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Manual Number 9019286 • Revision E, January 06, 2022
Case and Hardware
The mechanical construction plays a key role in the design to specifically support optimal
functionality, mitigate and contain any potential failure, and withstand the expected aircraft
environment. Material selections, component design, assembly processes and test all
contribute to the performance and safety of the product.
Nickel bus bars are used to connect the individual cells within the modules. Larger bus bars
then connect each module to the main connector to deliver the battery power. Temperature
and electrical insulating materials are used to support the cells within the modules and to
isolate all internal surfaces from the metal case. Each module uses an internal aluminum
heat sink that connects to the machined lid for thermal management, particularly during
charge current limiting and high discharges. A threaded connection is provided for
convenience to ground the battery to the airframe. A nylon handle is used for ease of
transport and handling.
The case is constructed to address the unique needs of lithium technology. In particular, it is
designed to contain and direct emitted gases overboard, maintain a safe external
temperature and pressure, constrain any debris or flame and ultimately to prevent any effect
on its surroundings in the aircraft, even during a worst-case failure scenario.
Visual Status Indicator
The battery has a built-in/on-board status indicator incorporated into the front face of the
battery. This can be used to quickly and visually determine the battery’s status and state of
charge either on the aircraft or off, during storage or service. The status indicator will identify
any of the following states: ACTIVE, FAULT, HEAT, and/or SERVICE. It can also be used to
assess the state of charge. More details can be found in Sections 4.3 and 4.4.
Data Exchange Access
The front face of the battery has a sealed hexagonal access cover below the main power
connector, secured with a single screw. When removing the cover, it reveals access to a
USB Type-A port, a recessed service button, and a service light. These can be used in
Control Mode to update the battery software, configure its customizable parameters, validate
the custom parameters and download the event log. More details can be found in Section
5.3.
Summary of Contents for True Blue Power TB20 Series
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