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4                             Manual Number 9018558 • Revision H, April 13, 2021 

SECTION 1  GENERAL DESCRIPTION 

1.1 

INTRODUCTION 

The model TC120 DC/DC Power Converter is a lightweight power converter that translates a direct 
current (DC) input of 28 volts to an adjustable 5 to 18 volt direct current (DC) output. 
  
The input operating voltage (24–32VDC) makes the TC120 suitable for nearly any common 
general, business, or commercial aviation application and provides an adjustable DC output 
voltage of 5 to 18VDC. The unit is rated for a nominal output of 120 watts to power avionics, 
instrumentation, personal charging, lighting, and many other applications. The TC120 DC/DC 
Converter is FAA certified to TSO-C71 and tested to rigorous environmental standards and levels 
of RTCA DO-160G. 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 input voltage shut-
down, temperature monitoring, reverse polarity protection, a self-resettable over-temperature 
disable and an optional remote enable (on/off) feature.  
 
The TC120 DC/DC converter has a robust Military-rated circular connector and a rugged aluminum 
case which dissipates heat and provides excellent mechanical strength. It is engineered to require 
no external cooling and contains no internal fans or cooling methods, which saves energy, reduces 
weight and allows more flexible installation locations. At only 11.0 oz (312 g), it is lighter and 
smaller than any other certified solution in the aviation market today.  
  
 

 

Summary of Contents for 6430120-1

Page 1: ...Revision H April 13 2021...

Page 2: ...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...

Page 3: ...NS 6 2 5 MODIFICATION 7 SECTION 3 INSTALLATION 8 3 1 GENERAL INFORMATION 8 3 2 UNPACKING AND INSPECTING EQUIPMENT 8 3 3 CABLE HARNESS 8 3 4 MOUNTING 11 3 5 INSTALLATION CAUTION 11 3 6 INSTALLATION COM...

Page 4: ...C 03 15 2016 Add 2 version BAW D 05 27 2016 Updated wiring drawings in Section 3 VAA E 02 10 2016 Updated Section 4 2 1 KJW F 05 07 2020 Updated style and brand to meet Marketing and Engineering guid...

Page 5: ...60G 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 challenge...

Page 6: ...ominal Table 1 1 Physical Attributes Weight 11 0 oz 312g Dimensions not including connector mate 2 75 inches long x 3 75 inches wide x 1 29 inches high 69 9 mm long x 95 3 mm wide x 32 8 mm high Matin...

Page 7: ...tions 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 re...

Page 8: ...plate 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...

Page 9: ...nt make a visual inspection for evidence of any damage that may have incurred during shipment The following parts should be included A DC DC Converter P N 6430120 B Connector Kit P N 9018651 i Mating...

Page 10: ...it and use a multi meter to measure and verify the power ground and enable voltages on the appropriate pins within the mating harness Output voltage Adjustment The output voltage can be set to any val...

Page 11: ...USTMENT TRIMMER DC RETURN 6430120 1 NOT CONNECTED Figure 3 2 Typical 6430120 1 Aircraft Wiring Installation Constant On A B C ON OFF ON OFF ENABLE D DC INPUT TC120 E 5 18 V OUTPUT ADJUSTMENT TRIMMER D...

Page 12: ...120 DC DC Converter Outline Drawing 3 5 INSTALLATION CAUTION Under no circumstances should the output of the Converter to be connected to another power output source or damage will occur to the unit o...

Page 13: ...the typical maximum current of the MIL 510514 5P connector and mating harness connector See Figure 4 1 for maximum continuous and temporary output current for a given voltage output The left side of...

Page 14: ...ote ON OFF feature that allows the user to enable or disable the output of the unit remotely By providing a ground to the appropriate pin the user can enable the output of the unit via a remote mounte...

Page 15: ...tact Mid Continent Sales In the Temporary Operating Range of Figure 4 2 the TC120 cannot boost the input voltage to produce a higher output voltage As an example if the output voltage is set for 18 Vo...

Page 16: ...rcuits When the unit senses an internal condition that exceeds maximum temperature ratings the output is disabled The converter will continue to remain shut down until the temperature returns to withi...

Page 17: ...TDS 627 STANDARD RTCA DO 160 Rev G dated 12 08 10 CONDITIONS SECTION DESCRIPTION OF TEST Temperature and Altitude 4 Category F2 Temperature Variation 5 Category S2 Humidity 6 Category B Operational Sh...

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