True blue power TC240 Documento técnico
Revision F • October 21, 2020
1 Manual Number 9018640 • Revision F, October 21, 2020
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. 34
th
St. N.
Wichita, KS 67226 USA
Phone 316-630-0101
Fax 316-630-0723
© Copyright 2016
Mid-Continent Instrument Co., Inc.
Download the current
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2 Manual Number 9018640 • Revision F, October 21, 2020
TABLE OF CONTENTS
SECTION 1GENERAL DESCRIPTION 4
1.1INTRODUCTION 4
1.2TECHNICAL SPECIFICATIONS 5
SECTION 2PRE-INSTALLATION CONSIDERATIONS 6
2.1COOLING 6
2.2EQUIPMENT LOCATION 6
2.3ROUTING OF CABLES 6
2.4LIMITATIONS 7
2.5MODIFICATION 8
SECTION 3INSTALLATION 9
3.1GENERAL INFORMATION 9
3.2UNPACKING AND INSPECTING EQUIPMENT 9
3.3CABLE HARNESS 9
3.4MOUNTING 13
3.5INSTALLATION CAUTION 13
3.6INSTALLATION COMPLETION 13
SECTION 4OPERATION 14
4.1ELECTRICAL PERFORMANCE 14
4.2PROTECTIVE FEATURES 14
SECTION 5CONFORMANCE 16
5.1INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 16
5.2ENVIRONMENTAL QUALIFICATION STATEMENT 16
3 Manual Number 9018640 • Revision F, October 21, 2020
REVISION HISTORY
Rev Date Detail Approved
A 05/23/2016 Initial release SHO
B 06/22/2016
Corrected typo, page 12, 4.2.3, ‘maximum.’
5.2 Environmental Qualification Statement:
Section 4, changed from F2 to F1;
Section 4.5.1 Operating Low Temp changed from -55C to -40C
Section 4.5.3 Operating High Temp changed from +70C to +55C.
KJW
C 12/02/2016
Corrected description, Figure 3.3. Revised the Environmental
Qualification Statement table for Temperature and Altitude,
Section 4.
KJW
D 10/24/2017 Changed Environmental Qualification Statement to add helicopter
vibe levels. KJW
E 05/07/2020 Updated style and brand to meet Marketing and Engineering
guidelines. DLR
F 10/21/2020 Updated weight. MEK
4 Manual Number 9018640 • Revision F, October 21, 2020
SECTION 1 GENERAL DESCRIPTION
1.1 INTRODUCTION
The model TC240 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 TC240 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 240 watts to power avionics,
instrumentation, personal charging, lighting, and many other applications. The TC240 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 TC240 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 ounces (312 g), it is lighter and
smaller than any other certified solution in the aviation market today.
5 Manual Number 9018640 • Revision F, October 21, 2020
1.2 TECHNICAL SPECIFICATIONS
Electrical Attributes
Input Voltage Rated 28VDC nominal, Operating 24 – 32VDC.
Input Current (full load) 10 amps max at nominal input voltage
Output Voltage 5 – 18VDC adjustable
Output Power 240 watts nominal
Efficiency 95% nominal
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)
Mating Connector Kit 6430240-1 MCIA P/N 9018654
6430240-2 MCIA P/N 9018655
Mounting Base mount – orientation not critical
Table 1.2
Qualifications
Certification FAA TSO-C71
Environmental Qualification RTCA DO-160G Environmental Category;
See Section 5.2
Altitude -15,000 feet to +55,000 feet
Temperature -55°C to +70°C (-67°F to +158°F)
Table 1.3
6 Manual Number 9018640 • Revision F, October 21, 2020
SECTION 2 PRE-INSTALLATION CONSIDERATIONS
2.1 COOLING
The TC240 product does not require external cooling or contain internal active cooling. Cooling of
the unit occurs exclusively through passive conduction through the base or radiated cooling across
the metal case. Additional cooling can be realized through convection (exposure to free moving air)
or conduction (mounting to a thermally conductive metal surface). These methods are not required
to achieve rated performance but can help prevent potential overheating and extend life when the
unit is operated at full power or during overload conditions. Specifically, mounting the unit to a
metal surface is preferred, but not required.
2.2 EQUIPMENT LOCATION
The TC240 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.
However, 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.
7 Manual Number 9018640 • Revision F, October 21, 2020
2.4 LIMITATIONS
The conditions and tests for TSO approval of this article are minimum performance standards.
Those installing this article, on or in a specific type or class of aircraft, must determine that the
aircraft installation conditions are within the TSO standards. TSO articles must receive additional
installation approval prior to being operated on each aircraft. The article may be installed only
according to 14 CFR Part 43 or the applicable airworthiness requirements.
The TC240 is designed to operate at full rated load (per Figure 4.1) throughout the specified
environmental temperature range (per section 5.2). Note that when operating at full power, the unit
case can be hot to the touch. Reference the following examples of selected conditions when
operating at maximum rated load of 240 watts (stabilized after 20 minutes):
At an ambient test temperature of +23°C when not mounted to a metal surface, the
maximum case temperature can reach +62°C. (+42°C when mounted to a metal surface)
At an ambient test temperature of +70°C when not mounted to a metal surface, the
maximum case temperature can reach +87°C. (+68°C when mounted to a metal surface)
Caution and consideration should be taken with respect to aircraft installation and operation.
8 Manual Number 9018640 • Revision F, October 21, 2020
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
MOD 0
MOD 1
MOD 1
& MOD 2
9 Manual Number 9018640 • Revision F, October 21, 2020
SECTION 3 INSTALLATION
3.1 GENERAL INFORMATION
This section contains interconnect diagrams, mounting dimensions and other information
pertaining to the installation of the TC240 DC/DC 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.
The following two versions of the unit are available. See Section 4.2.1 for additional details of the
remote enable (on/off) feature and installation details within Section 3.
Part Number Remote On/Off
6430240-1 No (output always enabled)
6430240-2 Yes (enable signal required)
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. DC/DC Converter MCIA P/N 6430240-( )
B. Connector Kit
i. 6430240-1 MCIA P/N 9018654
ii. 6430240-2 MCIA P/N 9018655
C. Installation Manual MCIA P/N 9018640
Equipment not provided:
A. Mounting Hardware Four 6-32 x 1” (min) pan head screws
#6 lock washers (optional)
B. Cable Harness Wire See Section 3.3 for specifications
3.3 CABLE HARNESS
Construct the cable harness with regards to the instructions below, and using Connector Pinout of
Table 3.1 or 3.2 and referencing Typical Wiring Diagrams of Figures 3.3 or 3.4, as applicable.
Refer to Section 2: Pre-Installation Considerations in regards to routing precautions.
Wire Gauge Selection
Use of PTFE, ETFE, TFE, Teflon, or Tefzel insulated wire is recommended for aircraft use.
Use the following wire gauges for each of the pins in the connector:
Pins A and B – 16 AWG stranded or solid
Pin C – 14 AWG or 16 AWG stranded or solid
Pin D (for -2) – 24 AWG stranded or solid
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