Installation Manual and Operating Instructions
Contents
1. BRIGHTNE TMENT M MULAS IS R Se D Test out to MD835 Pin 2 Y Test in to MD835 Pin 6 Figure 2 3 MD835 Control Switch Annunciator Outline Drawing and Pinout Specifications 8 VDC 15 amps max EDs 33 lbs 55 C to 70 C 0 to 55 000 Ft MS3102E16S 1P MS3106F16S 1S Bezel and Case Black Arm Off Test Labels Opaque and Backlit White TBY Annunciator Backlit Amber on discharge TEST Annunciator Backlit Green pass no light fail ighting Weight Temperature Altitude Connector Mating Connector 0 to 55 000 Ft Mi MS3106F168 15 0 00 0 0 Bezel and Case Black Power Input Table 2 3 MD835 Annunciator Specifications True Blue Power 9 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 3 1 SECTION 3 INSTALLATION GENERAL This section contains mounting electrical connections and other information required for installation These instructions represent a typical installation and are not specific to any aircraft 3 2 A 3 3 PRE INSTALLATION INSPECTION Unpacking Carefully remove the T8835 EPS from the shipping container The shipping container and packing are designed specifically for the transit of lithium batteries and approved by international transportation agencies These materials should be retained for use should these units require future shipment Inspect for Damage Inspect the shipping container and units for any signs of damage2. L 02 26 2015 Add Mod 3 Extended filtering for high transient load current True Blue Power a division of Mid Continent Instrument Co Inc 3 Manual Number 9016798 Rev L February 26 2015 TABLE OF CONTENTS FOREWORD ERROR BOOKMARK NOT DEFINED REVISION HISTORY 2 TABLE OF CONTENTS 4 SECTION 1 GENERAL DESCRIPTION 5 1 1 PURPOSE 5 1 2 PHYSICAL DESCRIPTION 5 1 3 FUNCTIONAL DESCRIPTION 5 1 4 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 MODIFICATIONS 7 SECTION 3 INSTALLATION 10 3 1 GENERAL 10 3 2 PRE INSTALLATION INSPECTION 10 3 3 PARTS 10 3 4 INSTALLATION 11 SECTION 4 OPERATION 19 4 1 DESCRIPTION 19 4 2 THEORY OF OPERATION 19 4 3 INSTALLED OPERATION 21 4 4 MAINTENANCE 22 4 5 PERFORMANCE 24 SECTION 5 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 27 5 1 TEST AND VERIFICATION INTERVALS 27 5 2 COMPONENT MAINTENANCE MANUAL 27 5 3 STORAGE INFORMATION 27 5 4 DISPOSAL 27 APPENDIX 1 28 True Blue Power 4 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 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
3. 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 MOD3 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 FAA TSO C179a RTCA DO 160F DO 311 M f i od 3 of the T8835 EPS contains the following changes from MOD 2 KANA Extended filtering for high transient load current True Blue Power 7 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 3 1 6 45 CG ref e 1 37 CG ref 12 68 1 000 Q 221 Alignment hole e _A Auxiliary PG output adjustment Connector 5 only a 1 keying 3 87 Nameplate gt e l e Y Figure 2 2 TS835 Outline Drawing Model Number Mid Continent Identifying Feature Part Number Standard model TS835 5 MD835 5 Additional auxiliary output 3 5 5VDC Table 2 2 Model and Part Numbers True Blue Power 8 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 1 40 THREAI 45 DEEP MAX lb eh e
4. 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 4 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 14 TECHNICAL SPECIFICATIONS TS835 EPS Physical Characteristics Weight 4 8 pounds 2 16 kg Dimensions 12 7 inches long max 1 inch for handle see Figure 2 2 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 1 TS83
5. capacity versus load see Figure 4 2 The TS835 is rated for 4 5Ah at the 1C rate This will support a 4 5A load for 1 hour of operation However its constant capacity versus load capability means that at double the load or 9 0A the battery still maintains the linear instead of logarithmic relationship of load versus time producing 30 minutes or 0 5 hours of power 9 0A x 0 5 hours 4 5Ah at 2C rate Similar results can be found at the maximum power rating of the TS835 For a 20A load or approximately a 4 5C rate the battery will last approximately 13 5 minutes 4 5Ah 20A 0 225 hours 13 5 minutes Ultimately this allows a much longer lasting battery at all load levels The battery cells are stable and perform well over temperature While comparable technologies suffer significantly from the effects of high temperature the lithium cells used in the TS835 can retain more than 90 of their capacity after 200 full discharge cycles at 60 C True Blue Power 20 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 True Blue Power s use of lithium nanophosphate cells translates to less long term maintenance costs At the 1C rated load of 4 5A data from the cell manufacturer demonstrates that 80 of the original capacity is retained after 7000 complete discharge and recharge cycles While the emergency use of the T8835 system in an aviation application may only experience a few complete dis
6. sustained in transit If necessary return the units to the factory using the original shipping container and packing materials File any claim for damages with the carrier NOTE The unit is shipped with approximately a 5096 state of charge to extend storage life and prevent loss of capacity Perform a complete charge on the TS835 using the procedures listed in this manual prior to installation and or use PARTS 3 3 1 Included Parts A MD835 Emergency Power Supply B 20A mini blade fuse installed MCI p n 9016763 or equivalent C Installation Manual MCI p n 9016798 D CRI diode kit MCI p n 9017207 Mod 0 units only 3 3 2 Installer Supplied Parts Rack 1 4 ATR MCI p n 5120 107 C01 or equivalent Mating Connector 13 pin ARINC MCI p n 9016600 2 4 5 or equivalent Emergency Fuse Bypass Switch 2 version only Two position off on capable of appropriate current for applied load om Panel Controls D MCI Control Switch Annunciator MCI p n 9017176 E Annunciator Mating Connector 7 pin circular MCI p n 9017119 or equivalent OR alternative option D Panel Switch Three position off on momentary capable of 20A minimum E Test Annunciator 327 lamp or equivalent 3 3 3 Optional Parts for Emergency Power On Annunciation This feature is included in the MCI Control Switch Annunciator p n 9017176 A Diodes 1N5614 aty of 2 or equivalent B Annunciator 327 lamp or equivalent
7. the current draw of the unit reaches 0 15A or below the unit is fully charged True Blue Power 22 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 4 4 2 Fast Charging Mod 0 units only By grounding an additional pin on the connector during charging pin 4 the unit can be put into fast charge mode This allows the unit to draw up to 3A and fully charge the battery cells in approximately 2 hours The unit must be removed from the airplane to utilize the fast charge procedure A B To manually fast charge a unit apply a ground to pin 4 to enable the fast charge mode Apply 28 9 0 1VDC of power to the input pin pin 10 and connect the ground to pin 12 THE POWER SUPPLY MUST BE SET TO A CONSTANT CURRENT OF 3 0A The unit will draw 3 0A of power until the batteries have been charged to the voltage set limit At that time the current draw will begin to decrease and the voltage of the cells will remain constant CCCV method constant current constant voltage When the current draw of the power supply reaches approximately 1 0A or below complete the charge cycle by removing the ground to pin 4 and follow step 4 4 1 B above Do not allow the unit to remain in fast charge mode for extended periods of time once the current draw reaches this low level 4 4 3 Capacity Verification To test the unit for capacity verification apply the following procedure 15 40 C A Charge
8. to add 5VDC Auxiliary Power Output to 1 or 2 versions This feature includes CR1 diode and Mating Connector C MD835 5V Module MCI p n 9017201 to attach a vent hose to the MD835 unit this is only for units made after 1 15 14 D Vent kit MCI p n 9017983 Use with 34 ID x 1 OD min high temp silicone tubing True Blue Power 10 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 3 4 INSTALLATION Install the EPS in the aircraft in accordance with the aircraft manufacturer s instructions and the following steps HARNESS PREPARATION A If using the MD835 5V Module MCI p n 9017201 i Prepare aircraft wiring with mating connector in accordance with Installation Wiring Diagram Figure 3 5 ii MD835 5V Module includes the Mating Connector shown in Figure 3 2 If using the MD835 Control Switch Annunciator MCI p n 9017176 i Prepare aircraft wiring with mating connectors and appropriate interconnects per Figure 3 3 and 2 3 If installing an MD835 MOD O i The CR1 Diode identified in the Installation Wiring Diagrams is REQUIRED as an external installation component for Mod 0 units which do not use the MD835 Control Switch Annunciator or the MD835 5V Module ii Prepare aircraft wiring with mating connector in accordance with Installation Wiring Diagram Figure 3 3 iii See RACK PREPARATION and Figure 3 7 below for CR1 diode mounting instructions If installing an MD835
9. 16798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 SECTION 4 OPERATION 4 1 DESCRIPTION The True Blue Power TS835 Emergency Power Supply is designed to supply backup power to any load desired in the case of primary power loss in an aircraft It utilizes rechargeable lithium iron nanophosphate chemistry to provide 20 0 28 0VDC and 4 5 Ampere hours of capacity at the 1C rate see Performance below It utilizes a 13 pin ARINC style connector and is designed to be installed in a standard ATR equipment rack 4 2 THEORY OF OPERATION The TS835 Emergency Power Supply system provides a nominal voltage of 24 5VDC and a fuse limited maximum power output of 20 amps The TS835 5 model also provides an additional auxiliary output that is adjustable 3 0 5 5VDC The unit is designed to receive a 20 32VDC input from the aircraft 4 2 1 Maintaining Charge In normal operation the unit continuously monitors the input voltage from the aircraft s essential bus and only provides battery power when the input is lost The unit uses the aircraft power to maintain a full charge on the battery cells This is not a constant load on the aircraft The charging circuit only activates when the voltage on the cells drops below a set value When in this recharging mode the load on the aircraft system is typically less than 0 3A but can be as high as 5 5A if recharging an empty battery 3 5A and powering the heater 1 7A in a cold
10. 2 The following are descriptions of the current modification releases of the T8835 EPS RTCA DO ak DO Aii mA 1005000 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 FAA TSO C179a EAT RTCA DO 160F DO 311 Mod 0 is the initial release of the T8835 EPS Hee 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 FAA TSO C179a Mod 1 of the TS835 EPS contains the following changes from MOD 0 RTCA DO 160F DO 311 IPIE EE BE E 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 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 FAA TSO C179a RTCA DO 160F DO 311 Mod 2 of the TS835 EPS contains the following changes from MOD 1 bur EREEEE HEE End plates and connecter are sealed to prevent discharge gases from escaping these locations
11. 28VDC 6 5VDC Out IN See Note 5 e Pag o GN GN KE KE EN 2 7 5 5VDC Adjustable Output mig 8 E Ba IN E 0 D g IN Figure 3 5 Installation Wiring Diagram MD835 1 With 9017201 5V Module True Blue Power a division of Mid Continent Instrument Co Inc 16 Manual Number 9016798 Rev L February 26 2015 1 67 14 43 12 50 r 1 50 Alignment Pin p ese 2 35 m AM 1 T e Spring Nut 4X 0 175 THRU m 100 Y 0 337 2 40 9 00 5 u A i V e N 4 45 o y sp 1 mo i 0 38 i gt 3 03 z NE s DPXB Cut Out l l i per ARINC 404 0 48 Figure 3 6 Installation Rack Drawing Per P N 5120 107 CO1 True Blue Power 17 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 Item 1 1 jNu440Hex 000 1 1 1 1 1 1 Figure 3 7 Example I nstallation of CR1 Diode p n 54 2007 1 into Rack required for Mod 0 unit only Figure 3 8 i Installation of 5V Module p n 9017201 into Rack True Blue Power 18 Manual Number 90
12. 3 2 18h 2 0A 1 00 8 88h 0 5A 0 10 Q Q o S capacity hours True Blue Power 25 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 TRUE SLUE POWER 3 MDE3S Performance Capacity vs Temperature and Load 50 Constant Current Discharge of 4 5A 55 C 3 hour Temperature Pre Soak warm up time min 50 60 70 R 8 E capacity min 10 Figure 4 3 Nominal Battery Capacity versus Warm up Time Cycle life performance 100 DOD various temperatures TE g 8g 3 emm 25 deg C 2 3A charge 2 3A discharge 45 deg C 3A charge 5A discharge F E Discharge capacity 96 2 60 deg C 3A charge 5A discharge 20 10 0 0 200 400 600 800 1 000 Cycles True Blue Power 26 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 SECTION 5 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 5 1 TEST AND VERIFICATION INTERVALS A A remote in panel test see Section 4 3 1 should be performed prior to flight to verify the state of charge of the battery Should the test not pass the unit should be removed and either recharged or capacity checked per Section 4 4 3 If the unit continues to fail the remote test it should be returned to the manufacturer for maintenance B Routine testing and capacity verification should be performed on a bi annual schedule every 24 months from date ins
13. 5 EPS Functional Performance Certification FAA TSO C179a EASA TSO ETSO C179a Performance RTCA DO 311 Minimum Operational Performance Standards for Qualification Rechargeable Lithium Battery Systems Environmental RTCA DO 160F Qualification F2S2BB RCC1 UG U2FF1 EXXXXXZ ZXX AZ ZC RR IH A3H33 XXAX With MD835 5V Module P N 9017201 installed DO 160E Section 20 HG DO 160F Section 22 A4G44 Power Input 20 to 32 VDC 5 2A max Power Output 20A max total Primary 24 5 VDC nominal Auxiliary 3 0 5 5VDC adjustable 5A max Battery Capacity 4 5 Ah nominal 1C rate Perform capacity check every 2 years Reliability 10 year expected life 8096 initial capacity retained Table 1 2 True Blue Power 5 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 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 tempe
14. An auxiliary power output is available for the T9835 that simultaneously provides the primary 24 5V nominal output as well as a separate adjustable 3 0 5 5V lighting output This can be provided by adding the MD835 5V Module p n 9017201 to the TS835 1 or TS835 2 models or is a built in feature of the TS835 5 model This output is available during normal operation aircraft power available and emergency operation However it is recommended that an external relay be provided on the 5V output so that it only provides power to the emergency lighting bus load when aircraft power has failed See Figure 3 4 4 4 MAINTENANCE Because the cells are designed to maintain their charge holding capability over time True Blue Power is recommending a two year maintenance cycle The two year check includes a full charge discharge and recharge while evaluating the discharge time against minimum requirements Additionally at any time when the capacity of the unit is in question or after being utilized in an in flight emergency situation True Blue Power recommends conducting this procedure 4 4 1 Standard Charging A If 28V power is applied to the primary input pin power on pin 10 ground on pin 12 a standard charge will take approximately 1 5 hours for a fully discharged unit up to 8 hours for Mod 0 The current draw should be 0 15 3 5A throughout the charge cycle Use of a power supply capable of 5A is recommended to provide full charge current B When
15. H ANNUNCIATOR P N 9017176 5 INSTALLER SUPPLIED SWITCH S2 FOR 2 FUSE BYPASS VERSION 6 USE AWG 16 WIRE FOR POWER AND GROUND ALL OTHER LINES CAN BE AWG 22 WIRE Figure 3 3 Installation Wiring Diagram MD835 1 and MD835 2 True Blue Power 14 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 4 e O O L l J L ESSENTIAL 3 S1 OONARMED Y BUS 10 O O OFF P _ CRI A TEST ff EN EMER de 1 gt POWER oe eo EMERGENCY 0 MASTER pr EPA ME e uis d BATTERY MAN DS1 i O RELAY _ BATTERY Vcr _ DS2 TEST EMER 6 N O e 4 POWER El cm ON E R1 CRI 1N3620 ieee Bol r 2 200 OHM CR2 amp CR3 1N5614 Un pepe LIGHTING BUS 10W DS1 amp DS2 327 LAMPS DIMMING CONTROL Lio o oos sd OR EQUIVALENTS xd 5 O En Po 4 L ESSENTIAL E RELAY Bus 12 6 5V LIGHTING LOAD 1 CR1 IS REQUIRED FOR MOD 0 UNITS CR1 IS OPTIONAL FOR MOD 1 AND ABOVE SEE SECTION 3 3 1 AND NOTE 4 BELOW 2 INSTALL CR2 CR3 DS1 AND R1 IF ANNUNCIATION OF EMERGENCY POWER ON IS REQUIRED SEE SECTION 3 3 3 AND NOTE 4 BELOW 8 S1 IS ON OFF MOMENTARY SWITCH 4 THIS PART OF THE CIRCUIT IS INCLUDED IN THE MCI MD835 SWITCH ANNUNCIATOR P N 9017176 5 9 AND 13 CONNECTED INTERNALLY EITHER CAN BE USED FOR 5V INPUT ENABLE 6 SUGGESTED 5V INSTALLATION INSTALLER SUPPLIED COM
16. IS REQUIRED True Blue Power 12 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 Pn 6 Test Output Pin 8 reserved Cd ino se Bypass 2 only OR 5V Enable 5 only note unused reserved pins may not be populated MD835 1 5 Figure 3 1 Pinout and Unit Connector MCI P N 9016600 2 MCI P N 9016600 4 MCI P N 9016600 5 for MD835 1 or 5 for MD835 2 for MD835 5 optional Figure 3 2 Mating Connectors True Blue Power 13 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 o of N gt ESSENTIAL BUS 3S1 p 10 O gt O OFF ATEST CR1 WO cwn PoweR O 8 e O O HA 4 EMERGENCY MASTER O BUS BATTERY RELAY E __ BATTERY __ DS2 TEST 6 x zL 5 cns ON E n R1 CRI 1N3620 T 7 o jo EMERGENCY S 200 OHM CR2 amp CR3 1N5614 T FUSE BYPASS 5 10W DS1 amp DS2 327 LAMPS 9 do 2 VERSION L OR EQUIVALENTS 4 Rex ESA rr 112 _ 1 CR1 IS REQUIRED FOR MOD 0 UNITS CR1 IS OPTIONAL FOR MOD 1 AND ABOVE SEE SECTION 3 3 1 AND NOTE 4 BELOW 2 INSTALL CR2 CR3 DS1 AND R1 IF ANNUNCIATION OF EMERGENCY POWER ON IS REQUIRED SEE SECTION 3 3 3 AND NOTE 4 BELOW 3 S1 IS ON OFF MOMENTARY SWITCH 4 THIS PART OF THE CIRCUIT IS INCLUDED IN THE MCI MD835 SWITC
17. MOD 1 MOD 2 or MOD 3 i Prepare aircraft wiring with mating connector in accordance with Installation Wiring Diagram Figure 3 3 ii The CR1 Diode is optional for Mod 1 Mod 2 and Mod 3 units and allows the emergency loads or bus to be powered through the main bus when the battery is removed from the installation iii The CR1 Diode is included as part of the MD835 5V Module or Control Switch Annunciator if used If not used instructions for installing the CR1 diode can be found in Step C ii above RACK PREPARATION A Select location in accordance with Section 2 and mount the ATR rack according to the aircraft manufacturer s recommended specification See sample of 1 4 ATR rack in Figure 3 6 Other racks may vary Refer to the Unit Connector Figure 3 1 and Mating Connector Figure 3 2 to ensure that the three half hex alignment pins are installed correctly to mate with the alignment holes in the unit connector Note there are three possible configurations as shown in the figures referring to the MD835 versions and their corresponding alignment pins If used install the MD835 5V Module in the 1 4 ATR rack according to MCI P N 9017201 drawing See Figure 3 8 If required install CR1 diode onto rack Firmly mount diode to a thermally conductive surface heatsink An electrical insulator which is thermally conductive must be placed between the diode and heatsink included with unit in CR1 diode kit Mounting the diode to the
18. PONENTS 7 USE AWG 16 WIRE FOR POWER AND GROUND ALL OTHER LINES CAN BE AWG 22 WIRE Figure 3 4 Installation Wiring Diagram MD835 5 True Blue Power 15 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 15A e eek O O i J L ESSENTIAL 3 gt S1 OON ARMED Y BUS O O OFF A TEST EMER ZN POWER O 9 EMERGENCY MASTER BUS BATTERY DS1 O RELAY BATTERY i DS2_ TEST ENER POWER ON 2 R1 AIRCRAFT 200 OHM CR2 amp CR3 1N5614 o POWER 10 W DSi amp DS2 327 LAMPS OR EQUIVALENTS 5VDC OUT 9017201 6 POLE TERMINAL BLOCK CR1 IS INCLUDED IN THE MCI MD835 5V MODULE P N 9017201 SEE SECTION 3 3 3 INSTALL CR2 CR3 DS1 AND R1 IF ANNUNCIATION OF EMERGENCY POWER ON IS REQUIRED SEE SECTION 3 3 3 AND NOTE 4 BELOW S1 IS ON OFF MOMENTARY SWITCH THIS PART OF THE CIRCUIT IS INCLUDED IN THE MCI MD835 SWITCH ANNUNCIATOR P N 9017176 THIS PART OF THE CIRCUIT IS INCLUDED IN THE MCI MD835 5V MODULE P N 9017201 PORTIONS OF INTERNAL CIRCUITRY NOT SHOWN USE AWG 16 WIRE FOR POWER AND GROUND ALL OTHER LINES CAN BE AWG 22 WIRE 3 Power 4 Test Ground __ _ Switch 2 20 26VDC 5 Test Out Z5 1 Indicator 1
19. TRUE BLUE POWER A division of Mid Continent Instrument Co Inc www truebluepowerusa com Installation Manual and Operating Instructions TS835 Series Emergency Power Supply True Blue Power is a division of Mid Continent Instrument Co Inc Mid Continent Instrument Co Inc dba Mid Continent Instruments and Avionics 9400 E 34 Street N Manual number 9016798 Wichita KS 67226 Rev L February 26 2015 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 Street N Wichita KS 67226 USA PH 316 630 0101 FX 316 630 0723 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 reference and the page number Send your comments to True Blue Power c o Mid Continent Instrument Co Inc Attn Technical Publications 9400 E 34th Street N Wichita KS 67226 USA PH 316 630 0101 FX 316 630 0723 All products produced by Mid Continent Instrument Co Inc including those identified as Mid Continent Instruments and Av
20. Temp 55C High Temperature 5 Operating High Temp 70C Decompression 6 Altitude 55 000 ft Overpressure 15 000 ft Temperature Variation Category S2 Humidity 26 Category B Operational Shock and Category B Crash Safety Vibration Category R Curve C C1 Category U Curve G Category U2 Curve F F1 RCC1 UG U2FF1 9 Category E Waterproofness Category X Category X Sand and Dust Category S Audio Frequency Conducted 18 Category Z Susceptibility Induced Signal Susceptibility Category ZC 9 Radio Frequency Susceptibility Category RR 1 Emission of Radio Freg Energ Susceptibility True Blue Power 28 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015
21. ch Annunciator the ARM OFF TEST display is opaque white for daytime viewing and backlit dimmable for night time viewing Brightness can be set on the side of the annunciator during installation To test the TS835 typically required by the aircraft operation manual prior to dispatch press and hold the three way switch into the Test position When installed correctly per Figure 3 3 the test annunciation light will illuminate Release the switch This indicates that the T8835 has a minimum of 80 of the unit s current capacity available and also verifies that the heater and temperature monitoring is operational This indicates that the battery has a minimum of 8096 capacity available and is qualified for use On the MD835 Control Switch Annunciator the green TEST annunciation light will appear For most accurate results the remote test procedure should be to select the TEST position on the panel switch from the OFF position prior to activating the system see Section 4 3 2 and prior to applying power to the essential aircraft bus True Blue Power 21 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 4 3 2 4 3 3 4 3 4 4 3 5 4 3 6 Activation To activate or arm the system prior to flight place the three way activation switch in the ARM or ON position This will apply power to the unit allowing it to maintain its maximum charge capability and to provide uninterrupt
22. charges in its lifetime its cycle life also translates to calendar life The cell manufacturer asserts a projection of more than 10 years of usable life in the field 4 2 7 Heater Although the cells are designed to operate at low temperatures the unit also incorporates a heater to provide additional performance at even lower temperatures A temperature monitoring circuit is incorporated in the cell pack that is used to activate the heater when ambient temperature drops below approximately 0 C The heater draws about 1 7A when in use This prevents the cell electrolyte from freezing during discharge or charging at extremely low temperatures A temperature monitor in the circuit also checks for any over temperature condition that could arise from either the cells or the heater A fault would result in the unit shutting down to prevent damage to the pack The replaceable fuse in the unit prevents damage to equipment in the event of a short circuit at the load 4 2 8 Software and Complex Hardware No software or complex hardware is incorporated in the design of this product 4 3 INSTALLED OPERATION The following are operating instructions for using the T5835 Emergency Power Supply when installed in an aircraft 4 3 1 Remote Test The remote test activation switch installed in the panel MCI p n 9017176 or installer provided has three positional settings OFF latched ARM latched and TEST momentary On the MD835 Control Swit
23. e 4 3 for required warm up time and available capacity The warm up procedure requires input power to be applied and the activation switch to be in the On Arm position The TS835 is designed for high cycle life and long calendar life However all batteries degrade in performance over time even when correctly maintained Figure 4 4 demonstrates cycle life at various temperatures A poorly maintained battery will suffer accelerated degradation in excess of the guidelines given in this document Extended storage in a highly discharged state or at high ambient temperatures above 35 C may permanently damage a battery or reduce its performance Complete charging is required every six months if not in use True Blue Power 24 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 TRUE BLUE POWER Mons peto A division of Mid Continent instrument Co inc www ruebluegowerusa com Voltage vs Time 30 Constant Current Discharge of 4 5A Temperature of 23 C 25 20 3 t 15 4 2 2 10 5 0 4 T 7 T T r r r r y 8 8 8 8 8 8 8 8 8 8 8 8 8 8o B 3 3 35 38 3 3 amp f g discharge time mm ss TRUE BLUE POWER 3 A Gon of Was Continent instrument Co ic ewe truebiuepomerusa Com yg miU CONTINENT MOI PRS NSTRUMENTS H cii idis Capacity vs Load 100 00 Constant Current discharge 10096 SOC to 20V EPV 25 C 0 17 h 25 0A 0 43 h 10 0 A 10 00 0 88 h 5 0 A E 5
24. ed power to the loads on the emergency bus should primary aircraft power fail If installed the optional Emergency Power On feature provides annunciation of when the battery is in use discharging This feature is included in the MD835 Control Switch Annunciator and is indicated by an amber STBY annunciation Disarm By placing the three way activation switch in the OFF position the input voltage to the unit will be disconnected disabling both the ability of the battery to charge or discharge The activation switch should always be kept in the OFF position when not in use to prevent accidentally discharging the battery Resetting the Automatic Shut off The unit is designed to shut down within 5 minutes to prevent unwanted discharge in the event that input power is lost and the load is below 150mA In order to reactivate the unit for charging or discharge restore an input voltage of 22 32V or briefly activate the test feature and then return the switch to the ARM position Either action will reset the automatic timer and allow the unit to function properly Emergency Fuse Bypass TS835 2 ONLY The TS835 2 has a fuse bypass feature available When installed a panel mounted switch allows the pilot or crew to route battery power around the internal fuse of the TS835 This would allow the emergency bus to remain powered in the event that primary aircraft power fails and the internal fuse of the T8835 was open Auxiliary Power Output
25. environment When the aircraft voltage drops below 24V the battery will stop charging in order to minimize the load on the main power system 4 2 2 Discharge In order to produce battery power the unit must first have input power applied then removed 4 2 4 Automatic Shut off When the input voltage to the unit is applied and drops below 21 5V the unit will begin supplying power to the associated load The output voltage can range from 28 0 to 20 0VDC during a discharge cycle However the output voltage is typically between 24 25V during the majority of the discharge time after the first 596 is discharged and then until about 1596 of the battery s capacity is remaining The unit will shut itself off when the voltage provided by the internal cells reaches approximately 19 5V This is to prevent permanent damage to the unit or individual cells At the end point voltage of 19 5V the battery has approximately 196 of remaining power available Therefore this precautionary shut off does not significantly detract from the amount of available power that might be supplied to the load in an emergency 4 2 3 Auxiliary Power Output For the TS835 5 model the Auxiliary Power Output is available and typically used for lighting of required equipment during an emergency The output is adjustable from 3 0V to 5 5V and provides up to 5A of current While the auxiliary power is available during both normal and emergency operation an equivalent installation
26. er and temperature monitoring is operational 4 2 6 Battery Performance and Capacity Based on new nanoscale materials initially developed at MIT low impedance nanophosphate electrode technology provides significant performance advantages over alternative high power technologies A standard measure of rechargeable battery capacity involves both the current for time performance i e amp hours and also the C rate Many typical lead acid batteries and some lithium systems as well are defined at a 1 20 0 05 or 1 1 o 0 1 C rate This is defined as the constant load that can be applied over 20 or 10 hours respectively For example a battery rated at 5 Ah at a 0 1 C rate can deliver 0 5A for 10 hours 0 5A x 10 hours 5Ah However that same system typically does not perform linearly at higher C rates As an example a 5Ah lead acid battery rated at 0 1C can typically support approximately a 3 6A load for 1 hour equal to a 1C capacity of 3 6Ah The capacity is defined by a logarithmic function of load versus time Therefore loads applied to this type of battery which exceed the rated C rate quickly decrease the time available Applying a 5A load to a 5Ah battery rated at 0 1C does not last 1 hour rather would last approximately 36 minutes Doubling the load to 10A for the same system would last less than half the time or approximately 15 minutes One of the significant advantages to the lithium nanophosphate technology is its constant
27. eriods In addition self discharge rates are directly related to the storage temperature Higher storage temperatures will result in faster self discharge rates Recommended maximum storage temperature is 35 C 97 F Exposure to higher storage temperatures for sustained periods of time are possible but may increase the self discharge rate or result in some loss of capacity B lf left unused for more than 6 months the battery should be recharged prior to use following the procedure set forth in Section 4 4 5 4 DISPOSAL NOTE All lithium ion batteries are classified by the federal government as non hazardous waste and are safe for disposal as normal municipal waste However these batteries do i contain recyclable materials and recycling options available in your local area should be considered when disposing of this product Do not incinerate True Blue Power 27 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 APPENDIX 1 ENVIRONMENTAL QUALIFICATION STATEMENT NOMENCLATURE Emergency Power Supply MODEL PART NUMBER TS835 MD835 TSO NUMBER C179a MANUFACTURERS SPECIFICATIONS Minimum Performance Specifications Test Specification TS 443 Test Data Sheet TDS 443 QUALIFICATION STANDARD RTCA DO 160F dated Dec 6 2007 RTCA DO 160G dated Dec 8 2010 CONDITIONS SECTION DESCRIPTION OF TEST Temperature and Altitude Category F2 Low Temperature 5 Operating Low
28. ionics or True Blue Power are designed and manufactured in Wichita KS USA Copyright 2015 Mid Continent Instrument Co Inc REVISION HISTORY True Blue Power 2 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 Rev Date Detail 1 04 30 09 Preliminary release 2 12 02 09 Updated information A 03 11 10 Production release B 04 15 10 Revised Figure 3 3 Installation Diagram C 05 18 10 Added MCI P N 54 2007 1 to diode options in Section 3 3 2 Add Section 4 3 5 and related information regarding MD835 2 version D 10 12 10 Update unit picture with True Blue Power label E 01 13 11 Updated to include optional annunciator switch F 04 14 11 Added 9017201 5V Module as an optional part G 07 27 11 Added additional installation instructions for 9017201 5V Module H 07 06 12 Update manual to add references to True Blue Power division of Mid Continent Instrument Co Inc Identify new model number TS835 while 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 J 11 15 12 Add ETSO to Table 1 2 Updated Section 2 2 and 2 4 for equipment location limitations Removed 4 2 6 Updated 4 2 7 Add 4 2 8 regarding software complex hardware K 1 6 14 Updated document for vented version that applies to all 835 units
29. nally as part of the MD835 Control Switch Annunciator FINAL INSTALLATION A Install the mating harness into the 1 4 ATR rack If MD835 5V Module is installed adjust trimpot on Module for desired Auxiliary Power Supply output 3 0 5 5V B Slide the MD835 into the 1 4 ATR rack ensuring that the large spring loaded alignment pin mates with the Index Hole on the rear flange of the unit Hand tighten the spring nut of the rack onto the locking tab of the unit to secure If the MD835 5V Module is installed the mating connector may need to be aligned to the MD835 Loosen MD835 5V Module screws install MD835 into 1 4 ATR rack tighten top two screws remove MD835 and then tighten remaining screws to secure MD835 5V Module C For MD835 5 version set the output voltage 3 0 5 5V of the Auxiliary Power Supply by gently turning the adjustment screw accessed through the front of the unit See Figure 2 2 D If using the MCI vent kit p n 9017983 remove the label from the MD835 case marked Vent Cover Install the vent with the supplied gasket between the vent and the case Fasten the vent with the supplied screws using a medium strength thread locker Install a user supplied 34 ID x 1 OD minimum high temperature silicone tubing Use a clamp to attach the silicone hose to the vent Make sure tubing is securely fastened and no kinks or sharp bends exists anywhere in the silicone tubing E NO INTERNAL OR EXTERNAL COOLING OF THE UNIT
30. rature 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 4 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 T8835 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 structu
31. res 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 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 True Blue Power 6 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 TRUE SLUE POWER i 2 5 MODIFICATIONS EMERGENCY POWER SERIAL NO OAK Each model TS835 part number MD835 has a nameplate that identifies the Wut 24 32 VDG ana manufacturer part number description certifications and technical specifications of Capacity 45 Ah Nominal the unit It also includes the MOD or modification number representing notable eue ANM changes in the revision history of the unit See Table 2
32. side of the ATR rack is an acceptable location See figure 3 7 for an example True Blue Power 11 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 PANEL PREPARATION A Plan for parts in a location accessible to the pilot or crew during flight typically located in the instrument panel or other position in the cockpit B Install the MD835 Control Switch Annunciator or other 3 way switch and test annunciation lamp in the instrument panel For the MD835 2 unit install the user supplied Emergency Fuse Bypass switch in the instrument panel Installation of the Emergency Power On annunciation lamp is optional included with MD835 Control Switch Annunciator See Figure 3 3 3 4 or 3 5 If using the MD835 Control Switch Annunciator MCI p n 9017176 i Cut the instrument panel using the bezel dimensions and hole locations shown in Figure 2 3 ii Set the brightness of the ARM OFF TEST backlight for night time viewing using the adjustment on the side of the unit If the MD835 Control Switch Annunciator is not used i Parts must be provided and installed which include a panel switch S1 a power diode CR1 and an annunciator DS2 per Section 3 3 and Figure 3 3 C For optional indication of active battery output power Emergency Power On i Parts CR2 CR3 DS2 and R1 are required to be incorporated into the wiring harness and panel installation per Figure 3 3 ii These parts are included inter
33. talled See Section 4 4 for maintenance and test procedures C For short uses of the unit in the aircraft the aircraft system will recharge the unit on its own An in panel test can help determine whether the unit requires removal and recharge D Afull capacity check Section 4 4 should be performed any time there is concern regarding the capacity of the unit Mid Continent recommends removal of the unit and performance of a full capacity test any time after having incurred an in flight loss of power or subsequent activation and use of the T8835 Emergency Power Supply 5 2 COMPONENT MAINTENANCE MANUAL A The cells electronics fuse and other components that comprise the T8835 EPS are not user replaceable items Therefore data is not available from the manufacturer to conduct field repairs in the case of a faulty or expired product B Estimated life and recommended replacement interval for the internal battery cells can extend up to 10 years In the event that the unit exhibits failure insufficient capacity or expired life contact True Blue Power for overhaul exchange or replacement 5 3 STORAGE INFORMATION A n normal use the TS835 EPS utilizes the input power supplied to maintain the proper charge voltage and sustain the battery cells at peak capacity Although the chemistry of the cells used in the T8835 maintain an extremely low relative self discharge rate all batteries will slowly self discharge if left unused for long p
34. the unit using either the Standard Charge or Fast Charge method described in Section 4 4 1 and 4 4 2 respectively B Apply 28 0V to the input pin C Provide constant current load to the output pin 11 of 4 5A Tek Power TP3711 A or equiv D Remove the input power E Monitor the time required from removal of input power until the unit stops providing output power to the load F To be approved for service in standard applications the unit must provide 48 minutes of output power per the required procedure listed above NOTE For a specific aircraft installation and certification this value can be altered based on the particular load supported and the time necessary for regulatory or application need G Recharge the unit per Section 4 4 1 or 4 4 2 True Blue Power 23 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 4 5 PERFORMANCE Two of the many advantages of lithium battery technology are the relatively constant output voltage over time and the linear performance of capacity at multiple load levels The performance of the TS835 in these regards is demonstrated in Figures 4 1 and 4 2 respectively Actual capacity of the TS835 Emergency Power Supply may vary considerably depending on temperature charge status and battery condition Low temperatures can temporarily degrade battery capacity If the unit is stored below 18 C 0 F for 3 hours or more prior to dispatch refer to Figur
35. to that shown in Figure 3 5 is recommended such that it is only connected to the required load when primary aircraft power is lost If the aircraft power should return to normal levels the battery will cease to provide an output when the aircraft voltage exceeds the battery voltage The unit will begin recharging the cells if needed when the aircraft power returns to 24V or higher True Blue Power 19 Manual Number 9016798 a division of Mid Continent Instrument Co Inc Rev L February 26 2015 4 2 4 Automatic Shut off This feature allows the unit to prevent accidental or excessive self discharge when the aircraft is not in use When the input voltage drops below 21 5V and the load is below 150mA for a period of 5 minutes or no load exists then the unit will turn itself off and the output power is no longer available The unit can be activated either with an input voltage greater than 22V or by activating the test feature This safety and functional feature prevents downtime of the aircraft by ensuring that the unit is charged and ready for operation prior to each flight 4 2 5 Remote Test The unit has a self test feature that can be accessed remotely through a pair of pins on the connector When activated via a switch from the panel the circuit will close and light an annunciator if the unit passes the built in self test routine This indicates a minimum of 80 of the unit s current capacity is available and also verifies that the heat
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