TRUE BLUE POWER TFC4000 Aircraft Maintenance Frequency Converter Instruction Manual

: June 3, 2024
: TRUE BLUE POWER

Table of Contents

TFC4000 Aircraft Maintenance Frequency Converter
SECTION 1 GENERAL DESCRIPTION
SECTION 2 PRE-INSTALLATION CONSIDERATIONS
SECTION 3 INSTALLATION
SECTION 4 OPERATION
SECTION 5 CONFORMANCE
References
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Installation Manual and Operating Instructions
TRUE BLUE POWER

TFC4000
FREQUENCY CONVERTER
Manual Number 9019509 /

TFC4000 Aircraft Maintenance Frequency Converter

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
All products produced by Mid-Continent Instrument Co., Inc., including those identified as MidContinent Instruments and Avionics or True Blue Power ® , are designed and manufactured in Wichita, Kansas, USA.

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REVISION HISTORY

Rev	Date	Detail	Approved
A	11/4/2022	Initial release.	CAS

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

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.

1.2 TECHNICAL SPECIFICATIONS

Electrical Attributes

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

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.)
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

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

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.

3.3.2.5 Fault Status
(9-Pin Connector, Pin C) Fault – Grounded output signal, typically connected to an indicating LED or lamp, showing that the unit is experiencing a fault condition.
(9-Pin Connector, Pin G) Fault Return – Should be connected to chassis, either near the unit or, twisted with Pin A wire and grounded to chassis at the panel.

5-Pin Connector Pinout

Figure 3.1
Pinout View of Unit Connectors
5-Pin (MS3102A18-11P)
9-Pin (MS3102A24-11S)

9-Pin Connector Pinout

Table 3.1
Connector Pinout
3.3.3 Use with GFCI, and Other Earth/Neutral Situations
The TFC4000 series of converters is fully electrically isolated from the AC input and provides a balanced AC output where AC output and AC return are not associated with the converter case ground. This is different from terrestrial AC systems where Neutral is connected to ground at an AC distribution transformer at the power mains. Some consumer items contain internal power supplies that require an Earth-Neutral connection for their noise filters to work properly. Similarly, some GFCI protection will not function properly if there is not an Earth/Neutral connection or if there is noise between
Earth and Neutral.
If there is not a GFCI, the AC_Output and AC_Return should not be tied to Chassis. If a GFCI is used, the output AC RTN (Neutral) should be tied to Chassis at the unit or the GFCI box.

3.3.4 Wiring Examples
The wiring diagram of Figure 3.2 provides general examples of typical installations. The configuration of individual aircraft installations may vary.

3.3.5 Harness Verification
With the TFC4000 Series Frequency 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.

3.4 MOUNTING
Refer to Section 2: Installation Considerations in regards to equipment location.

The TFC4000 Series Frequency Converter is designed for base mounting only (in any orientation).
Four thru holes for ¼-20 bolts or screws should be provided in the aircraft in accordance with Figure 3.3. Secure the unit with four ¼-20 bolts, pan head Phillips screws, or equivalent.
Screws/bolts must not extend into the unit more than 0.3 inches MAX. A lock- washer under the head of each screw is recommended.

3.5 INSTALLATION CAUTIONS

The TFC4000 converter does not have the ability to phase sync the output to other AC power sources. Do not connect the output of the TFC4000 to any other converter or AC source or damage to the TFC4000 will result.
As noted in Section 3.3.3, the TFC4000 has a balanced AC output that is not referenced to the chassis. If a digital meter is used to measure the AC output relative to chassis, the measurement may erroneously show up to half of the converter rated output voltage. This voltage is not a problem and is the result of making a high-impedance measurement of AC voltages.
3.6 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.

SECTION 4 OPERATION

4.1 ELECTRICAL PERFORMANCE
The TFC4000 Series Frequency Converter converts three-phase 115 VAC at 360 to 800 Hz into single-phase 115 VAC at 60 Hz. The unit is capable of providing 4000 VA (4 kW at power factor = 1), 115 VAC that powers outlets to support a variety of aircraft electronics and appliances including laptops, computer systems, TVs, vacuums, and many others (See Table 1.2 for tolerance ranges).
The unit is designed as a three-stage, solid-state switch-mode power supply. The Front End is Bridgeless PFC circuit with Boost topology. The Second stage utilizes a power transformer for isolation and step down followed by an H-bridge AC forming third stage. All the three stages utilize ‘current-mode’ control providing instantaneous load protection.

4.2 PROTECTIVE FEATURES
4.2.1 Remote On/Off
The TFC4000 Series Frequency 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 3.1) the user, via a remote mounted switch or similar method, can enable the output of the unit. The unit can be similarly disabled by removing the ground signal (open circuit) to the same pin.
4.2.2 Over-Voltage
When the input voltage exceeds the operating range of the unit (See Table 1.1; absolute maximum input of 134 VAC) the unit senses an over-voltage condition and disables the output. The unit will dynamically monitor the input voltage such that if the input returns to within the normal operating range, the output will be enabled and allow the unit to operate normally.
4.2.3 Under-Voltage
When the input voltage drops below the operating range of the unit (See Table 1.1; absolute minimum input of 97 VAC/168 VAC) the unit senses an under- voltage condition and disables the output. The unit will monitor the input voltage such that if the input returns to within the normal operating range, the output will be enabled and allow the unit to operate normally.
4.2.4 Over-Temperature
The TFC4000 Series incorporates an internal temperature sensing device that provides monitoring and feedback to the control circuits. When the unit senses an internal condition that exceeds maximum temperature, the converter output is disabled, and the internal cooling fans will continue to operate. The unit output will be enabled when the temperature returns to within acceptable limits. This over-temperature reset occurs automatically without any external intervention required.

4.2.5 Short Circuit and Over-Current
The TFC4000 Series is capable of surviving a short circuit or over-current event without permanent damage or effect to long-term reliability. The unit can provide over its rated power output up to 125% of rating or 5000 VA continuously if the ambient is low enough not to trip the thermal protection. The unit can provide over its rated power output up to 150% of rating or 6000 VA for 5 minutes, before an internal timer interrupts its output and Fault pin goes high impedance. The enable pin will need to be reset to TURN ON the unit. The unit can provide over its rated power output up to 200% of rating or 8000 VA for 5 seconds before an internal timer interrupts its output and Fault pin goes high impedance. The enable pin will need to be reset to TURN ON the unit.
At full short circuit, the unit detects abnormal conditions and limits output Current to 54 A peak. If the short circuit is removed within 2 seconds, the converter will return to full power, otherwise the output will shut off until the enable or the power input is cycled off and on again.

4.2.6 Temperature Regulated Cooling
The unit is equipped with three internal brushless DC fans for cooling to extend the power range and long-term life. The fans are activated at a specified point determined by the continuous monitoring of the internal temperature. After the fans are activated, the speed of the fans are directly proportional to internal temperature. However, the fans will limit their speed to half if the output is not enabled or the unit goes into thermal shutdown. The fans operate very quietly to reduce the audible noise in any environment. The three fans provide independent redundancy for protection of the unit in the event that one becomes inoperative.

SECTION 5 CONFORMANCE

5.1 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS
No periodic scheduled maintenance or calibration is necessary for continued airworthiness of the TFC4000 Series Frequency 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.

5.2 ENVIRONMENTAL QUALIFICATION STATEMENT
MODEL NUMBER: TFC4000
PART NUMBER: 6434000-( ) Series
DESCRIPTION: Frequency Converter, 4 kVA
CERTIFICATION: 6434000-( ) Series
CERTIFICATION:
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) 710 Test Data Sheet (TDS) 710
STANDARD: RTCA DO-160, Rev G, dated 12/08/10

CONDITIONS	SECTION	DESCRIPTION OF TEST
Temperature and Altitude	4	Category F3
Temperature Variation	5	Category S2
Humidity	6	Category B
Operational Shock and Crash Safety	7	Category B(5R)
Vibration	8	Category R; Curve C, C1
Explosion	9	Category E
Waterproofness	10	Category W
Fluids	11	Category X
Sand and Dust	12	Category X
Fungus	13	Category F
Salt Spray	14	Category X
Magnetic Effect	15	Category Z
Power Input	16	Category A(CF)
Voltage Spike	17	Category B
Audio Frequency Conducted Susceptibility	18	Category R(WF)
Induced Signal Susceptibility	19	Category AC
Radio Frequency Susceptibility	20	Category TT
Emission of Radio Frequency Energy	21	Category B
Lightning Induced Transient Susceptibility	22	Category A3G3L3
Lightning Direct Effects	23	Category X
Icing	24	Category X
ESD	25	Category A
Flammability	26	Category X