TCW Technologies IBBS-12v-3ah Manual de usuario

Integrated Back-up Battery System

Model: IBBS-12v-3ah

The Integrated Back-up Battery System, IBBS,is an electronic system

that combines a Lithium-Iron-Phosphate (Li-Fe-PO4) battery pack, a

charger and switching logic in one convenient package. The IBBS

provides an engineered solution to enable an endurance bus for critical

loads found in aircraft. It simplifies the wiring and installation of a source

of back-up power by integrating all of the key elements into a single

enclosure. The IBBS system provides back-up power to critical

electronic loads such as EFIS, GPS, Autopilots and engine monitor

systems.

Integral to the IBBS is a lithium-iron-phosphate battery pack and a

matched charging system to ensure the battery is properly charged and

maintained. The system also includes switching circuitry to provide a

stable source of output power during normal and emergency operations.

The IBBS system also provides signals to other equipment such as EFIS

systems to communicate the operating state of the main aircraft bus as

well as the state of the battery.

The IBBS system connects to the standard aircraft power bus and

provides an output to critical equipment that requires back-up power.

Additionally, the IBBS system provides surge and sag protection for

connected equipment, allowing operation of critical equipment during

engine starting.

The IBBS system is suitable for use with equipment such as Garmin

GNS and GTN series navigators, G3X series of avionics, Grand Rapids

Technologies EFIS systems, Advanced Flight Systems EFIS, Dynon

EFIS, and MGL EFIS, TruTrak Autopilots and EFIS, Trio Autopilots.

No other uses of the IBBS system are permitted except for those

identified in this installation manual.

IBBS must be installed using the current aircraft standards and practices

as shown in AC 43.13-2A/1B. The installer/builder is solely responsible

for determining the suitability of the installation and use of this product.

IBBS products are protected by US Patent 8,189,305

Table of Contents

Installation Information: pg. 3

General Product info: pg. 5

Battery Capacity details: pg. 6

Product Operation: pg. 7

Requirements for Continued Airworthiness: pg. 8

Specifications pg. 11

Connector Pin-out pg. 12

Mounting plate drawing pg. 13

General Wiring diagram pg. 14

Example Wiring diagrams pg. 15-19

Warranty information pg. 20

Service and Support information:

610-928-3420 TCW Technologies, LLC.

www.tcwtech.com 2955 Main Road East

email: [email protected] Emmaus, PA 18049

Installation Instructions:

1. Consult the attached wiring diagrams to identify wiring connections similar to your

particular installation. Please note, some equipment such as GPS’s and EFIS systems may

be provided with multiple power inputs. For these installations the output of the IBBS must

be connected to their “back-up” power input. The “back-up” power source should be

provided through the IBBS product. For equipment having a single source of power, the

IBBS system may be fed from a bus that remains active during engine starting, such as the

master bus or it may be fed from an avionics bus that is switched off during engine starting.

2. Check that the total connected load (summed value of all four output wires) is less than

the following product ratings:

IBBS-12v-3ah: 5 amps maximum continuous current,

10 amps peak for radio transmissions and transient loads.

3. Mount the IBBS in a suitable location in the aircraft. Ensure the mounting points and

fasteners are suitable for the weight of the product, consult the specifications for details. The

IBBS must be mounted inside the aircraft, do not mount the IBBS in the firewall forward

area. Do not mount the IBBS unit up under the instrument panel unless the panel is

properly ventilated to ensure heat does not build up in the area. Select an area that is

accessible to allow for future battery servicing. The operating temperature range of the

system is -10 C° to 60 C°, the effective charging temperature range is 0 C° to 40 C°.

Select an installation location that will comply with these requirements.

4. Connect the aircraft wiring according to one of the wiring diagrams shown.

The IBBS must be powered through a properly sized circuit breaker or fuse. ENSURE the

proper size wire is utilized for the input feed, output supply and ground connection.

Power Input Requirements: The IBBS has multiple power inputs.

Pin 5 provides charging and bus voltage sensing for the IBBS unit and must be connected

to an aircraft power bus. When the voltage on pin 5 falls below about 11 volts the system

automatically transfers the load current on the output pins to the internal back-up battery

source. Pin 5 maximum current draw is 2.5 amps during charging.

Pins 6,7,8 receive power that is passed-thru the IBBS unit to the loads connected to the

output pins. These pass-thru power connections are optional and are only required for

systems that do not have multiple power inputs. These pins can also be used if it is desired

to have redundant power paths feeding the connected loads. These pins are internally

wired in parallel, it is recommended to populate all three pins and join the wires together at

the pass thru power breaker. Note: these pins do not individually correspond to any

particular output pin (12-15). The pass-thru breaker must be sized for whatever load is

connected to the IBBS outputs. The maximum combined load is 10 amps peak, 5 amps

continuous. If Pins 6,7,8 are used they MUST be connected to the same power bus as Pin

Output Power connections:

The IBBS-12v-3ah has four output pins, Pins 12,13,14,15. These pins provide power to the

connected load. These four wires may be paralleled together for redundancy and load

current sharing. Use 20 awg wire for each pin. Maximum output current of 3.5 amps per

pin and 5 amps maximum continuous combined. The output wires of the IBBS system are

protected with a single 10 amp, mini ATC fuse. This fuse is accessible on the side of the

enclosure.

IMPORTANT NOTE ON CHANGING FUSE:

Disconnect the main product connector before changing the fuse!

Replace fuse with 10 amp, mini ATC fuse only

5. The Back-up Power Master switch must be utilized to turn the back-up battery system off

when not in use, except for installations where the off state current requirement is less than

50 micro-amps, such as with the AFS EFIS systems. Follow the specific wiring diagram for

this application. This back-up power master switch gives the pilot the ability to turn the back-

up battery system off. In some installations this may be the only means to shut down the

connected equipment.

6. The IBBS unit has a low voltage warning output, pin 3. This pin may be used to drive an

LED indicator or to provide a digital signal to indicate the main input bus is in a low voltage

condition. When the main input bus (connected to pin 5) falls below about 11 volts this

output will drive to a low state. Maximum current sourced on this pin is 25 milliamps.

7. The IBBS unit has in internal battery monitor connection, pin 2. This pin allows the

voltage state of the internal battery to be monitored with a separate voltage meter or analog

input. This pin will only report internal battery voltage when the unit is enabled by turning the

Back-up Master switch ON. A fully charged battery back will indicate about 13-14.7 volts on

this pin. . Important note: the meter utilized to measure pin 2 must have an input

impedance >100k ohms otherwise it will load down pin 2 and provide an artificially low

voltage reading.

8. Complete the installation of the wiring harness and connector prior to attaching the

connector to the IBBS product. This is essential to ensure the wires do not inadvertently

short together during installation. Remember, the IBBS pack is a back-up source of power

and is ready to deliver output power even when the aircraft electrical system is in the off

state.

9. When using the IBBS product to provide back-up power to an electronic ignition system it

MUST be used to back-up one and only one electronic ignition module. Do not use one

IBBS to back up both electronic ignition modules in a dual electronic ignition system. Follow

the wiring diagram for installation with electronic ignition module. Note, the Light Speed

Electronic ignition system connects directly to aircraft battery as shown. Other brands of

electronic ignition systems connect to the switch side of the aircraft master bus. Follow the

instructions per the electronic ignition manufacture for your installation.

10.When using the IBBS product to provide back-up power to an electronic ignition system

(CDI), pull-able circuit breakers must be used for over current protection as shown on page

19.

11.When using the IBBS product to provide back-up power to an electronic ignition system,

connect one and only one CDI module to an IBBS unit. DO NOT CONNECT any other loads

to the IBBS. It must only be used to back up the CDI unit.

Product Details and General Information:

The Charging System:

The IBBS automatically maintains its internal battery pack. The internal charging circuit

monitors the state of the internal battery and recharges it as necessary when the aircraft is

operational. The maximum input current for battery recharging is 2.5 amps.

If the internal battery is fully discharged for any reason it may require up to two hours of

recharge time with the normal aircraft bus on. NOTE: Do not attempt to recharge the IBBS

product by using an external battery charger directly connected to the input of the IBBS.

Battery chargers typically provide pulsating voltages that will damage the IBBS product if the

system is not connected to a typical primary aircraft battery.

Back-up Power Master Switch:

The IBBS has one input switch connection as identified in the wiring diagrams: Back-up

Power Master. This switch enables back-up power from the IBBS system to be available on

the output wires when power on the normal aircraft bus falls into the range of 10-11 volts.

If the back-up power master switch is enabled and normal aircraft power falls into the range

of 10-11 volts, then the internal back-up battery will be connected to the outputs and be

utilized to supply back-up power to the connected load.

If the normal aircraft power bus is above 11 volts, then the outputs are energized with normal

aircraft power (if the pass thru-power connections are utilized) and the back-up battery

remains off-line. This operation occurs regardless of the state of the Back-up Power Master

switch. This allows for automatic pass through of power during normal operation.

Ground Based Recharging:

To accomplish ground based charging, connect an approved battery charger or DC power

source to the main aircraft battery and energize the main aircraft power bus by turning on the

master switch, leave all other aircraft loads in their off state. Note, the ground base source

of power must be able to supply the load current of all devices that can not be turned off in

this nominal state, plus the 2.5 amps of IBBS recharge current. Leave the ground based

charging system connected and powered until the IBBS system completes its recharge cycle

of its internal battery, for a fully discharged battery this may take up to two hours.

Alternately, a ground based charger is available from TCW Technologies LLC., model #

IBBS-12v-CHARGER-LI-FE. This charger may be used for recharging the IBBS unit as

well as keeping it topped off during long term product storage. (9 months or longer)

Battery Capacity:

The IBBS provides an energy capacity of 3 amp-hours at 12.8 volts when the system is fully

charged and operated at 25 C°. Depending on various conditions including operating and

storage temperature and age of the battery pack, the capacity of the system will vary. With a

fully charged battery, the following average performance can be expected in terms of

operating duration. The operating duration is for output voltage down to 9.5 volts.

Nominal Current Draw Duration

total connected load

1.5 amps 120 minutes

3.0 amps 55 minutes

6.0 amps 25 minutes

The internal battery in the IBBS system is replaceable, however, the IBBS product must be

returned to TCW Technologies, LLC. for this service. Battery life depends strongly on many

factors including operating and storage temperature, number of discharge cycles and depth

of discharge. The battery capacity should be checked at least annually for suitable back-up

power operation of the connected equipment. When the battery capacity no longer meets

the operating criteria of the aircraft it must be replaced. Contact TCW Technologies, LLC.

for battery replacement.

Storage beyond 9 months:

If the IBBS unit is to be stored without connection to the aircraft for a period greater than 9

months it must be connected to a source of DC power to maintain the battery’s charge. Only

connections to the ground terminal and the main power terminal are required. Connect Pin

5 (main power) and Pin 9 (ground) of the IBBS to any source of regulated DC power at 12-15

volts with a current capability of > 2.5 amps to accomplish full recharging. Charger model

IBBS-12v-CHARGER-Li-Fe is available from TCW Technologies, LLC. to simplify this

requirement, it has the mating connector installed.

Upon completion of installation:

1) The builder/operator is responsible for determining the minimum operating duration of the

back-up enabled equipment.

2) The required back-up operating time for the connected equipment should be recorded in

the aircraft log-book with follow-up entries confirming the annual testing results that

indicate that the required operating time is satisfied.

Normal Product Operation:

For normal operation the following is the recommend operating procedure, it is strongly

recommended that this operating procedure be added to the aircraft operating check-list for

standard procedures.

Start-up Procedure:

1) Prior to turning on the Aircraft Master Switch, turn ON the Back-up Power master switch.

2) Turn on any equipment that derives back-up power from the IBBS product.

3) Ensure the connected equipment successfully boots-up and is operating properly. (During

this period of time the equipment is running off of the back-up battery in the IBBS product.

This test ensures the transfer circuit and back-up battery are properly working)

4) Turn on the Aircraft Master Switch; ensure the connected equipment remains energized.

(If you are utilizing a separate avionics bus, this may need to be turned ON to continue the operation

equipment connected to the IBBS output.)

5) Start and operate the aircraft according to normal operating procedures.

Shut-down Procedure:

1) Shut down aircraft engine using normal procedures.

2) Shut down the Aircraft Master Switch

3) Verify that equipment that derives back-up power from the IBBS product remains ON

4) Turn-off Back-up Power Master switch, ensure that equipment powers down.

(This procedure further ensures the operation of the transfer circuit in the IBBS product.)

Emergency Procedure for loss of main aircraft electrical power:

1) Operate the Aircraft Master Power Switch per the Emergency Procedure checklist already

established for the aircraft.

2) Ensure the Back-up Master Switch is in the ON position.

3) Land aircraft as soon as practical to resolve the loss of main electrical power.

Requirements for continued airworthiness:

On at least an annual basis the endurance capability of the IBBS system shall be confirmed and compared

against the back-up endurance required for the connected equipment.

As an alternate to these tests, the IBBS unit may be returned to TCW Technologies for a

loaded endurance test, contact TCW Technologies, LLC. for details.

Procedure for endurance testing

All applications except electronic ignition systems

1) Turn off the Aircraft Master Switch

2) Turn on the Back-up Power Master Switch

3) Turn on all equipment connected to and supplied with back-up power from the IBBS

product.

4) Measure and record at least the following information: The time until the first piece of

connected equipment no longer functions or the time until the output of back-up power

supply voltage drops to 9.5 volts. AVOID allowing the back-up battery voltage to fall

below 9 volts.

5) After completing the endurance test, recharge the IBBS product by operating the system

with the Aircraft Master Switch in the ON position for up to two hours. This may done by

operating the aircraft in conditions known to not require back-up power or by powering the

aircraft system on a suitable ground power source as described in the section: Ground

Base Recharging.

6) Record the results of the endurance testing in the aircraft log book.

7) If the IBBS no longer meets the endurance testing requirement, the back-up battery may

need replacement.

Requirements for continued airworthiness:

Electronic Ignition System Back-up

On at least an annual basis the endurance capability of the IBBS system shall be confirmed and compared

against the back-up endurance required for the connected equipment.

As an alternate to these tests the IBBS unit may be returned to TCW Technologies for a

loaded endurance test, contact TCW for details.

Procedure for endurance testing of system providing back-up power

to electronic ignition systems:

COMPLETE THESE STEPS IN ORDER! Perform these tests with the aircraft properly

secured on the ground, these are not flight test procedures.

1) Start the aircraft using normal starting procedures, including turning ON the Back-up

Master switch

2) Select engine operation based on the use of only the electronic ignition module provided

with back-up battery power.

3) PULL the 5 amp breaker feeding the Back-up Master Switch, confirm engine continues to

run.

4) PULL the 7.5 amp breaker feeding pins 6,7,8 of the IBBS, confirm the engine continues to

run.

5) Perform the following; test A or test B:

Test A: abbreviated battery test:

Monitor engine operation and voltmeter reading on any of pin 12,13,14,15, the back-up

power output. Confirm back-up voltage begins above 12.0 volts and for a period of 15

minutes remains above 11.0 volts. If these requirements are met the battery pack is

satisfactory.

Test B: full endurance test:

Operate the engine on the electronic ignition system for the required minimum run-time

requirement (typically 60 minutes ) monitor the back-up battery voltage on the voltmeter

connected to an output pin, the battery voltage must remain above 10 volts for the

duration of the test. If this requirement is met the battery pack is satisfactory.

6) Turn off the Back-up Master Switch and confirm that the engine turns off.

7) IF all these tests pass, the IBBS system is functioning properly, record the results in the

aircraft log book.

8) IF any of these tests fail, the IBBS system is not functioning properly and corrective action

must take place. If the IBBS no longer meets the endurance testing requirement, the

back-up battery may need replacement.

9) Return all pullable breakers to the normal ON position and ensure aircraft engine is

properly returned to the off position by following normal run and shut down procedures.

10)After completing these tests, recharge the IBBS product by operating the system normally

for up to two hours. This may done by operating the aircraft in conditions known to not

require back-up power or by powering the aircraft system on a suitable ground power

source as described in the section: Ground Base Recharging.

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