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Manual Number 9019286 • Revision E, January 06, 2022

Battery Protections

The TB20 Advanced Lithium-ion Battery has built-in protections for conditions that may
exceed specified operating limits:

Protection

Parameter(s)

Action

Recovery

Under Voltage
(low current)

If discharge current < 80A
and
battery voltage < 16VDC
or
cell string voltage < 1.8VDC

Discharging
disabled

Battery Voltage > 20VDC and
Cell string voltage > 2.5VDC

(Charging will be limited to
4A/Module until Module Voltage
> 20VDC or Module Cell String
Voltage > 2.5VDC)

Under Voltage
(high current)

If discharge current > 80A
and
battery voltage < 12VDC
or
cell string voltage < 1.0VDC

Discharging
disabled

Battery Voltage > 20VDC and
Cell string voltage > 2.5VDC

(Charging will be limited to
4A/Module until Module Voltage
> 20VDC or Module Cell String
Voltage > 2.5VDC)

Over Discharge

Any module cell string voltage
< 1.2VDC and current
< 100mA for 10 seconds

Module is
disabled

Factory Service

Over Voltage

Module voltage > 30.6VDC
or
Any cell string voltage
> 3.8 VDC

Charging
disabled

Module voltage < 29.2 VDC
and
All cell string voltages
< 3.6 VDC

Over Current

Battery discharges > 560A for
more than 15 seconds

Discharging
Disabled

External Load removed or
charging current detected

Short Circuit

Battery detects current > 1000A
for > 100ms

Discharging
Disabled

External Load removed or
charging current detected

Over
Temperature
(Discharging)

Any cell temperature > 95°C
or
Discharge control circuitry
> 130°C

Discharging
Disabled

All cell temperatures < 80°C
and
Discharge control circuitry
< 90°C

Over
Temperature
(Charging)

Any cell temperature > 72°C
or
Charge control circuitry > 130°C

Charging
disabled

All cell temperatures < 62°C
and
Charge control circuitry < 90°C

Cell Over
Temperature Fail

Any cell temperature > 110°C

Module is
disabled

Factory Service

Module Charge
Required

One or more modules have
charged/discharged 50Ah or
more without being fully
recharged

Battery
SOC may
not be
accurate

Fully Charge Battery

Table 4.1

Battery Protections

Содержание True Blue Power TB20 Series

Страница 1: ...Revision E January 6 2022...

Страница 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 pleas...

Страница 3: ...LATION 12 3 1 GENERAL 12 3 2 PRE INSTALLATION INSPECTION 12 3 3 PARTS 12 3 4 INSTALLATION 13 SECTION 4 OPERATION 21 4 1 DESCRIPTION 21 4 2 CONSTRUCTION AND THEORY OF OPERATION 21 4 3 OPERATIONAL MODES...

Страница 4: ...0 Updated style and brand to meet Marketing and Engineering guidelines Added downloadable event log feature and instructions to load download custom configuration parameters Updated DO 160 qual and in...

Страница 5: ...ee operation with on condition end of life Multiple safety protections continuous data monitoring and an on board status indicator also add value reliability and reduced cost of ownership for the life...

Страница 6: ...ure monitors and an integrated heater that improves cold weather performance Two modules connected in parallel through a network of bus bars provide combined power to the main connector and thus the a...

Страница 7: ...including vent lid and connectors 6 0 x 8 2 x 9 3 inches see Figure 1 1 153 x 208 x 236 mm Quick Disconnect Power Receptacle Communications Connector USB Service Data Port 2 pin per MIL PRF 18148 3 fo...

Страница 8: ...7 Manual Number 9019286 Revision E January 06 2022 6 0 8 8 0 5 8 6 7 7 4 6 6 9 9 1 8 2 1 3 0 6 Figure 1 1 Outline Drawing...

Страница 9: ...es when working with battery packs A battery could produce a short circuit current high enough to weld jewelry to metal and cause a severe burn Always use appropriate Electrostatic Discharge ESD prote...

Страница 10: ...ed by industry and regulatory standards This includes compliance with the UN recommendations on the Transport of Dangerous Goods IATA Dangerous Goods Regulations applicable U S DOT regulations for the...

Страница 11: ...t which should be connected and diverted overboard in the event of such an occurrence Details for vent installation are provided in Section 3 For additional precaution installation near potential sour...

Страница 12: ...ameplate 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...

Страница 13: ...ustained in transit If necessary return the unit to the factory using the original shipping container and packing materials File any claim for damages with the carrier Note The unit is shipped at appr...

Страница 14: ...proper Wire Size and Type Table 3 1 Connection Features Figure 3 1 and Pin Identification Diagrams Figures 3 3 and 3 4 Proper grounding requires connecting the ground lug on the chassis to the aircraf...

Страница 15: ...022 Figure 3 1 Connection Features 2 1 2 3 5 1 7 4 0 8 2 5 1 1 7 0 1 3 1 3 0 9 Figure 3 2 Connection Locations 20 Threaded Ground Lug Quick Disconnect Receptacle per MS3509 MIL PRF 18148 3 18 pin Data...

Страница 16: ...the TBX battery models with p n ending in 1 Communication Connector 18 pin Pin Description A Analog SOC B Battery Disable Input C Heater Disable Input D RTD 1A E RTD 1B F RTD 2A G RTD 2B H ARINC 429 A...

Страница 17: ...e outboard sides and two perpendicular slots on each side to keep the rod vertical using an alignment washer The battery is then secured with the appropriate nut or hardware designed to mate with the...

Страница 18: ...stallations require usage of the mounting kit see Section 3 3 2 which includes corner braces and a silicone pad to limit overall motion of the battery Alternative similar mounting hardware can be used...

Страница 19: ...screws and blank plate from the alternate location switch the positions and reinstall Visually verify that the silicone gasket between the port or plate and the case fully covers the holes in the cas...

Страница 20: ...urrent Limit can also be disabled by setting Charge Current Limit to 0 allowing the battery to charge as quickly as possible and take up to its maximum charge current The Charge Current Limit paramete...

Страница 21: ...t required An Engine Start Peak Current parameter of 0A bypasses evaluating the maximum current required for an engine start The Engine Start parameters are not required to be programmed they are both...

Страница 22: ...with significantly less energetic failure modes The Nanophosphate advantage enhances typical lithium iron phosphate chemistries by providing exceptional power and energy The combination of these chara...

Страница 23: ...ttery Management System BMS The BMS board is independent of the modules and manages the power control and external data interface of the battery Using cell and battery conditions passed to it by the C...

Страница 24: ...ed 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 o...

Страница 25: ...will enter Sleep Mode when the Battery Disable control discrete is engaged closed when the battery is inactive or when the STATUS SOC button is held for 3 seconds The battery is inactive when all of t...

Страница 26: ...y conditions to manage operation and mitigate exceedances as needed through its various protection methods Data and status is available through the communication connector and the heater is available...

Страница 27: ...rovide approximately 28 volts Depending on the load the battery will provide an average of approximately 25 5 volts for the duration of discharge See Section 4 5 for more details on available capacity...

Страница 28: ...0 F utilizing the internal self powered heaters bringing the battery up to full operational capability Pre heat time will vary depending on temperature but can be fully warmed in 15 minutes or less af...

Страница 29: ...seconds Module is disabled Factory Service Over Voltage Module voltage 30 6VDC or Any cell string voltage 3 8 VDC Charging disabled Module voltage 29 2 VDC and All cell string voltages 3 6 VDC Over Cu...

Страница 30: ...from the dual independent RTDs and analog state of charge Each RTD has a resistance of 100 ohms at 0 C Resistance ohms for all temperatures T in degrees Celsius can be calculated using the following...

Страница 31: ...ater Disable This input when grounded manually disables the heaters from operating Discrete Communication Signals Heating Active when the Heater is providing heat Fault Active when the battery has an...

Страница 32: ...rate Deliverable Energy is defined as State of Charge x Current Maximum Capacity Example A TB20 has aged and its current maximum capacity is 18Ah instead of its original beginning of life 20Ah If its...

Страница 33: ...of Charge BNR 128 11 0 0625 1000 2000 346 Estimated Life Remaining BNR 128 11 0 0625 1000 2000 350 Software Version DISCRETE X Y Z 1000 2000 351 Operational Status DISCRETE 500 1000 352 Fault Status D...

Страница 34: ...C See Section 4 4 3 for further description Heat Flashing White indicator Battery heaters are currently heating Solid Yellow indicator Heater is disabled Service Solid Red indicator Battery has a perm...

Страница 35: ...are set to active for 10 seconds o If the battery has reached the end of discharge and under voltage protection is activated pushing the status button will clear the under voltage fault if battery vol...

Страница 36: ...that can be applied over 20 or 5 hours respectively For example a lead acid battery rated at 20Ah at a 0 2 C rate can deliver 4A for 5 hours 4A x 5 hours 20Ah However that same system typically does...

Страница 37: ...priate pre heat time This feature prevents the necessity to remove the unit from the aircraft when stored at extremely low temperatures overnight or for longer periods of time The battery also exhibit...

Страница 38: ...see Section 4 4 In Flight Monitoring Typically all annunciations from the unit should be inactive during flight However the HEATING signal may be observed depending on the temperature of the unit and...

Страница 39: ...pdate file from https www truebluepowerusa com software updates to the root directory of a standard FAT formatted USB 2 0 compatible flash drive ensuring the filename is exactly update muf It is recom...

Страница 40: ...located above and to the left of the USB port until the service light located above and to the right of the USB port changes from solid white to blinking white approximately 3 seconds and releasing be...

Страница 41: ...talled first and then the getcfg cmd file will generate the installer txt file in this sequence H Remove the USB flash drive and the battery will reboot into flight mode I Replace the USB access cover...

Страница 42: ...mmunication is available to the cockpit to validate the battery is transmitting data appropriately To perform this turn on the avionics master and deactivate the battery disable if installed Verify ba...

Страница 43: ...y ages the accuracy of its reported capacity can change due to a variety of factors associated with its use environmental conditions and the characteristics of the cells Using the procedures in this s...

Страница 44: ...erminals is greater than 27 6 VDC A unit should never be returned to service if the voltage is less than this value after charging C Re install the unit in the aircraft including securing it via prope...

Страница 45: ...C Upon receipt the battery shall be fully charged using the procedures listed in this manual prior to storage and again prior to installation use STORED BATTERIES MUST BE FULLY RECHARGED AT A MINIMUM...

Страница 46: ...rge End of life is represented by the inability of the unit to meet the minimum capacity requirement of the aircraft either as programmed and self determined by the battery or upon verification of man...

Страница 47: ...acity Test Pass 20Ah minimum 2 4 4 6 Capacity Test at Low High Temp Pass 16 5Ah 40 C 19 5Ah 70 C 2 4 4 7 Constant Voltage Discharge Pass IPP 900A IPR 700A 18V 2 4 4 8 Charge Acceptance Pass 18Ah 40 C...

Страница 48: ...gory W Fluids 11 Category F Sand and Dust 12 Category S Fungus 13 Category F Salt Fog 14 Category S Magnetic Effect 15 Category A Power Input 16 Category B RX Voltage Spike 17 Category A Audio Frequen...

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