Introduction
The TB40 series Advanced Lithium-ion Battery is engineered for high current capability, essential for starting aircraft engines and powering the aircraft's electrical bus during generator function loss. This sophisticated energy storage system utilizes state-of-the-art Nanophosphate® lithium-ion cell technology, offering optimized performance, safety, lifespan, and weight compared to traditional batteries. Designed to meet and exceed industry standards, the TB40 provides exceptional performance and safety for aircraft designers, owners, and operators.
Key features across the TBX series (including TB20, TB30, TB40, and TB60) include real-time state of charge and capacity reporting, programmable parameters for individual installations, and maintenance-free operation with on-condition end-of-life monitoring. Enhanced safety, continuous data monitoring, and an on-board status indicator contribute to the product's reliability and reduced ownership costs.
This manual covers specifications, installation, operation, storage, scheduled service, and other relevant topics for the proper care and use of the TBX series Advanced Lithium-ion Batteries, which are intended for professional use with minimal service requirements.
Physical Attributes
The TB40 is a single, integrated unit housed in a metal enclosure with multiple connection points. It features a primary 2-pin mil-spec quick disconnect power receptacle, an 18-pin circular communications connector, and a threaded grounding location. For ground operations, a USB service port and an integrated push-button status indicator with LED indicators are provided. The enclosure lid includes two hold-down features for typical aircraft mounting and integrated handles for ease of lifting and transport. A 1.50-inch diameter vent port, located on the front or top, is designed for exhaust connections.
Unit Architecture
The unit comprises two main components: battery cell modules with integrated monitoring, logic, and protections, and a Battery Management System (BMS) for control and communication. Each battery module contains thirty-two cells arranged in groups, connected in series with fuses for each cell. Multiple temperature monitors and an integrated heater enhance cold-weather performance. Four modules are connected in parallel to provide combined power to the aircraft. The BMS, a microprocessor-based system, monitors individual module signals, manages battery operation, and reports status information to the aircraft, also managing heater functionality, storing parameters, and providing interface capabilities. Additional Resistance Temperature Detectors (RTDs) provide redundant temperature monitoring via the 18-pin connector.
Technical Specifications
Electrical Attributes: Power Input: 28.8 volts DC Nominal, 400A Max. Power Output: 26.4 volts DC Nominal, Continuous Current 525A; Peak Current (IPP) 1390A; Rated Current (IPR) 1125A. Battery Capacity: 40 Ah @ 23°C.
Physical Attributes: Weight: 36.6 pounds (16.65 kg). Dimensions: 12.1 x 8.21 x 9.2 inches (308 x 208 x 236 mm). Receptacles include a 2-pin MIL-PRF-18148/3 power receptacle and an 18-pin MS3114E14-18P communications connector. A USB 2.0 Type-A port is available for service.
Qualifications: Certification: FAA TSO-C179b, Class A-4B. Performance Qualification: RTCA/DO-311A. Environmental Qualification: RTCA/DO-160G. Software Qualification: RTCA/DO-178C, DAL A.
Important Safety Information
Symbol Definitions: Warnings indicate potential personal injury, while Cautions highlight risks of equipment damage.
Handling Precautions: The battery pack's high energy requires safety precautions such as wearing safety glasses, fire-retardant smocks, and using insulated tools. Remove metal items like jewelry. Use Electrostatic Discharge (ESD) protection and ensure appropriate short-circuit protection for all connections. The service area must be well-ventilated. Avoid sparks and flames near the battery. Use caution when handling tools to prevent short circuits. Turn off accessories before removing the ground terminal and use appropriate lifting devices.
Additional Precautions: Do not combine or use unauthorized battery cells or modules. The battery is designed for operation in various temperature and pressure conditions and does not emit or absorb gas. Ensure correct terminal connections during installation and shipping. Battery terminals must be covered with non-conductive protective devices.
Shipping: True Blue Power batteries comply with all applicable shipping regulations, including UN, IATA, and U.S. DOT standards. For air transport, batteries are shipped at a state of charge (SOC) not exceeding 30%. The battery is classified as Class 9 Dangerous Goods. Contact the manufacturer for specific shipping instructions.
Note: The unit is shipped with approximately 30% SOC and requires full charging upon receipt and prior to installation/use. Batteries stored thereafter need recharging every six months.
Pre-Installation Considerations
Cooling: No external cooling is required; the unit is designed for wide temperature ranges with internal thermal monitoring and protection.
Equipment Location: The battery offers mounting flexibility, with no specific temperature or pressure control required. For optimal performance and life, a temperature-controlled environment is recommended. The unit is designed to withstand high humidity but should be protected from direct water exposure and mounted upright. While gas release is improbable, a vent connection is provided for mitigation. Avoid installation near ignition sources. Consider how status and reporting functions will be displayed in the aircraft, and be aware that existing aircraft systems may require adjustments for voltage output and communication capabilities.
Routing of Cables: Use heavy gauge wire for power terminals due to significant power flow. Route cables away from other electronics and sensitive wire bundles. Avoid sharp bends in power and signal cables, and be cautious when routing near aircraft control cables or structures. Do not run cables adjacent to heaters or engine exhausts. Signal cable bundles should be at least 24 gauge.
Limitations: TSO approval conditions are minimum performance standards. Aircraft installation must be within TSO standards, requiring additional installation approval. The TBX series operates up to 70°C; charging is disabled if internal cell temperatures exceed 72°C until they fall below 62°C.
Modification: The product nameplate includes manufacturer, part number, description, certifications, and technical specifications, along with a modification (MOD) number. MOD 0 is the initial release. Subsequent modifications are indicated by marking out the corresponding MOD number on the nameplate. Refer to published Service Bulletins at www.truebluepowerusa.com for details on specific changes.
