True blue power TC120 Documento tecnico
Revision J • September 3, 2021
1 Manual Number 9018558 • Revision J, September 3, 2021
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 9018558 • Revision J, September 3, 2021
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 6
2.5MODIFICATION 7
SECTION 3INSTALLATION 8
3.1GENERAL INFORMATION 8
3.2UNPACKING AND INSPECTING EQUIPMENT 8
3.3CABLE HARNESS 8
3.4MOUNTING 11
3.5INSTALLATION CAUTION 11
3.6INSTALLATION COMPLETION 11
SECTION 4OPERATION 12
4.1ELECTRICAL PERFORMANCE 12
4.2TC120 AVILABLE CURRENT OVER THE OUTPUT VOLTAGE RANGE 12
4.3PROTECTIVE FEATURES 13
SECTION 5CONFORMANCE 16
5.1INSTRUCTIONS FOR CONTINUED AIRWORTHINESS 16
5.2ENVIRONMENTAL QUALIFICATION STATEMENT 16
3 Manual Number 9018558 • Revision J, September 3, 2021
REVISION HISTORY
Rev Date Detail Approved
A
02/10/2016 Initial release SHO
B 03/04/2016 Updated EQF in Section 5, corrected input voltage range,
added note to Section 2.4. BAW
C 03/15/2016
A
dd -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
guidelines. DLR
G 10/21/2020 Updated weight. MEK
H 04/13/2021
Updated Section 4 – provided additional clarification in the
operation section; correct graph info; added new graph to
illustrate power range. Section 5 corrected typo
DLR
J 09/03/2021 Updated Sections 1.1, 1.2 and 5.2 to include MIL-STD testing WVC
4 Manual Number 9018558 • Revision J, September 3, 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, MIL-STD-461F, MIL-STD-704F and MIL-STD-810F. 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.
5 Manual Number 9018558 • Revision J, September 3, 2021
1.2 TECHNICAL SPECIFICATIONS
Electrical Attributes
Input Voltage Rated 28VDC nominal, Operating 24
–
32VDC
Input Current (full load) 5 amps max at nominal input voltage
Output Voltage 5
–
18VDC adjustable
Output Powe
r
120 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 MCIA P/N 9018651
Mounting Base mount
–
orientation not critical
Table 1.2
Qualifications
Certification FAA TSO-C71
Environmental Qualification
RTCA DO-160G Environmental Category,MIL-
STD-461F, MIL-STD-704F & MIL-STD-810F;
See Section 5.2
Altitude -15,000 feet to +55,000 feet (65,000 feet non-
operating)
Temperature -55°C to +70°C (-67°F to +158°F)
Table 1.3
6 Manual Number 9018558 • Revision J, September 3, 2021
SECTION 2 PRE-INSTALLATION CONSIDERATIONS
2.1 COOLING
The TC120 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 TC120 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.
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.
7 Manual Number 9018558 • Revision J, September 3, 2021
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
8 Manual Number 9018558 • Revision J, September 3, 2021
SECTION 3 INSTALLATION
3.1 GENERAL INFORMATION
This section contains interconnect diagrams, mounting dimensions and other information
pertaining to the installation of the TC120 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
6430120-1 No (output always enabled)
6430120-2 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 incurred during shipment. The following parts should be included:
A. DC/DC Converter P/N 6430120-( )
B. Connector Kit P/N 9018651
i. Mating Connector
ii. Strain Relief
C. Installation Manual P/N 9018558
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 Figures 3.3 – 3.5,
and Wiring Diagram of Table 3.3.
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 – 18 or 16 AWG stranded or solid
Pins C and D – 16 AWG stranded or solid
Pin E – 24 AWG stranded or solid
9 Manual Number 9018558 • Revision J, September 3, 2021
Pin Assignment Information
DC Input – (24-32 VDC). Connect pin A to the aircraft positive 28 VDC bus
(7.5 amp circuit breaker recommended)
DC Return – Connect pin B to input power return or aircraft ground. Equivalent to pin D
DC Output – Connect pin C as the positive output voltage (adjustable)
DC Return – Connect pin D to output return or aircraft ground. Equivalent to pin B
Enable – 6430120-1: pin E to remain open/unconnected
6430120-2: pin E to be grounded to enable power output
(via switch or other means. See section 4.2.1 and figure 3.3 for related details)
Figure 3.1 Table 3.1
Pinout View of Unit Connector Connector Pinout
Harness Verification
With the TC120 DC/DC Power Converter disconnected, activate the aircraft power bus that
supplies the unit 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 value between 5 and 18VDC.
NOTE: The default output voltage is initially set to approximately 13.8V at the factory.
The output voltage may be adjusted while the TC120 DC/DC Power Converter is
connected to the mating harness and aircraft power, but disconnected from the output load.
Use a multi-meter at the load end of the harness to measure output voltage.
The adjustment trimmer may be accessed by removing the 4-40 screw near the label as
shown in Figure 3.4. After removing the screw, a flat blade screwdriver (2mm) will fit into
the hole and the trimmer. Turn the trimmer carefully either clockwise to increase voltage or
counter-clockwise to decrease voltage. Replace the 4-40 screw after adjustment is
complete.
Connector Pinout
A
DC Input
B DC Return
C DC Output
D DC Return
E Enable
A
D
B
E
C
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