TRUE BLUE POWER TC2000 Series Static Electrical Power Converter Instruction Manual

TRUE BLUE POWER TC2000 Series Static Electrical Power Converter

GENERAL DESCRIPTION

INTRODUCTION

The model TC2000 Series Static Electrical Power Converter is a lightweight power converter that translates an aircraft alternating current (AC) input of 115 volts at 360-800 Hertz to a 28 volt direct current (DC) output. Additionally the TC2000 can be bench operated on AC Mains with 115 or 230 volts at 47-65 Hz input and provide a 28 volt direct current (DC) output (see Note 1 below).

The wide input operating voltage and frequency make the TC2000 suitable for nearly any common business or commercial aircraft which provides 100-125 VAC between 360-800 Hertz. The output of 71 amps @ 28 VDC produces 2000 watts of power to supply avionics, instrumentation, seating, personal charging, lighting, and many other applications. The TC2000 Series Static Converter is FAA certified to TSO-C71 and tested to rigorous environmental standards and levels of RTCA DO160G. The small size and light weight 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 TC2000 Series has a robust Military-rated circular connector, and the rugged extrusion that houses the unit is designed to help dissipate heat and provide mechanical strength against vibration or other possibilities of damage. Two independent fans allow for a smaller unit and quiet operation, and keep the internal components cool extending the life of the unit.

TECHNICAL SPECIFICATIONS

Table 1.1

Electrical Attributes

Input Voltage| Aircraft: 115VAC nominal, 360-800 Hz.
AC Mains: 115VAC or 230VAC, 47 to 65 Hz. (Note 1)
Input Current (full load)| 22 Amps nominal; 28 Amps max
Input Current (unit off)| 2 Amps
Recommended Input Circuit Breaker| 30 Amps (for 115VAC aircraft use)
Output Voltage| 28VDC ± 0.5 VDC
Output Power| 2000 watts (28VDC @ 71 Amps rated)
Efficiency| 88% nominal

Table 1.2

Physical Attributes

Weight:| 9.9 lbs [4,49 kg]
Dimensions:

(not including connector mate)

| 14.00 inches x 6.32 inches x 3.46 inches (LxWxH) [35,5 x 16,1 x 8,8 cm]
Mating Connector (and cable clamp):| MCI P/N 9018993-1 and 9018550-2
Mounting:| Base mount – orientation not critical

Note 1: The TC2000 has not been tested to UL, CE, or other ground regulatory requirements.
Powering from AC mains is intended for testing or temporary use only.

Table 1.3

Qualifications

Certification:| FAA TSO-C71
Environmental Qualification:| RTCA DO-160G Environmental Category; See Section 5.2
Altitude:| 35,000 feet
Temperature:| -55°C to +70°C (-67°F to + 158°F)

PRE-INSTALLATION CONSIDERATIONS

COOLING
No external cooling is required. The unit is equipped with two internal DC fans that are thermostatically controlled. The fans normally run at a slow speed, but depending upon load and ambient temperature one or both fans may operate at a higher speed.

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.

EQUIPMENT LOCATION
The TC2000 Series is designed for mounting flexibility, allowing for installation inside or outside the pressure vessel with no requirement for temperature control within the temperature specifications.
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.
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.

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.

LIMITATIONS
The TC2000 contains an internal DC-to-DC conversion function to produce the rated output as specified. This function meets the requirements of FAA TSO-C71. The TC2000 also creates an initial translation of an alternating current (AC) input to the intermediate DC voltage, which then gets converted to the rated output. This initial translation of AC-to-DC power is considered a nonTSO function. This is due to the lack of an available AC-to-DC Technical Standard Order.

However, the AC-to-DC function is fully tested and verified per the equipment requirements and design as well as the stated environmental requirements. The data to support the non-TSO function has been submitted to and reviewed by the FAA along with the TSO-C71 requirements and functionality.
Additionally, there are limitations associated with a derating of the maximum continuous power available at the high end of the rated temperature and altitude specification. For more details, see Figures 2.1 and 2.2 below.

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 receive additional installation approval prior to being operated on each aircraft. The article may be installed only according to 14 CFR Part 43 or the applicable airworthiness requirements.

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 2.2 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.

INSTALLATION

GENERNAL INFORMATION
This section contains interconnect diagrams, mounting dimensions and other information pertaining to the installation of the TC2000 Series Static 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.

UNPLACKING AND INSPECTING EQUIPMENT
When unpacking this equipment, make a visual inspection for evidence of any damage that may have incurred during shipment.

The following parts should be included:

• A. Static Converter MCIA P/N 6432001-1
• B. Installation Manual MCIA P/N 9019049

Available Equipment:

• A. Mating Connector (& cable clamp) MCIA P/N 9018993-1 and 9018993-3

Equipment not provided:

• A. Mounting Hardware four (4) ¼-20 pan head screws ¼” lock washers (optional)
• B. Cable Harness Wire See Section 3.3 for specifications

CABLE HARNESS

Construct the cable harness with regards to the instructions below, and using Figures 3.3 – 3.5, and Wiring Diagram of Table 3.3.

Refer to Section 2: Pre-Installation Considerations in regards to routing precautions.

Wire Gauge Selection

Use of PTFE, ETFE, TFE, Teflon, or Tefzel insulated wire is recommended for aircraft use.
Use the following wire gauges for each of the pins in the connector. For the higher current input and output wires, use the larger wire size listed if the wire run is long to avoid voltage drop.

• Pins C and D – 4 to 6 AWG stranded wire
• Pins B and E – 8 to 10 AWG stranded wire
• Pins A, G, and F – 16-22 AWG stranded wire

Table 3.3 Connector Pinout

MS3102A32-10P Connector Pinout

A| Enable
B| AC IN Line
C| +28 VDC Output
D| 28VDC Return
E| AC IN Neutral
F| Parallel
G| Chassis Ground

Pin Assignment Information

1. Converter Input Power:
   AC Line input – Pin B – 115 VAC. Connect to the aircraft 115 VAC bus using a 30 Amp circuit breaker. AC Neutral input – Pin E – Connect to the aircraft 115VAC Return Bus.

2. Converter DC Output:
   The TC2000 DC Output is isolated from the incoming 115VAC and the inverter chassis. This allows the TC2000 to provide 28V DC output independent and isolated from other aircraft DC power sources if desired. DC +28V Output – Pin C – Positive 28 volt output from the converter. Use of one or more circuit breakers is optional.
   DC -28V Output – Pin D – Negative 28 volt output from the converter. In typical aircraft, the negative 28V is connected to the airframe. However with the TC2000 converter the 28V negative can be connected to an isolated return bus if it is desirable to have a 28V DC bus independent and isolated from the aircraft DC bus.
   Note: Use of a circuit breaker on the DC output is optional. For the full output of 2000W, a single circuit breaker current of 75 Amp maximum is recommended. If multiple branching circuits are connected to the output, then the total rating of all circuit breakers should not exceed 75 Amps.

3. Converter Remote Enable Control: (see section 4.2.1)
   Remote ENABLE (ON/OFF Control) – Pin A – Connecting this pin to the converter DC -28V Output turns-ON the 28V output of the Converter. If the Converter DC- 28V Output is connected to the airframe then a remote ENABLE switch only needs to connect this pin to the airframe to turn ON the output of the converter. When unconnected (output is OFF) this pin will have approximately 28 VDC present, internally limited to a few milliamps. If the Converter is to be enabled at all times, pin A is to be connected to pin D.

4. Converter Chassis Ground
   Chassis Ground – Pin G – Typically the converter chassis is grounded when the converter is mounted to the aircraft structure. This pin provides an additional chassis ground connection independent from the mounting. It is recommended that a wire of less than 18 inches in length be connected to this pin to provide additional grounding for the Converter.

5. Converter Parallel Operation
   Parallel – Pin F – More than one TC2000 can be connected in parallel to provide more than 2000 Watts of power conversion to 28 VDC. Contact Mid- Continent Instruments, True Blue Power for additional information on this feature. If the parallel operation feature is not being used, this pin should remain unconnected.

Example Wiring Diagrams
See Figures 3.4 and 3.5 for examples of potential wiring diagram options for installation purposes.

Harness Verification
With the TC2000 Series Static Converter disconnected, activate the aircraft power bus that supplies the unit and use a multi-meter to verify that aircraft power and ground with appropriate voltage is on the pins within the mating harness.

MOUNTING

Refer to Section 2: Pre-Installation Considerations in regards to equipment location.
The TC2000 Series Static Converter is designed for base mounting only (in any orientation). Four ¼-20 mounting holes should be provided in the aircraft in accordance with Figure 3.6. Secure the unit with four ¼-20 pan head screws, or equivalent. A lock-washer under the head of each screw is recommended.

INSTALLATION COMPLETION

Prior to operating the unit in the aircraft, it is recommended to verify the output and functionality of the unit. In order to prevent accidental damage to other systems, it is best not to attach the output to other equipment or power busses prior to verification. Verify the output of the unit at the terminating end of the cable with a multi-meter to ensure proper voltage and polarity. Once verified, installation can be completed and functionality of the remote on/off feature (if used) should be checked.

INSTALLATION CAUTION

Do not connect the output of the TC2000 Series Static Converter to the output of any other Converter or damage will result. Under no circumstance allow the output of the Converter to be connected to ground utility AC power or damage will result.

OPERATION

ELECTRICAL PERFORMANCE
The TC2000 Series Static Converter converts an alternating current (AC) voltage input to a regulated VDC output. See Table 4.1 specific output and input frequency.
Table 4.1 TC2000 Series Electrical Performance

The unit is capable of providing 2000 watts to power a variety of aircraft accessories including lights and onboard systems.

PROTECTIVE FEATURES

1. Remote On/Off
   The TC2000 Series Static Converter incorporates a remote on/off feature that allows the user to enable or disable the output of the unit. By providing a ground on the appropriate pin (See Table 3.3) the user, via a remote mounted switch, can enable the output of the unit. The unit can be similarly disabled by removing the ground signal (open circuit) to the same pin.

2. Over-Temperature
   The TC2000 Series Static Converter incorporates an internal temperature sensing device that continually provides monitoring and feedback to the control circuits. When the unit senses an internal condition that exceeds maximum temperature ratings, the output is disabled and the internal cooling fans cease to operate. The unit output will be enabled when the temperature returns to within acceptable limits. This over-temperature reset occurs automatically without external intervention required.

3. Short Circuit and Over-Current
   The TC2000 Series Static Converter is capable of surviving a short circuit or over-current event without permanent damage or effect to long-term reliability. Under standard conditions, the unit can provide over its rated power output up to 2200 watts for over 5 minutes (until over-temperature shutdown occurs).

CONFORMANCE

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
No periodic scheduled maintenance or calibration is necessary for continued airworthiness of the TC2000 Series Static Converter. If the unit fails to perform to specifications, the unit must be removed and serviced by Mid- Continent Instruments and Avionics or their authorized designee.

ENVIRONMENTAL QUALIFICATION STATEMENT
MODEL NUMBER: TC2000 PART NUMBER: 6432001-( )
DESCRIPTION: Static Electrical Power Converter CERTIFICATION: FAA TSO-C71
MANUFACTURER: True Blue Power, a division of Mid-Continent Instrument Co., Inc.
ADDRESS: 9400 E. 34th St. North, Wichita, KS 67226, USA.
SPECIFICATION: Test Specification (TS) 714 Test Data Sheet (TDS) 714
STANDARD: RTCA DO-160, Rev G, dated 12/08/10

Remarks:
Section 4: Category C3 with excursions as declared by the manufacturer:

• 4.5.1 Ground Survival and Short-Time Operating Low Temp: -55°C
• 4.5.3 Ground Survival and Short-Time Operating High Temp: +70°C
• 4.5.4 Operating High Temp: +70°C

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 316-630-0101
Fax 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 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 316-630-0101
Fax 316-630-0723

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References

• Aviation Parts Supplier | Mid-Continent Instruments and Avionics | Mid-Continent Instruments and Avionics
• Aviation Parts Supplier | Mid-Continent Instruments and Avionics | Mid-Continent Instruments and Avionics
• True Blue Power® | USB charging ports, inverters, converters, emergency power supplies and advanced lithium-ion batteries
• True Blue Power® | USB charging ports, inverters, converters, emergency power supplies and advanced lithium-ion batteries

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