Mid-Continent Instrument TRUE BLUE POWER TB40 Series Technical Document

Revision F • June 23, 2022

1 Manual Number 9019288 • Revision F, June 23, 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. 34
th
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 9019288 • Revision F, June 23, 2022
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LIMITATIONS 11
2.5MODIFICATION 11
SECTION 3INSTALLATION 12
3.1GENERAL 12
3.2PRE-INSTALLATION INSPECTION 12
3.3PARTS 12
3.4INSTALLATION 13
SECTION 4OPERATION 21
4.1DESCRIPTION 21
4.2CONSTRUCTION AND THERORY OF OPERATION 21
4.3OPERATIONAL MODES 24
4.4BATTERY COMMUNICATION 29
4.5PERFORMANCE 35
SECTION 5CONFORMANCE 37
5.1DISPATCH VERIFICATION AND IN-FLIGHT MONITORING 37
5.2INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 37
5.3CONTROL MODE 38
5.4OPTIONAL SERVICE 41
5.5COMPONENT SERVICE 43
5.6STORAGE INFORMATION 44
5.7END OF LIFE 45
5.8DISPOSAL 45
5.9DO-311A COMPLIANCE QUALIFICATION FORM 46
5.10DO-160 ENVIRONMENTAL QUALIFICATION FORM 47

3 Manual Number 9019288 • Revision F, June 23, 2022
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
D 12/30/2020 Revised mounting instructions, corrected number of cells,
updates related to software version 1.0.2. WVC
E 01/06/2022 Added recommended chargers; updates related to
software version 1.0.3; updated EQF. WVC
F 06/23/2022 Updated ARINC 352 status; revised EQF. VAA

4 Manual Number 9019288 • Revision F, June 23, 2022
SECTION 1 GENERAL DESCRIPTION
1.1 INTRODUCTION
The TB40 series Advanced Lithium-ion Battery, part numbers 6430040-( ), are designed to deliver
high current capability to start piston and turbine aircraft engines and subsequently, provide power
to the aircraft electrical bus in the event of generator function loss. The TB40 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 TB40 is a complete
battery solution providing significant value and benefit to an aircraft designer, owner and operator.
Key features of the TBX series (inclusive of the TB20, TB30, TB40 and TB60) 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 TBX series Advanced Lithium-ion Batteries require 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 TB40 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. Handles integrated into the lid of the enclosure provide
ease of lifting and carrying for installation, removal and transport. The 1.50 inch diameter vent port
can be located on either the front or top of the unit for an exhaust connection that directs any
released emissions appropriately.