020

Update style and brand to meet Marketing and

Engineering guidelines.

Updated section 5.5 Radio Frequency

Susceptibility.

BAW

MKN

BAW

BAW

JDS

CAS

KW

BAW

DLR

VAA

3 Manual Number 9016798 • Revision Q, October 6, 2020

SECTION 1 GENERAL DESCRIPTION

1.1 PURPOSE

The TS835 series Emergency Power Supply (EPS) is designed to supply DC power to the aircraft
emergency bus when the main power bus has been de-energized. This emergency power can be
utilized to maintain operation of required equipment in the event of a primary system power loss.
During normal aircraft operation, the TS835 EPS will utilize the aircraft’s primary power bus to
recharge or maintain existing charge at full capacity.

1.2 PHYSICAL DESCRIPTION

The TS835 EPS consists of a single chassis with a 13-pin ARINC-style connector for electrical
interface. Units with modification (MOD) 2 include a factory replaceable fuse that limits the output
current of the EPS. The unit is designed to be mounted in a ¼-ATR aircraft equipment rack. The end
plate of the unit also provides an alignment hole that mates with the mounting rack. A handle on the
front of the unit allows ease of removal and a convenient carrying method. There is an adjustment on
the front of the unit for setting the variable 3.0-5.5VDC output for the -5 version of the product.

1.3 FUNCTIONAL DESCRIPTION

During typical operation, the TS835 utilizes input power from the primary aircraft power supply to
charge and/or maintain the charge on the internal battery cells. In the event of primary aircraft power
loss, the TS835 will automatically supply power to the associated external loads without interruption.

4 Manual Number 9016798 • Revision Q, October 6, 2020

1.4 TECHNICAL SPECIFICATIONS

Electrical Attributes

Power Input 20 to 32 VDC, 5.2A max

20A max total

Power Output

Primary: 24.5 VDC nominal; Auxiliary: 3.0-5.5VDC

adjustable (5A max)
Battery Capacity 4.5 Ah nominal @ 1C rate
Maintenance Perform capacity check every 2 years
Reliability 10 year expected life (80% initial capacity retained)

Table 1.1

Physical Attributes

Weight 4.8 pounds (2.16 kg)
Dimensions

(see Figure 2.2)

12.7 inches long max. (+1 inch for handle)

3.1 inches high max. (excluding rear tab)

2.3 inches wide max.

Mating Connector ITT Cannon DPXB-13-33S-0001 or equivalent

Mounting 1/4 ATR Rack

Table 1.2

Qualifications

Certification

Performance Qualification

FAA TSO-C179a
EASA TSO (ETSO) C179a
RTCA DO-311 Minimum Operational Performance
Standards for Rechargeable Lithium Battery Systems
RTCA DO-160G See Section 5.5

Environmental Qualification

With MD835 5V Module (P/N 9017201) installed: DO­160E, Section 20 (HG); DO-160F, Section 22 [A4G44]

Table 1.3

5 Manual Number 9016798 • Revision Q, October 6, 2020

SECTION 2 PRE-INSTALLATION CONSIDERATIONS

2.1 COOLING

No internal or external cooling of the unit is required. The unit is designed to operate over a wide
temperature range and is designed with internal thermal monitoring and protection circuits. See
Section 4: Operation for more details.

2.2 EQUIPMENT LOCATION

The TS835 EPS 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 TS835 in a temperature controlled section of the aircraft. In addition to
altitude and temperature tolerance, 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. Tested and certified mounting includes the use of a standard ¼-ATR
avionics mounting rack. Access to the rear connector may be needed for installation but the nature of
the rack allows for convenient removal and installation of the unit from the front.

Failure mode, effects, and criticality analysis of the TS835 has shown that the potential for the release
of toxic or flammable gases as a result of over charge and over discharge conditions is extremely
improbable. However, if the unit does not have the add-on vent kit and exhaust hose, the unit should
be installed in a well-ventilated (positive flow) compartment for additional risk mitigation. The unit shall
not be installed in compartments where lines, tanks or equipment containing fuel, oil or other
flammable fluids are present; nor shall it be installed adjacent to engine firewalls or sources of ignition.

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 exhaust hose. Avoid routing near aircraft control cables. Also avoid
proximity and contact with aircraft structures, avionics equipment, or other obstructions that could
chafe wires and hoses during flight, and cause undesirable effects. The interconnect cables and
exhaust hose should not run adjacent to heaters, engine exhausts, or other heat sources.

6 Manual Number 9016798 • Revision Q, October 6, 2020

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 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.

See Section 4.5 for Performance Specifications and potential limitations and ratings under various
environmental and application installations. Also see Section 2.2 for limitations associated with
equipment installation location.

2.5 MODIFICATIONS

Each model TS835 (part number MD835-( )) has a nameplate that identifies
the manufacturer, part number, description, certifications and technical
specifications of the unit. It also includes the “MOD” or modification number
representing notable changes in the revision history of the unit (See Table 2.2).
The following are descriptions of the current modification releases of the
TS835 EPS.

MOD 0

Modification (MOD) 0 is identified on the nameplate by the lack of marking on the MOD numbers 1
through 9 (i.e. 1-9 are visible).

Mod 0 is the initial release of the TS835 EPS.

MOD 1
Modification (MOD) 1 is identified on the nameplate by the marking/blacking out of MOD number 1 (i.e.
1 is not visible and 2-9 are visible).

Mod 1 of the TS835 EPS contains the following changes from MOD 0:

-Updated TSO from C179 to C179a

-The external installation of CR1 diode per Installation Wiring Diagrams is NOT required (optional)

-The 3.0 amp maintenance fast charge feature has been removed

-Standard charge rate during both operation and maintenance has been increased from 0.8 amps to

3.5 amps

-Adjustable 5 volt auxiliary power output is available for TS835-5 model

-Connector has been modified to accept multiple mating connector configurations for -1 and -5 models

7 Manual Number 9016798 • Revision Q, October 6, 2020

MOD 2
Modification (MOD) 2 is identified on the nameplate by the marking/blacking out of MOD number 2 (i.e.
1 and 2 are not visible; 3-9 are visible).

Mod 2 of the TS835 EPS contains the following changes from MOD 1:

-End plates and connecter are sealed to prevent discharge gases from escaping these locations.

-Case has a ‘vent’ hole, covered by a label, for gases to escape in the event of a catastrophic
overcharge. The label can be removed and an MCIA vent kit (p/n 9017983), and customer supplied
high temperature silicone hose, can be installed for controlled venting.

MOD 3
Modification (MOD) 3 is identified on the nameplate by the marking/blacking out of MOD number 3 (i.e.
1, 2 and 3 are not visible; 4-9 are visible).

Mod 3 of the TS835 EPS contains the following changes from MOD 2:

-Extended filtering for high-transient load current.

8 Manual Number 9016798 • Revision Q, October 6, 2020

6.45 CG (ref)

1.37 CG (ref)

3.1

2.365

12.68

Ø.221 Alignment hole

Auxiliary
output

Connector
keying.

Nameplate

adjustment
(-5 only)

Figure 2.2 TS835 Outline Drawing

1.000

3.87

Model Number

Mid-Continent

Part Number

Identifying Feature

TS835-1 MD835-1 Standard model
TS835-2 MD835-2 Fuse bypass option

Additional auxiliary output (3-

TS835-5 MD835-5

Table 2.2 Model and Part Numbers

9 Manual Number 9016798 • Revision Q, October 6, 2020

5.5VDC)