Mid-Continent Instrument TRUE BLUE POWER TFC4000 Technical Document

Revision A • November 4, 2022

1Manual Number 9019509 • Revision A, November 4, 2022
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. 34th St. N.
Wichita, KS 67226 USA
Phone [phone]
Fax [phone]
All products produced by Mid-Continent Instrument Co., Inc., including those identified as Mid-
Continent Instruments and Avionics or True Blue Power®, are designed and manufactured in Wichita,
Kansas, USA.
© Copyright 2022
Mid-Continent Instrument Co., Inc.
Download the current
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installation manual
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2Manual Number 9019509 • Revision A, November 4, 2022
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 7
SECTION 3 INSTALLATION 8
3.1 GENERAL INFORMATION 8
3.2 UNPACKING AND INSPECTING EQUIPMENT 8
3.3 CABLE HARNESS 8
3.4 MOUNTING 12
3.5 INSTALLATION CAUTIONS 12
3.6 INSTALLATION COMPLETION 12
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

3Manual Number 9019509 • Revision A, November 4, 2022
REVISION HISTORY
Rev
Date
Detail
Approved
A
11/4/2022
Initial release.
CAS

4Manual Number 9019509 • Revision A, November 4, 2022
SECTION 1 GENERAL DESCRIPTION
1.1 INTRODUCTION
The model TFC4000 Series Frequency Converter is a lightweight frequency converter that
translates a 115/200 VAC, 3 phase, 360-800 Hz input to this application option:
Configurations
Model
Part Number
Output
Typical Application
TFC4000
6434000-1
4.0 kVA, 115 VAC, 60 Hz
General Purpose, 115V cabin power
Table 1.1
Model TFC4000 provides 4000 VA (watts) of output power. The alternating current output is
defined as a pure sine wave with less than 3% of total harmonic distortion for clean, noise-free,
harmonic-free power to supply loads of corresponding voltage, power and frequency. For the
TFC4000, the 115 VAC 60 hertz (Hz) is suitable for nearly any common commercial or consumer
load rated for a nominal input of 115 VAC.
The TFC4000 Series Frequency Converter is tested to rigorous environmental standards and
levels of RTCA DO-160G. The light weight and quiet converter 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 rugged extrusion that supports the unit is designed to help dissipate heat and provide
mechanical strength against vibration or other possibilities of damage. Three independent fans
allow for a smaller unit and quiet operation, and keep the internal components cool extending the
life of the unit.

5Manual Number 9019509 • Revision A, November 4, 2022
1.2 TECHNICAL SPECIFICATIONS
Electrical Attributes
Input Voltage:
115/200 VAC 3 phase, 360 Hz - 800 Hz
Input Power:
4.3 kW, 13.2 A at 400 Hz, 15.0 A at 800 Hz
Output Voltage:
115 VAC ±3% at 60 Hz (single phase)
Output Power:
4000 VA, 4 kW at power factor = 1
Output Waveform:
Single phase sine wave
Power Factor:
-0.8 to +0.8
Efficiency:
93% nominal
Total Harmonic
Distortion (THD):
< 3%
Fault Output:
Discrete GND/open, 100 mA maximum
Table 1.2
Physical Attributes
Weight:
19.8 pounds (not to exceed +5%)
Dimensions:
(not including connector
mate)
15.7 inches long x 7.0 inches wide x 5.0 inches high
Mating Connector (and cable
clamp):
MCI P/N 9019110-4 and 9019507-2
Mounting:
Base mount –orientation not critical
Table 1.3
Qualifications
Environmental Qualification:
RTCA DO-160G Environmental Category; See Section
5.2
Altitude:
55,000 ft
Temperature:
-55 °C to +75 °C (-67 °F to +167 °F)
Table 1.4

6Manual Number 9019509 • Revision A, November 4, 2022
SECTION 2 PRE-INSTALLATION CONSIDERATIONS
2.1 COOLING
No external cooling is required. The unit is equipped with three internal DC fans. 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 TFC4000 Series Frequency Converter 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.
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 conditions and tests for environmental qualification of this article are minimum performance
standards that match the technical requirements of SAE AS6349 for Airborne AC to AC
Converters. (No FAA TSO is currently available for the certification of AC-to-AC converters.)

7Manual Number 9019509 • Revision A, November 4, 2022
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.
Figure 2.1
Nameplate and MOD Status Example
MOD 0
MOD 1
MOD 1
& MOD 2

8Manual Number 9019509 • Revision A, November 4, 2022
SECTION 3 INSTALLATION
3.1 GENERAL INFORMATION
This section contains interconnect diagrams, mounting dimensions and other information
pertaining to the installation of the TFC4000 Series Frequency 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 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. Frequency Converter MCIA P/N 6434000-( )
B. Installation Manual MCIA P/N 9019509
Available Equipment:
A. Mating Connectors (& cable clamps) MCIA P/N 9019110-4 and 9019507-2
Equipment not provided:
A. Cable Harness Wire See Section 3.3 for specifications
B. Mounting Hardware eight (8) ¼-20 bolts or pan head screws
¼” lock washers (optional)
3.3 CABLE HARNESS
Construct the cable harness with regards to the instructions below, and using the Connector Pinout
of Figure 3.1, Table 3.1, and Wiring Diagram of Figure 3.2.
Refer to Section 2: Pre-Installation Considerations regarding routing precautions.
3.3.1 Wire Gauge Selection
Use of PTFE, ETFE, TFE, Teflon, or Tefzel insulated wire is recommended for aircraft use.
The following wire gauges are recommended for each of the pins in the connector:
5-Pin Connector (MS3102A18-11P):
Pins A, B, C, D, E - 12 AWG stranded
9-Pin Connector (MS3102A24-11S):
Pins A, B, C, G - 22 AWG stranded
Pins D, E, F - 8 AWG stranded

9Manual Number 9019509 • Revision A, November 4, 2022
3.3.2 Pin Assignment Information
3.3.2.1 Input Power
(5-Pin Connector, Pin A) Positive AC, Phase A input –115/200 VAC, 360-800 Hz.
(5-Pin Connector, Pin B) Positive AC, Phase B input –115/200 VAC, 360-800 Hz.
(5-Pin Connector, Pin C) Positive AC, Phase C input –115/200 VAC, 360-800 Hz.
(5-Pin Connector, Pin E) Chassis Ground –Internally the chassis ground pin is connected
to the converter enclosure. Connect to aircraft structure close to the unit.
(5-Pin Connector, Pin D) Neutral
3.3.2.2 Converter Output
(9-Pin Connector, Pin D) AC Output –115 VAC, 60Hz, 4.0 kVA. Used for powering
devices where terrestrial/utility power designations are used. This would be connected as
“Line” or “Hot”.
(9-Pin Connector, Pin E) AC Return –Used for powering devices where terrestrial/utility
power designations are used. Pin E can be connected as “Neutral”.
(9-Pin Connector, Pin F) Chassis Ground - Internally the chassis ground pin is connected
to the converter enclosure. Connect to aircraft structure close to the unit.
3.3.2.3 Circuit Breakers on Input Power
Circuit breakers should be rated at the maximum fault current, 30 Amperes on the AC
input.
3.3.2.4 Converter Remote On/Off Control (see section 4.2.1)
(9-Pin Connector, Pin A) Remote ON/OFF Enable Control –Connecting this pin to
Chassis (pin B) will enable the AC output of the inverter. Install a switch to chassis to
allow remote on/off control of the unit. This pin is internally pulled to 12 VDC with a limit of
1 mA.
(9-Pin Connector, Pin B) Remote Return –Should be connected to chassis, either near
the unit or, twisted with Pin A wire and grounded to chassis at the switch.