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Certified Lithium-ion Aircraft Battery Upgrade

Cessna Grand Caravan EX · Supplemental Type Certificate

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Overview

This document is a Supplemental Type Certificate (STC) for the installation of the TB44 Certified Lithium-ion Aircraft Battery on Cessna Caravan 208 and 208B series aircraft, including the Cessna Grand Caravan EX. It outlines the benefits of upgrading to this advanced battery technology, which offers significant weight savings, reduced maintenance requirements, and improved performance in various environmental conditions. The document is intended for operators of Cessna Caravan aircraft who are looking to enhance their aircraft's efficiency and reliability through the adoption of modern battery technology. Key features of the TB44 battery include its lightweight design, long lifespan, and smart technology that ensures safety and performance.

  • Battery weight: 51.7 pounds, 29-32 pounds lighter than lead-acid alternatives.
  • Capacity: 46 amp-hours, with a nominal voltage output of 26.4 VDC.
  • Maintenance interval: every 2 years, with an average useful life of 8 years.
  • Temperature range: -40°C to +70°C (-40°F to +158°F).
  • Estimated operational savings: up to $2,000 per year per aircraft.

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Source

Originally published by kadexaero.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.

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Document details

Type
Supplemental Type Certificate
Pages
5
File size
2.1 MB
Publisher
kadexaero.com
Documentation completeness
5/7

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In this document

Battery Overview

The TB44 Certified Lithium-ion Aircraft Battery utilizes advanced lithium-ion chemistry, providing operators with increased power and reduced weight. It is approximately 29 to 32 pounds lighter than traditional lead-acid and NiCad batteries, and it offers an extended useful life of around 8 years with maintenance intervals of 2 years.

Technical Specifications

The TB44 battery has a capacity of 46 amp-hours and operates at a nominal voltage output of 26.4 VDC. It weighs 51.7 pounds and is designed to function in extreme temperatures ranging from -40°C to +70°C (-40°F to +158°F). The battery features built-in protections against overcharge, over-discharge, and short circuits.

Operational Benefits

Upgrading to the TB44 battery can lead to significant operational savings, including reduced fuel and maintenance costs, estimated at up to $2,000 per year per aircraft. The battery's lightweight design increases the useful load, allowing for more cargo and passengers.

Installation and Compatibility

The STC approves the installation of the TB44 battery on all Cessna Caravan 208 and 208B series aircraft equipped with PT6A-114, -114A, -140, and -42A engines. The installation process is straightforward and can be completed with minimal modifications to the existing aircraft systems.

Safety Features

The TB44 battery incorporates multiple safety features, including a smart pack design that protects against various electrical issues. This ensures reliable performance in both hot and cold weather conditions, making it suitable for high-utilization environments.

Safety notes

  • The TB44 battery includes protections against overcharge, over-discharge, over-current, short circuit, and temperature extremes.

Full document text

Cessna Caravan® 208 / 208B Series PT6A-114 / -114A / -140 / -42A Engines Certified Lithium-ion Aircraft Battery Upgrade Cessna Grand Caravan® EX STCAPPROVED DISTRIBUTED BY DISTRIBUTED BY parts@kadexaero.com / Toll Free: +1-888-523-3988 / International: +1-705-742-9725 / www.kadexaero.com The TB44 Certified Lithium-ion Aircraft Battery features the most sophisticated lithium-ion chemistry available, providing Cessna Caravan® operators with an unmatched advantage of increased power, reduced weight, extended useful life, 2-year maintenance intervals, lower direct operating cost and higher profit potential. The intelligent battery system’s Nanophosphate® lithium-ion cells provide 3x the energy per kilogram and are rated up to 10,000 cycles, per cell. This results in a battery that is 29 - 32 pounds (36 - 38%) lighter than lead-acid and NiCad alternatives. Safety is addressed on multiple levels, including chemistry, cell design, containment and the integration of electronic protections. The TB44 is a ‘smart pack’ engineered to protect against overcharge, over-discharge, over-current, short circuit, over-temperature and under-temperature. Ideal for high utilization and rugged environments, the TB44 starts the aircraft’s engine quickly and offers superior hot and cold weather performance. A Supplemental Type Certificate (STC) approves installation of the TB44 on all Cessna Caravan® 208 and 208B series aircraft; engine types PT6A-114, -114A, -140, -42A. TB44 Certified Lithium-ion Aircraft Battery Product Comparison – One Battery Per Aircraft Less Weight. Less Maintenance. More Power. More Profit. TB44 Battery Technology Lithium-ion Lead-acid Nickel-cadmium Voltage Output 26.4 VDC 24 VDC 24 VDC Capacity (1C rate) 46 amp-hour 38 amp-hour 43 amp-hour Weight 51.7 pounds 81 pounds 84 pounds Maintenance 2 years 1 year (annual), 3 – 6 months (subsequent) 200 – 400 hours Useful Life 8 years (average) 2 – 4 years 5 – 10 years Concorde RG-380E/40 Saft 4078-19 DISTRIBUTED BY parts@kadexaero.com / Toll Free: +1-888-523-3988 / International: +1-705-742-9725 / www.kadexaero.com + Reduces empty weight and increases useful load 29 - 32 pounds less when compared to lead-acid and NiCad + Significantly reduced maintenance Capacity check every two years + Superior high temperature and cold weather performance -40°C to +70°C (-40°F to +158°F) + Reduces Caravan® fuel and maintenance costs Up to $2,000 per year per aircraft when compared to lead-acid batteries + Increased net present worth over 10 years More than $11,000 per aircraft when compared to lead-acid batteries + Environmentally friendly No heavy metals and easy disposal Reduced carbon emissions Caravan® Certified Lithium-ion Aircraft Battery Upgrade Benefits Operational Value + Significant weight savings + 8 year (average) useful life + Reduced direct operating costs less fuel less maintenance less ground personnel less infrastructure + Reduced turn times + Improved flight performance + Increased dispatch reliability + Increased engine & component life + Lower internal turbine start temperatures + Faster engine starts + Increased useful load more cargo more passengers more baggage more fuel + Increased customer satisfaction + No specialized test equipment required + Rapid recharge and high duty cycle + Built-in, automatic heater + Intelligent ARINC communication + Increased aircraft appreciation value + Higher turbo shaft rotation (N1) percentage Installation of (1) TB44 Certified Lithium-ion Battery in Caravan® aircraft ACU installation has multiple approved placements on the instrument panel DISTRIBUTED BY parts@kadexaero.com / Toll Free: +1-888-523-3988 / International: +1-705-742-9725 / www.kadexaero.com Present Worth of Battery Related Costs per Aircraft (10 year) This Supplemental Type Certificate approves installation of the True Blue Power® TB44 battery on all Cessna Caravan® 208 and 208B Series aircraft with these engine types. Initial Costs (PWic) Fuel Savings (PWƒs) Maintenance Costs (PWmc) Replacement Costs (PWrc) Aircraft Appreciation (∆PWa/c) Total Present Worth Total Present Worth Differential – $3,200 $0 – $2,458 – $5,570 $0 – $11,230 – $13,500 $8,388 – $614 – $5,670 $11,408 $12 $11,242 True Blue Power® Certified Lithium-ion Battery PT6A-114 PT6A-114A PT6A-140 PT6A-42A After testing the True Blue Power lithium-ion battery and understanding the amazing capabilities of this new technology, I am convinced that the old lead acid or NiCad batteries will go the way of the rotary dial telephone. It’s just so far advanced over current generation batteries. With built-in sensors to monitor the health of the battery as well as a built-in heater, coupled with the weight savings and triple the lifespan, nothing can compete with this battery. We are very excited to offer it to our Caravan® operators around the world. Jim Allmon President & CEO, Blackhawk Modifications “ ” Concorde RG-380E/40 Lead-acid Battery DISTRIBUTED BY parts@kadexaero.com / Toll Free: +1-888-523-3988 / International: +1-705-742-9725 / www.kadexaero.com Connector Service Connector Communications/ Switch RTD Temp. Receptacle Heater Quick Disconnect Vent ® Annunciation Control Unit The MD41-1844 is a compact, self-contained Annunciation Control Unit (ACU). The fully integrated control unit provides annunciation for True Blue Power TB44 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, daylight readable, deadfront inactive annunciations and automatic dimming. An external dimming adjustment is provided for balancing low-level light conditions. MD41-1844 9.6 10.14 11.02±0.02 10.87 10.48 11.71 TB44 Technical Specifications CAPACITY 46 amp-hour CHARGE VOLTAGE 28 VDC nominal OUTPUT VOLTAGE 26.4 VDC nominal OPERATING TEMPERATURE -40˚C to +70˚C (-40˚F to +158˚F) WEIGHT 51.7 pounds MAINTENANCE

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Capacity check every two years TECHNOLOGY Nanophosphate® lithium-ion cell chemistry from A123 Systems, LLC PROTECTION Overcharge, over-discharge, over-current, short circuit, over- and under-temperature MONITORING ARINC 429 and analog data to the cockpit CASE Powder-coated steel, built to withstand 35 PSI pulse CERTIFICATION FAA TSO and EASA ETSO Certified RTCA DO-311, DO-160G, DO-178B Qualified UNDOT / IATA Certified DISTRIBUTED BY parts@kadexaero.com / Toll Free: +1-888-523-3988 / International: +1-705-742-9725 / www.kadexaero.com