INSTALLATION MANUAL AND OPERATING INSTRUCTIONS MD41-1817 Annunciation Control Unit For Lithium Ion Battery Systems MD41-1817 28vdc Horizontal Mount Mid-Continent Instruments and Avionics Manual Number 9018252 9400 E. 34th Street N., Wichita, KS 67226 USA Rev. D January 27, 2020 Phone 316-630-0101 Fax 316-630-0723
INSTALLATION MANUAL AND. OPERATING INSTRUCTIONS. MD41-1817. Annunciation Control Unit. For Lithium Ion Battery Systems. MD41- ...
OPERATING INSTRUCTIONS MD41-1817 Annunciation Control Unit For Lithium Ion Battery Systems MD41-1817 28vdc Horizontal Mount Mid-Continent Instruments and Avionics Manual Number 9018252 9400 E. 34th Street N., Wichita, KS 67226 USA Rev. D January 27, 2020 Phone 316-630-0101 Fax 316-630-0723
INSTALLATION MANUAL AND OPERATING INSTRUCTIONS MD41-1817 Annunciation Control Unit For Lithium Ion Battery Systems MD41-1817 28vdc Horizontal Mount Mid-Continent Instruments and Avionics 9400 E. 34th Street N., Wichita, KS 67226 USA Phone 316-630-0101 Fax 316-630-0723 Manual Number 9018252 Rev. D January 27, 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: Mid-Continent Instruments and Avionics Attn: Customer Service Dept. 9400 E. 34th ST North Wichita, KS 67226 USA Phone 316-630-0101 Fax 316-630-0723 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: Mid-Continent Instruments and Avionics Attn: Technical Publications 9400 E. 34th ST North Wichita, KS 67226 USA Phone 316-630-0101, Fax 316-630-0723 info1@mcico.com www.mcico.com Rev. D January 27, 2020 Copyright 2016 Mid-Continent Instruments and Avionics 2 Manual Number 9018252 REVISION DETAIL Rev. A B C D Date 09/29/14 07/29/15 04/25/16 01/24/20 Detail Initial Release. Added Environmental Qualification Form. Revised graphics and text to change annunciation text from STANDBY to CHARGING and FAIL to TEMP. Minor modifications to Sections 3 and 4. Added DO-160 section 22 qualification test. Added wiring diagrams for 6430017-2 battery connections. Rev. D January 27, 2020 3 Manual Number 9018252 TABLE OF CONTENTS SECTION 1 GENERAL DESCRIPTION 5 1.1 INTRODUCTION 5 1.2 TECHNICAL SPECIFICATIONS 5 1.2.1 MODELS 5 1.2.2 PHYSICAL ATTRIBUTES 5 1.2.3 PERFORMANCE 5 SECTION 2 INSTALLATION CONSIDERATIONS 6 2.1 COOLING 6 2.2 EQUIPMENT LOCATION 6 2.3 ROUTING OF CABLES 6 2.4 LIMITATIONS 6 2.5 TECHNICAL SPECIFICATIONS 6 SECTION 3 INSTALLATION PROCEDURE 7 3.1 GENERAL INFORMATION 7 3.2 UNPACKING AND INSPECTING 7 3.2.1 INCLUDED PARTS 7 3.2.2 AVAILABLE PARTS 7 3.3 CABLE HARNESS 7 3.3.1 LIGHTING CONTROLS 11 3.3.2 POWER AND SIGNALS 12 3.3.3 HARNESS VERIFICATION 12 3.4 MOUNTING 13 SECTION 4 OPERATION 14 4.1 FRONT PANEL CONTROLS AND ANNUNCIATIONS 14 4.1.1 CONTROLS 14 4.1.2 ANNUNCIATIONS 14 SECTION 5 CONFORMANCE 15 5.1 CONTINUED AIRWORTHINESS STATEMENT 15 APPENDIX 1 16 NUMBER LIST OF TABLES AND FIGURES TABLE 1 MODELS 5 TABLE 2 PHYSICAL ATTRIBUTES 5 TABLE 3 PERFORMANCE 5 FIGURE 1 25 PIN D-SHELL REAR VIEW CONNECTOR PINOUT 7 TABLE 4 SCHEMATIC PINOUT 8 FIGURE 2 WIRING DIAGRAM TWO TB17 (6430017-1) BATTERIES 8 FIGURE 3 WIRING DIAGRAM ONE TB17 (6430017-1) BATTERY 9 FIGURE 4 WIRING DIAGRAM TWO TB17 (6430017-2) BATTERIES 10 FIGURE 5 WIRING DIAGRAM ONE TB17 (6430017-2) BATTERY 11 FIGURE 6 OUTLINE DRAWING 13 FITURE 7 FRONT PANEL 14 Rev. D January 27, 2020 4 Manual Number 9018252 SECTION 1 GENERAL DESCRIPTION 1.1 INTRODUCTION The MD41-1817 products are compact, self-contained Annunciation and Control Units (ACUs). The fully integrated control unit provides annunciation for Mid-Continent Instruments and Avionics TB17 battery systems. It combines the necessary functions and annunciations required to interface with an approved system. Highlighted features include long-life LEDs used for all lighting, internally backlit selection switch, deadfront inactive annunciations, and the installation option for manual or automatic dimming. An external annunciation dimming adjustment is provided for balancing low-level light conditions. 1.2 TECHNICAL SPECIFICATIONS 1.2.1 MODEL Orientation Power Input Lighting Input MD41-1817 Horizontal 28VDC 28VDC TABLE 1 MODEL 1.2.2 PHYSICAL ATTRIBUTES Characteristics: Weight: Dimensions: (not including connector or mate) Mating Connector: Instrument Panel Mounting: 0.26 pounds 3.2 inches long 2.75 inches wide 0.8 inches high Positronic RD25F10JVL0 or equivalent (MCI P/N 7014517) Rear mount TABLE 2 PHYSICAL ATTRIBUTES 1.2.3 PERFORMANCE Specifications: Power Requirement: 0.20 A max TABLE 3 PERFORMANCE Rev. D January 27, 2020 5 Manual Number 9018252 SECTION 2 PRE-INSTALLATION CONSIDERATIONS 2.1 COOLING No direct cooling is required. As with any electronic equipment, overall reliability may be increased if the unit is not located near a high heat source or crowded next to other equipment. Means of providing some airflow is considered beneficial. 2.2 EQUIPMENT LOCATION The MD41-1817 ACU must be mounted as close to the pilot's field of view as possible. The unit depth, with connector attached, must also be taken into consideration when selecting an appropriate location. Allow at least 3 inches of space behind the unit for connector attachment and removal. 2.3 ROUTING OF CABLES Care must be taken not to bundle the MD41 series ACU logic and low level signal lines with any high energy sources. Examples of these sources include 400 Hz AC, Comm, DME, HF and transponder transmitter coaxial cables. Always use shielded wire when shown on the installation print. 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 Note that this product is part of an incomplete system. It is designed to be installed with other applicable equipment to provide functionality for main battery systems. 2.5 TECHNICAL SPECIFICATIONS The MD41-1817 complies with the manufacturers' specifications and has been verified and approved for use with the following systems: Mid-Continent Instruments and Avionics Model Number(s): MD41-1817 Designed for use with Battery System: Manufacturer: Mid-Continent Instruments and Avionics Model(s): TB17 Rev. D January 27, 2020 6 Manual Number 9018252 SECTION 3 INSTALLATION PROCEDURES 3.1 GENERAL INFORMATION This section contains interconnect diagrams, mounting dimensions and other information pertaining to the installation of the MD41 series ACU. After installation of cabling and before installation of the equipment, ensure that power is applied only to the pins specified in the interconnect diagram. 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. 3.2.1 INCLUDED PARTS A. Main Battery ACU B. Installation Manual MCIA P/N MD41-1817 series MCIA P/N 9018252 3.2.2 AVAILABLE PARTS A. J1 Connector Kit (25 pin) MCIA P/N 7014517 B. 7-pin Cylindrical TB17 Signal Connector MCIA P/N 9017889-1 C. Annunciator Cutout Template MCIA P/N 8014474 3.3 CABLE HARNESS The MD41 cable harness should be made using 24 AWG wire or larger for all connections. Construct the cable harness with regards to the instructions below and using the Connector Pinout of Figure 1, Schematic Pinout of Table 4, and Wiring Diagram of Figures 2 and 3. FIGURE 1 REAR VIEW OF 25-PIN D-SUB CONNECTOR (J1) Rev. D January 27, 2020 7 Manual Number 9018252 Pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 Connector Pinout Description Pin # Description CHARGING, Battery 1 14 Reserved HEATING, Battery 1 15 Pin 2 of RTD 1, Battery 2 FAIL/FAULT, Battery 1 16 Pin 1 of RTD 1, Battery 2 HEATING, Battery 2 17 Panel Lighting Input, 28VDC CHARGING, Battery 2 18 Pin 1 of RTD2, Battery 2 FAIL/FAULT, Battery 2 19 Output to Pin 1 of RTD 1, Battery 2 Pin 2 of RTD 1, Battery 1 20 Input from Pin 1 of RTD 2, Battery 1 Pin 1 of RTD 1, Battery 1 21 Input from Pin 1 of RTD 2, Battery 2 Pin 1 of RTD 2, Battery 1 22 Pin 1 of Over Temperature Warning Output to Pin 1 of RTD 1, Battery 1 23 Pin 2 of Over Temperature Warning 28 VDC, Battery 1 24 GROUND 28 VDC, Battery 2 25 GROUND 28 VDC, Aircraft Power TABLE 4 SCHEMATIC PINOUT J1 17 28VDC 13 28 VDC AIRCRAFT PWR 11 BATTERY 1, 28 VDC FROM LIGHTING BUS USE 2A CIRCUIT BREAKER 2A 24 BATTERY 1, GROUND 3 FAIL/FAULT ANNUN, BATT 1 2 HEATING ANNUN, BATT 1 1 CHARGING ANNUN, BATT 1 8 RTD1/PIN1, BATT 1 10 OUTPUT TO RTD1/PIN1, BATT 1 20 INPUT FROM RTD2/PIN1, BATT 1 9 RTD2/PIN1, BATT 1 7 RTD1/PIN2, BATT 1 22 OVER-TEMP WARN, PIN 1 23 OVER-TEMP WARN, PIN 2 14 RESERVED 12 BATTERY 2, 28 VDC 25 BATTERY 2, GROUND 6 FAIL/FAULT ANNUN, BATT 2 4 HEATING ANNUN, BATT 2 5 CHARGING ANNUN, BATT 2 16 RTD1/PIN1, BATT 2 19 OUTPUT TO RTD1/PIN1, BATT 2 21 INPUT FROM RTD2/PIN1, BATT 2 18 RTD2/PIN1, BATT 2 15 RTD1/PIN2, BATT 2 A B C D BATTERY 1 F E G A B C D BATTERY 2 F E G NOTES: 1) ALL WIRING SHALL BE 24 AWG UNLESS OTHERWISE NOTED. FIGURE 2 WIRING DIAGRAM - TWO TB17 (6430017-1) BATTERIES Rev. D January 27, 2020 8 Manual Number 9018252 J1 17 28VDC 13 28 VDC AIRCRAFT PWR 11 BATTERY 1, 28 VDC FROM LIGHTING BUS USE 2A CIRCUIT BREAKER 2A 24 BATTERY 1, GROUND 3 FAIL/FAULT ANNUN, BATT 1 2 HEATING ANNUN, BATT 1 1 CHARGING ANNUN, BATT 1 8 RTD1/PIN1, BATT 1 10 OUTPUT TO RTD1/PIN1, BATT 1 20 INPUT FROM RTD2/PIN1, BATT 1 9 RTD2/PIN1, BATT 1 7 RTD1/PIN2, BATT 1 22 OVER-TEMP WARN, PIN 1 23 OVER-TEMP WARN, PIN 2 14 RESERVED 12 RESERVED 25 RESERVED 6 RESERVED 4 RESERVED 5 RESERVED 19 A B C D BATTERY 1 F E G 16 15 18 21 NOTES: 1) ALL WIRING SHALL BE 24 AWG UNLESS OTHERWISE NOTED. FIGURE 3 WIRING DIAGRAM - ONE TB17 (6430017-1) BATTERY Rev. D January 27, 2020 9 Manual Number 9018252 J1 17 28VDC 13 28 VDC AIRCRAFT PWR 11 BATTERY 1, 28 VDC FROM LIGHTING BUS USE 2A CIRCUIT BREAKER 2A 24 BATTERY 1, GROUND 3 FAIL/FAULT ANNUN, BATT 1 2 HEATING ANNUN, BATT 1 1 CHARGING ANNUN, BATT 1 8 RTD1/PIN1, BATT 1 10 OUTPUT TO RTD1/PIN1, BATT 1 20 INPUT FROM RTD2/PIN1, BATT 1 9 RTD2/PIN1, BATT 1 7 RTD1/PIN2, BATT 1 22 OVER-TEMP WARN, PIN 1 23 OVER-TEMP WARN, PIN 2 14 RESERVED 12 BATTERY 2, 28 VDC 25 BATTERY 2, GROUND 6 FAIL/FAULT ANNUN, BATT 2 4 HEATING ANNUN, BATT 2 5 CHARGING ANNUN, BATT 2 16 RTD1/PIN1, BATT 2 19 OUTPUT TO RTD1/PIN1, BATT 2 21 INPUT FROM RTD2/PIN1, BATT 2 18 RTD2/PIN1, BATT 2 15 RTD1/PIN2, BATT 2 A B C D 105W, 1/4W F E G BATTERY 1 A B C D 105W, 1/4W F E BATTERY 2 G NOTES: 1) ALL WIRING SHALL BE 24 AWG UNLESS OTHERWISE NOTED. FIGURE 4 WIRING DIAGRAM - TWO TB17 (6430017-2) BATTERIES Rev. D January 27, 2020 10 Manual Number 9018252 J1 17 28VDC 13 28 VDC AIRCRAFT PWR 11 BATTERY 1, 28 VDC FROM LIGHTING BUS USE 2A CIRCUIT BREAKER 2A 24 BATTERY 1, GROUND 3 FAIL/FAULT ANNUN, BATT 1 A 2 HEATING ANNUN, BATT 1 B 1 CHARGING ANNUN, BATT 1 C 8 RTD1/PIN1, BATT 1 10 OUTPUT TO RTD1/PIN1, BATT 1 D BATTERY 1 20 9 INPUT FROM RTD2/PIN1, BATT 1 RTD2/PIN1, BATT 1 105W, 1/4W F 7 RTD1/PIN2, BATT 1 E 22 OVER-TEMP WARN, PIN 1 G 23 OVER-TEMP WARN, PIN 2 14 RESERVED 12 RESERVED 25 RESERVED 6 RESERVED 4 RESERVED 5 RESERVED 19 16 15 18 21 NOTES: 1) ALL WIRING SHALL BE 24 AWG UNLESS OTHERWISE NOTED. FIGURE 5 WIRING DIAGRAM - ONE TB17 (6430017-2) BATTERY Refer to Section 2: Pre-Installation Considerations in regards to routing precautions. 3.3.1 LIGHTING CONTROL Button backlighting (pin 17) is powered (28 VDC) from the aircraft's panel lighting bus. All annunciation and button backlight brightness will be automatically controlled by the internal photocell and the dimming circuit. Rev. D January 27, 2020 11 Manual Number 9018252 3.3.2 POWER AND SIGNALS Wire aircraft power and aircraft ground according to the associated ACU pins in the Pinout Diagram. Annunciation signals should be wired from the appropriate system inputs and outputs to the associated ACU pins in the Pinout Diagram. If an over temperature condition exists, pins 22 and 23 will be tied together with a 100 series resistance. This output signal can be utilized as a battery over temperature indicator to other systems in the aircraft. The TEMP annunciation will be lit in this condition. 3.3.3 HARNESS VERIFICATION With the MD41 ACU disconnected, turn on the avionics master switch and use a volt-meter (multimeter) to verify that aircraft power and panel lighting bus power is on the appropriate pin(s) with appropriate voltage. Also verify that aircraft ground is applied to the appropriate pins. Rev. D January 27, 2020 12 Manual Number 9018252 3.4 MOUNTING Refer to Section 2: Pre-Installation Considerations in regards to equipment location. The MD41 ACU is designed for rear panel mounting only. A cutout should be made in the panel in accordance with Figure 4 for the unit bezel and two mounting holes. A cutout template is available from Mid-Continent Instruments and Avionics (reference p/n 8014474) upon request. Prior to completing the mounting of the unit in the aircraft, make sure to set the Annunciator Dim Adjustment if automatic dimming is configured for the annunciations. Ideally this procedure is best performed in a dark cockpit to simulate low-light/night time conditions. Connect the unit to the cable harness and turn on master power to the instrument panel and lighting bus. Use a small flat-bladed screwdriver to access the adjustment screw inside the hole on the bottom of the unit (see Figure 4). Adjust the screw to increase or decrease the annunciator lighting brightness to a level appropriate with the rest of the panel instrument lighting. Secure the indicator to the panel with two #4-40 x 3/8 flat head phillips screws. 3.00 Text Direction 0.13 R0.16 typ. Momentary Switch Rev. D January 27, 2020 2.75 2X 4-40 UNC-2B 2.50 3/8" max thread depth 0.80 2.25 FIGURE 6 OUTLINE DRAWING MD41-1817 13 Manual Number 9018252 SECTION 4 OPERATION 4.1 FRONT PANEL CONTROLS AND ANNUNCIATIONS 4.1.1 CONTROLS BATT/HEAT There are 2 different TB17 battery modes of operation that will determine actions when the BATT/HEAT momentary switch is depressed (see Manual Number 9018047, section 4.3 that describes Sleep and Active mode of TB17): When the TB17 battery is in sleep mode, pressing the BATT/HEAT momentary switch lights all annunciations as depicted in Figure 5, which includes MAIN BATTERY, TEMP, FAULT, BATT/HEAT button, CHARGING and HEATING for at least 3 seconds or until the button is released When the TB17 battery is in active mode, pressing the BATT/HEAT momentary switch lights all annunciations as depicted in Figure 5, which includes MAIN BATTERY, TEMP, FAULT, BATT/HEAT button, CHARGING and HEATING until the button is released BATT/HEAT button is white backlit. Refer to the installation manual and operating instructions of the TB17 for additional operational and functional interface details. 4.1.2 ANNUNCIATIONS MAIN BATTERY (WHITE) TEMP (RED) FAULT (AMBER) CHARGING (WHITE) BATT/HEAT HEATING (WHITE) (WHITE) Lit when any of the annunciations are ON. Lit when over temperature sensed on battery. Land as soon as practical and present the battery for maintenance evaluation. Blinking - when battery has experienced a recoverable fault. Steady - when battery has experienced a nonrecoverable fault. For steady light, present battery for maintenance evaluation upon landing. Lit when battery is charging. If battery is used as an emergency power source, it is recommended flight not be initiated until CHARGING is no longer displayed, indicating a state of charge greater than 95%. Lit when panel lighting input is high (pin 17) and unit is connected to Battery 1 (pin 11), Battery 2 (pin 12), and/or aircraft power (pin 13). Lit when battery heater is activated due to unit temperature below 10°C and battery is in active state. It is recommended that an engine start not occur until the HEATING annunciation turns off. Rev. D January 27, 2020 FIGURE 7 FRONT PANEL 14 Manual Number 9018252 SECTION 5 CONFORMANCE 5.1 CONTINUED AIRWORTHINESS STATEMENT No periodic scheduled maintenance or calibration is necessary for continued airworthiness of the MD41 series ACU. If the unit fails to perform to specifications, the unit must be removed and serviced by MidContinent Instruments and Avionics or their authorized designee. Rev. D January 27, 2020 15 Manual Number 9018252 Appendix 1 DO-160 Environmental Qualification Form MODEL NUMBER: MD41-() PART NUMBER: MD41-1817 NOMENCLATURE: MD41-() Battery Annunciation Control Unit TSO APPROVALS: N/A MANUFACTURER: Mid-Continent Instrument Co., Inc. ADDRESS: 9400 E. 34th St. North, Wichita, KS 67226, USA. MANUFACTURERS SPECIFICATIONS: Minimum Performance Specifications: TS360, TDS360 Qualification Test Reports: QTR2104 QTR2108; QTR2115 QTR 2118 RTCA DO-160: Rev G, dtd 12/08/10 DATES TESTED: 4/2015-5/2015 CONDITIONS Temperature and Altitude Low Temperature High Temperature Altitude Temperature Variation Humidity Operational Shock and Crash Safety Vibration Explosion Waterproofness Fluids Sand and Dust Fungus Salt Fog Magnetic Effect Power Input Voltage Spike Audio Freq Conducted Susceptibility Induced Signal Susceptibility Radio Frequency Susceptibility Emission of Radio Freq Energy Lightning Induced Transient Susceptibility Lightning Direct Effects Icing ESD Fire, Flammability SECTION 4 4.5.1 4.5.2 4.5.3 4.5.4 4.6.1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 DESCRIPTION OF TEST Category F2 Survival and Short Operating Low Temp = -55C Normal Operating Low Temp = -55C Survival High Temp = +85C Short and Normal Operating High Temp = +70C Altitude = 55,000 ft Category S2 Category B Category B Category R Curves B&B1, Category U Curve G Category X Category X Category X Category X Category X Category X Category Y Category Z(XX) Category A Category Z Category ZC(X) Category T (conducted) Category T (radiated) [TT] Category M Category A3 (pin injection) Category G3L3 (cable bundle) [A3G3L3] Category X Category X Category A Category X Rev. D January 27, 2020 16 Manual Number 9018252Acrobat Distiller 10.1.16 (Windows)