Mid-Continent Instrument True Blue Power TB30 Series Technical Document

Revision C • May 21, 2020

1 Manual Number 9019287 • Revision C, May 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. 34th St. N.
Wichita, KS 67226 USA
Phone [phone]
Fax [phone]
© Copyright 2019
Mid-Continent Instrument Co., Inc.
Download the current
version of this
installation manual
using your
smartphone or tablet.

2 Manual Number 9019287 • Revision C, May 21, 2020
TABLE OF CONTENTS
SECTION 1 GENERAL DESCRIPTION 4
1.1 INTRODUCTION 4
1.2 PHYSICAL ATTRIBUTES 4
1.3 UNIT ARCHITECTURE 5
1.4 TECHNICAL SPECIFICATIONS 6
1.5 IMPORTANT SAFETY INFORMATION 8
SECTION 2 PRE-INSTALLATION CONSIDERATIONS 10
2.1 COOLING 10
2.2 EQUIPMENT LOCATION 10
2.3 ROUTING OF CABLES 10
2.4 LIMITIATIONS 11
2.5 MODIFICATION 11
SECTION 3 INSTALLATION 12
3.1 GENERAL 12
3.2 PRE-INSTALLATION INSPECTION 12
3.3PARTS 12
3.4 INSTALLATION 13
SECTION 4 OPERATION 20
4.1 DESCRIPTION 20
4.2 CONSTRUCTION AND THERORY OF OPERATION 20
4.3 OPERATIONAL MODES 23
4.4 BATTERY COMMUNICATION 28
4.5 PERFORMANCE 33
SECTION 5 CONFORMANCE 35
5.1 DISPATCH VERIFICATION AND IN-FLIGHT MONITORING 35
5.2 CONTROL MODE 35
5.3 OPTIONAL SERVICE 39
5.4 COMPONENT SERVICE 41
5.5 STORAGE INFORMATION 41
5.6 END OF LIFE 43
5.7 DISPOSAL 43
5.8 DO-311A COMPLIANCE QUALIFICATION FORM 44
5.9 DO-160 ENVIRONMENTAL QUALIFICATION FORM 45

3 Manual Number 9019287 • Revision C, May 21, 2020
REVISION HISTORY
Rev
Date
Detail
Approved
A
08/02/2019
Initial release.
BAW
B
10/01/2019
Revised EQF, added DO-311A Compliance Qualification
Form and provided additional limitation details (sec 2.5)
WVC
C
05/21/2020
Updated style and brand to meet Marketing and
Engineering guidelines.
Added downloadable event log feature and instructions to
load/download custom configuration parameters. Updated
DO-160 qual and installation instructions to include
grounding recommendations.
DLR

4 Manual Number 9019287 • Revision C, May 21, 2020
SECTION 1 GENERAL DESCRIPTION
1.1 INTRODUCTION
The TB30 series Advanced Lithium-ion Battery, part number 6430030-( ), is designed to deliver
high current capability to start piston and light turbine aircraft engines and subsequently, provide
power to the aircraft electrical bus in the event of generator function loss. The TB30 is a
sophisticated energy storage and power system that utilizes state-of-the-art Nanophosphate®
lithium-ion battery cell technology to optimize performance, safety, life and weight when compared
to traditional or competing aircraft batteries. The design of the battery includes detailed focus on
key electrical, mechanical, and software elements that combine to provide exceptional
performance and safety that meets and exceeds the latest regulatory and industry standards. The
TB30 is a complete battery solution providing significant value and benefit to an aircraft designer,
owner and operator.
Key features of the TB30 include real-time state of charge and capacity reporting, programmable
battery parameters configurable to individual installations, and maintenance-free operation with on-
condition end of life. Multiple safety protections, continuous data monitoring, and an on-board
status indicator also add value, reliability, and reduced cost of ownership for the life of the product.
The TB30 requires professional use and minimal service to deliver maximum performance and
value as designed. This manual contains information related to the specifications, installation,
operation, storage, scheduled service and other related topics associated with the proper care and
use of this product.
1.2 PHYSICAL ATTRIBUTES
The TB30 is a single, integrated component contained in a metal enclosure with multiple interface
connections. There is a primary 2-pin, industry standard mil-spec quick disconnect power
receptacle, an 18-pin circular communications connector, and a threaded grounding location. A
USB service port and an integrated push-button status indicator with LED indicators are available
for ground operations as well. The lid of the enclosure includes two hold-down features on either
side to support typical aircraft mounting. A handle integrated into the lid of the enclosure provides
ease of lifting and carrying for installation, removal and transport. The 1.25 inch diameter vent port
can be located on either the front or left side of the unit for an exhaust connection that directs any
released emissions appropriately.

5 Manual Number 9019287 • Revision C, May 21, 2020
1.3 UNIT ARCHITECTURE
The unit is comprised of two primary building blocks:
•Battery cell modules with on-board monitoring, logic, and protections
•Battery Management System (BMS) with control and communication functions
Each battery module consists of thirty-two (32) cells arranged as eight (8) groups of four (4)
parallel cells, connected in series. The cells are connected with welded bus bars which contain an
individual fuse for each cell in the module. Each module contains multiple temperature monitors
and an integrated heater that improves cold weather performance. Three modules connected in
parallel through a network of bus bars provide combined power to the main connector and thus the
aircraft.
The Battery Management System (BMS) is a microprocessor-based system that monitors
individual signals provided by each module, manages battery operation and reports status
information to the aircraft. It also manages heater functionality, stores operating parameters,
contains an event log and provides interface capability.
Additional components in the unit include independent Resistance Temperature Detectors (RTDs)
that produce analog electrical signals accessible through the 18-pin connector for redundant
temperature monitoring.

6 Manual Number 9019287 • Revision C, May 21, 2020
1.4 TECHNICAL SPECIFICATIONS
Electrical Attributes
Power Input
28.8 volts DC Nominal, 300A Max
Power Output
26.4 volts DC Nominal, Continuous Current 575A;
Power Peak Current (IPP) 1450A (at 17V CV discharge);
Power Rated Current (IPR) 1150A (at 17V CV discharge)
Battery Capacity (Beginning of Life)
30 amp hours (Ah) @ 23°C
Table 1.1
Physical Attributes
Weight
27.7 pounds (12.6 kg)
Dimensions at base
(not including vent, lid and
connectors)
6.0 x 11.6 x 9.3 inches (see Figure 1.1)
[153 x 295 x 236 mm]
Quick Disconnect Power Receptacle
Communications Connector
USB Service Data Port
2-pin per MIL-PRF-18148/3 form factor (MS3509)
18-pin per MS3114E14-18P
USB 2.0, Type-A port
Mounting
See Section 3.4.2
Table 1.2
Qualifications
Certification
FAA TSO-C179b, Class A-4B
Performance Qualification
RTCA/DO-311A Minimum Operational Performance
Standard for Rechargeable Lithium Batteries and Battery
Systems (See Section 5.8)
Environmental Qualification
RTCA/DO-160G (See Section 5.9)
Software / Complex Hardware
RTCA/DO-178C, Design Assurance Level (DAL) A
Table 1.3

7 Manual Number 9019287 • Revision C, May 21, 2020
8.8
0.5
6.0
11.6 0.6
1.3
6.97.7
8.6
6.8
12.5 0.9
Figure 1.1
Outline Drawing

8 Manual Number 9019287 • Revision C, May 21, 2020
1.5 IMPORTANT SAFETY INFORMATION
Read this safety information BEFORE maintaining or servicing the battery.
1.5.1 Symbol Definition
This section describes the precautions necessary for safe operations. The following safety
symbols have been placed throughout the guide.
Warnings identify conditions or practices that could result in personal injury.
Cautions identify conditions or practices that could result in damage to the equipment.
1.5.2 Handling Precautions
The battery pack’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 electrically 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.
•Use appropriate lifting devices or equipment for handling batteries; use battery handles
where provided.
WARNING
CAUTION
WARNING

9 Manual Number 9019287 • Revision C, May 21, 2020
1.5.3 Additional Precautions
The following design and operation factors are required for safe use.
•It is not acceptable to combine or use any battery cells or modules other than those
approved by True Blue Power within this battery pack.
•There are no limitations in storing or using this battery in the vicinity of other battery
chemistries. This battery does not emit or absorb any gas during
storage, transportation or during normal operating conditions.
•Batteries must not be installed with the output terminals reversed. A reversed battery
could be charged by other batteries in the circuit during discharge;
or discharged by the charging system during charge.
•Battery terminals must be covered with non-conductive protective devices to avoid
any possibility of shorting during handling, shipping or storage.
1.5.4 Shipping
True Blue Power lithium-ion cells and batteries are designed to comply with all applicable
shipping regulations as prescribed by industry and regulatory standards. This includes
compliance with the UN recommendations on the Transport of Dangerous Goods, IATA
Dangerous Goods Regulations, applicable U.S. DOT regulations for the safe transport of
lithium-ion batteries, and the International Maritime Dangerous Goods Code. In accordance
with IATA and per UN 3480, PI 965, Section 1A and 1B, when shipped by air, the True Blue
Power Advanced Lithium-ion Battery will be shipped with a state of charge (SOC) not to
exceed 30% of rated capacity. This battery is classified as a Class 9 Dangerous Goods. If the
battery requires shipment, please contact the manufacturer for additional instructions on
proper procedures.
NOTE: The unit is shipped with approximately 30% state-of-charge (SOC). Upon
receipt the battery shall be fully charged using the procedures listed in this manual
(prior to storage and again prior to installation/use).
Upon receipt the battery shall be fully charged. Batteries that are stored thereafter shall be
fully recharged at a minimum every six (6) months, following the procedure set forth in
Section 5.3.2. For more detailed storage instructions refer to Section 5.5.
CAUTION
CAUTION