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Aviation Battery Solutions |
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RED BOX
INTERNATIONAL LIMITED |
Red Box strives to provide customers with competitively priced, high quality, and technically advanced portable products.
Red Box strives to provide customers with competitively priced, high quality, and technically advanced portable products.
Red Box International holds ISO 9001:2000 accreditation which gives customers peace of mind that Red Box units are designed and built to the highest specifications. |
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The majority of the company's products are NATO codified and built to exacting military requirements. All Red Box customers can expect in-depth technical support, operational advice, together with global after-sales support and service. These are provided by an expanding number of international distributors and service centres. Red Box has a range of continuous power supplies from 230 VAC 50/60 HZ input to 28 Volts DC output. These switched mode, lightweight units, are used for servicing aircraft in the hanger, on the ramp, for powering communications, navigation and surveillance systems or servicing and supporting armored vehicles. These units are capable of outputting 50, 100, 150 or 200 Amps DC and can be used in a stand- alone mode or combined with battery systems. |
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This powerful Hand Portable Power Pack uses the latest in aerospace technology to achieve very high power to weight ratio. |
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Built in stainless steel and is designed for starting medium sized turboprop or turbine engines in all weathers. |
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NATO codified and in widespread use with NATO and other forces. |
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The packs can be used or stored in any orientation, including inverted, and may be used singly or in a dual format if more capacity is required. |
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Cells are cleared as non hazardous for transportation. |
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in aircraft. |
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They are able to operate in extremes of temperature and have excellent standby characteristics. |
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Units are maintenance free, do not need cycling and have no memory effects. |
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Supplying Ground Power for all your needs! |
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The RB Range : |
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Red Box portable ground power units (GPUs) and continuous power systems give the advantage of independent portable DC power. Whether for engine starting or technical support, these are ideal for use in remote sources are not available. Our portable GPU's are ruggedly built and capable of starting jet engines, battle tanks, marine diesels, trucks or heavy earth movers. At Red Box we provide a range of units to suit most needs and operational requirements for providing DC power in maintenance shops or in the field. |
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Used throughout the aviation industry, portable GPUs are normally supplied as complete, ready to use systems. Included are a multi-stage, automatic charger and heavy duty power cables with appropriate NATO 3 pin connector or high grade clips. |
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Typical units have been in production since 1994 and are in everday use throughtout the world in many military operations, including NATO. Our GPUs provide vital support throughout the Aviation Industry, Public Utilities, Offshore Exploration, Transport & Trucking, and many Police /Emergency services. |
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Power Pack indication table: |
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RB75A : |
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The RBS75A is the most powerful Hand Portable Power Pack available Wordwide. Red Box uses the latest in military aerospace technology to achieve a very high power to weight ratio. This power pack is designed for heavy duty starting of turboprop or turbine aircraft and helicopters in the field or in remote locations.
The power pack is an 'all weather' unit, and being modular, can be used in single or dual format. It can be used in any orientation, even inverted. Cells used are cleared as non-hazardous cargo for carriage in aircraft. They are able to operate in extremes of temperature and have excellent standby characteristics. They are maintenance free and do not need cycling. |
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They can be re-celled "on condition" at any Red Box service centre in the USA, Europe or Asia and are designed to give years of repeated service.
In addition to aviation, this highly portable unit can be used with armoured fighting vehicles and military equipment. It can be recharged from the charging system, which is supplied in the package or from an aircraft / vehicle using a suitable interface.
The military standard power pack system includes a portable power unit, a rugged multistage electronic charges with extreme weather capabilities and heavy duty cables with aviation or vehicle connectors. |
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RB5OA : |
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This powerful Hand Portable Power Pack uses the latest in aerospace technology to achieve very high power to weight ration. It is ruggedly built in stainless steel and is designed for starting medium sized turboprop or turbine engines in all weathers. It is NATO codified and in widespread use with NATO and other forces.
The packs can be used or stored in any orientation, including inverted, and may be used singly or in a dual format if more capacity is required. Cells are cleared as non hazardous for transportation in aircraft. They are able to operate in extremes of temperature and have excellent standby characteristics. Units are maintenance free, do not need cycling and have no memory effects.
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They can be re-celled " on condition" at any Red Box service centre in the USA, Europe or Asia and are designed to give years of repeated service.
This very portable unit is recharged from the standard charging system supplied, or from the aircraft using a suitable interface. The complete power pack system comprises the portable ground power unit, mutistage, automatic charger and heavy duty aircraft cables with NATO 3- pin aircraft connector. This power pack is available in alternative colours to meet with corporate or safety standards to order. |
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RB25A Minipak : |
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The Red Box MINIPAK is the ultimate in lightweight packaged power. It is designed specifically for the operator who needs alternative, compact and economical start power when the aircraft batteries may be marginal.
This packet rocket is the smallest in the Red Box professional range of aviation power packs. It is intended for first stat of the day or as a standby for difficult situations and is ideal for carrying onboard.
Half the size of a pilots case and weighing 16kg (35lb), the MINIPAK is able to start most light helicopter will shrug off the weight. These extremely economical units are affordable by even the most cost conscious operator.
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The GPU can be recharged with the multistage, automatic charger, supplied as standard. Included are aircraft power cables with the standard NATO 3 pin connector.
The GPU can also accept rapid charge from onboard aircraft generators if the aircraft is so configured.
MINIPAK is designed to hold power for long periods, meaning that it is always ready when needed. It is ruggedised in stainless steel and is maintenance free. It can be re-celled "on condition" at any Red Box service centre in the USA, Europe or Asia and is designed to give years of repeated service.
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Battery Systems : |
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The cells used in our GPUs utilise the latest in dry lead acid military / aviation technology which offer many valuable features. These cells are very rugged and allow the power pack to be used, stored or transported in any orientation, even inverted. They are cleared safe for transport in aircraft, by land or by sea. |
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They produce massive power for comparatively low weight and small size. Importantly, they hold their charge for very long periods when on standby or in storage. Shelf life can be as long as 15 years. Our GPUs can operate in very cold or hot climates, but being portable, they can be kept in sheltered conditions until needed, when they can deliver full high power on demand. They do not need cycling, or maintenance, other than charging after use. When they do become depleted, they can be refitted with new cells and returned to full service, a feature which makes for substantial savings over time. |
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Recharging |
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Red Box chargers are high quality and use microprocessor or intelligent switch-mode technology. Our equipment has outstanding features including automatic voltage sensing, anti condensation and cold temperature conditioning. In the field, Red Box hand portable ground power units can be recharged from other voltage controlled DC sources, such as road vehicles or 28v DC power outlets, even direct from aircraft main engine generators, when ground return is available.
Red Box can also provide special DC/DC battery chargers for recharging GPUs while in transit. |
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Operations |
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Red Box experience, plus the feedback from thousands of users, has shown that one type of portable GPU cannot possibly support all commercial and military needs satifactorily. Our versatile range is designed to meet the needs of air, land or marine users and their widely varying operating requirements. Our hand portable ground power units are built to operate in harsh conditions. We can configure hand portable packs in either 12v or 24v operation and continous power supplies in fixed, switchable (14 / 28 volts) or vatiable configurations.
When heavy duty use is required always choose the largest capacity. |
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General: |
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Red Box battery packs are extremely rugged and have low internal resistance which produces very high power. They are especially portable in that they can be moved around without difficulty and can be used in any orientation, even inverted. Tehy do not need cycling and therefor can be recharged at any time. Full charge is indicated by 26.0 volts on the built in voltmeter and fully discharged is indicated by 24.0 volts on the voltmeter. |
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Battery life is cycle and discharge dependent. This means that the more cycles the batteries are subjected to and the greater the depth of discharge in each cycle, the more the battery plates are stressed and the faster they wear out. The worst case is therefore when the batteries are discharged repeatedly from full charge to fully discharged. In this type of usage the batteries may only last 200 cycles but, if only a small amount of capacity is used each time before recharging, then up to 2000 cycles may be expected. |
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Corrected charging, float charging and the regularity of charging will also have an effect on battery life. It is most important to recharge the batteries as soon as possible after use to prevent the onset of sulphating of the plates. This condition will have an adverse effect upon the battery life and performance. It is also very important not to allow the batteries to become deep discharged, that is, discharged below 22.0 volts. If this occurs it will affect the battery life and it could result in the battery being very difficult, if not impossible, to recover to normal use. Generally, it is good practice to leave the power unit on the charger for as long, and as often as possible and it is recommended that when feasible they should be left on for 24 hours every 2 weeks or so, to allow full cell equilibrium to be achieved.
There is, therefore, no specific formula to calculate actual battery life but, Red Box has extensive experience, based upon the time from sale of some power units to the time that they were returned for new cells to be fitted. A rough rule of thumb suggest that the apporximate average life of these examples is around two years. Some units may be less and some considerably more. |
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Battery Capacity versus Voltage Drop : |
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One may think that two battery power packs of the same voltage, but with different capacities, would have the same voltage drop when put under the same load. Not true. The battery with the larger capacity will have a lower voltage drop due to having a larger plate surface area. Because the load is spread over a larger plate area the chemistry is less affected. Therefore, when you need greater performance, always choose a unit with higher capacity. |
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Battery Temperature |
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All batteries suffer from the effects of cold temperature. This is particularly true if the battery is allowed to become cold soaked. That is, if the cold is allowed to reach the core of the battery. In Red Box power packs this condition will take some time to occur. Also, it is worth noting that, if this cold soaked condition is achieved, it will take a similar time to recover the battery to full performance when it is placed in a warm atmosphere. |
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It is therefore important to manage the portable packs and whenever possible, to keep or store them in as worm an environment as possible. It is important to fit the thermal covers and to avoid wind chill. These actions will delay cold soaking. The "High Tech" lead acid batteries used in Red Box power units will be less affected by cold than most aircraft batteries but even these batteries will eventually suffer if the cold problem is not managed. |
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Storage |
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The Red Box power units are maintenance free with regard to electrolyte replenishment. Maximum storage life, between charges, is 2 years at 25 C. (Less at higher temperatures). Total storage life is 15 years (not affected by humidity). |
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The TC RANGE : |
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The TC range was initiated several years ago, to meet demands from customers either with larger aircraft than the hand portable pack could support alone, or with larger operations where several smaller aircraft are in more regular use. This led to the development of two concepts in highly manoeuvrable units. The provision of large capacity batteries for start power only or with the addition of high quality DC power supplies for both continous and start power.
The TC 400 series are designed for start power only giving a maximum of 6000 Amps if required in a highly portable package. The TC3000 series are a combination of the 400 series unit with addition of continuous DC supply giving 50, 100, 150 or 200 Amps at 28 Volts and up to 6000 Amps for starting.
These systems are suitable for a wide range of applications, from the supplying of auxiliary power for servicing, pre-flight checks, diagnostics, training or demonstrations.
They can be easily transported for use on the Ramp, in the Workshop or out in the Field. If required they can be simply and cost effectively transported to a different location or transported in an aircraft. These units can also be supplied for fixed installation use. |
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TC 400A |
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Compact GPU with extra high capacity for Turbine Aircraft. |
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A compact highly manoeuvrable GPU which is supplied with separate high capacity charging unit. A weight - balanced design on pneumatic tyres with an optional towbar, this GPU is fully all weather operational and is specailly designed for the heavy duty starting of turbine and turbo prop aircraft. (3 capacities are available).
For use at fixed bases or on remote stations, these units can operate in extremes of temperatue, their power cells have excellent standby characteristics and do not need cycling nor have any memory effect. The essentially dry lead acid batteries are maintenance free and are replaceable on condition.
The largest unit is this range is the TC400/28 which is a genuine 28 volt unit using 14, 2 volt lead acid cells. This extra 4 volts can be vital on some airframes which are particularly sensitive to the voltage of the ground supply, especially during a heavy start or in arduous operating conditions.
Each TC400 unit is fitted with a digital voltmeter for voltage audible warning device to advise when the cells have reached a Low State Charge / Flat condition.
A separate, powerful, 20 amp DC charger is provided with the GPU and is available in 110v OR 230v AC. Power for feeding these chargers can be supplied from fixed mains or portable generators.
The units are delivered as standard with 2.5 metre heavy duty aircraft power cable, fitted with a 3 pin NATO connector. A 50mm, 'pin through ', tow bar is optional and units are ready to use out of the box. |
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| TC400A-4 |
3500 Amps start power. 58 A/hr (1 hour rate) battery capacity. Complete with separate 20 amp charger and A/C power lead. Fully all weather. |
| TC400A-6 |
4500 Amps start power 86 A/hr (1 hour rate) (114 A/hr at 10 hr rate) battery capacity. Complete with separate 20 amp charger and A/C power cables. Fully all weather. |
| TC400A-28C |
28 Volt 3500 Amps start power 136 A/hr (1 hour rate) (152 A/hr at 10 hr rate) battery capacity. Complete with separate 20 amp charger and A/C power cables. Fully all weather. |
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TC 3000 : |
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Portable GPU with Continuous 28.5 V DC power available. |
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This is an extremely compact, weight balanced design, hand maneuverable on pneumatic tyres. These GPUs are specially designed for heavy duty starting of turbine and turbo prop aircraft. They provide 50, 100 or 150 amps of continuous power at 28.5 volts DC. For use at fixed bases or on remote stations, these units can operate in extremes of temperature and their power cells have excellent standby characteristics and do not need cycling. The essentially dry lead acid batteries are maintenance free and are replaceable on condition.
A 50, 100 or 150 amps, 28.5 volt power supply / charger is installed within the GPU. This can also be used to provide continuous filtered power for general workshop use, pre flight checks, avionics work , weapon system checks or to recharge the internal batteries of the unit.
Supplied ready to use out of the box, all units are complete with a heavy duty aircraft cable fitted with a 3 pin NATO connector and a suitable mains lead. These units, due to their high power, are normally 220 volt 50/60 Hz input, but other options are available on request.
TC3000 units are available in 3 battery capacities and 3 contiuous rating, which have been combined in a selection detailed in the table below, to deal with most customer demands, however custom configurations are always available. All TC3000 units feature a digital microprocessor control system which monitors several parameters and displays the voltage, current and system status. This also monitors and controls the voltage output and the automatic charging of the batteries. |
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| TC3000/50-4 |
3500 Amps start power 58 A/hr (1 Hr rate) (76 A/hr at 10 Hr rate) battery capacity and 50 amps @ 28v DC continuous power for workshops or training. A/C power lead. |
| TC3000/50-6 |
4500 Amps start power 86 A/hr (1 Hr rate) (114 A/hr at 10 Hr rate) battery capacity and 50 amps @ 28v DC continuous power for workshops or training. A/C power lead. |
| TC3000/100-4 |
3500 Amps start power 58 A/hr (1 Hr rate) (76 A/hr at 10 Hr rate) battery capacity and 50 amps @ 28v DC continuous power for workshops or training. A/C power lead. |
| TC3000/100-6 |
4500 Amps start power 86 A/hr (1 Hr rate) (114 A/hr at 10 Hr rate) battery capacity and 50 amps @ 28v DC continuous power for workshops or training. A/C power lead. |
| TC3000/150-4 |
3500 Amps start power 58 A/hr (1 Hr rate) (76 A/hr at 10 Hr rate) battery capacity and 50 amps @ 28v DC continuous power for workshops or training. A/C power lead. |
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RBSC Range : |
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The RBSC range of continuous power supplies evolved from the power units that were designed for the TC based product. A 50 Amp, lightweight switched mode module was developed that can be combined to produce DC outputs of virtually any size, however the common sizes that have been developed are 50, 100, 150 and 200 Amps. In the aviation and military markets these units are typically 28.5 Volts, however they can be fixed voltage (2 to 30 volts) selectable or adjustable, running from AC input, ranging from 190 to 270V AC. 45 to 65 Hz. They are normally 220 volt based systems due to the duty of input current; however other input voltages are available. |
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Using switchmode technology, these units are extremely lightweight and highly portable and provide stable DC power for general maintenance, gear servicing, avionics work, crew training or weapons systems checks. They are available for a wide range of applications for both fixed and rotary wing aircraft, for commercial and military applications. These units are also ideal for laboratory or workshop use for maintenance, repairs, or calibration. |
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The 50 and 100 Amp units can be used combinaton wth Red Box RB50A or RB75A portable battery start packs on a lightweight trolley, to provide serving and starting capability. For aircraft applicatons they are supplied complete with heavy duty leads fitted with 3 pin NATO connectors and mains input leads to customer requirements. Other leads wth NATO vehicle connectors, mil spec or amphenol are available to customer requrements. |
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The RBSC units use our digital microprocessor control system to monitor and control the outputs and monitor several parameters. These units display the voltage, current and system status. They also monitor and control the voltage outputs and the automatic charging of the batteries if connected. |
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RBC5000 |
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High Current, 28.5 volt DC for Support and Start Power.
When there is a requirement for 28.5 volt continuous power for heavy work on base, or for larger aircraft, Red Box provides Transformer Rectifier Units (TRU) which can produce up to 600 amps continuously and 2000 amps peak power for starting.
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These units convert direct from AC Mains Supply to 28.5 volts DC using the latest technology, providing stable outputs capable of rapid response to a change in load. Together with remote voltage sensing, this provides high quality steady DC at the aircraft. |
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These units are typically used for:
1)High current requirements during aircraft turn-round for gallery servicing and climate control.
2)Start power for large turbine and turboprop aricraft.
3)Service power for cycling gear, cargo doors and baggage handling systems.
4)Power for anti-ice systems, diagnostics, fuel transfer or hydraulics.
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They can be provided in both static and mobile formats and are ideal for supplying aircraft which require high levels of DC power during turn-round, whether for powering lighting, gallery equipment, or climate control. Units for fixed installation can be in a variety of configurations, however these units to be mobile, keeping heavy cable runs and therefore voltage drops to a minimum. |
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RBC6000 : |
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115/200 Volt 400 Hz Continuous supply for AC Aircraft.
For 115 Volt, 400 Hz AC powered aircraft, Red Box can provide a range of frequency / voltage converters, rated from 5 to 60 KVA. They can be configured to operate from almost any single or three phase supply. These continuously rated units are for aircraft ram, workshop, laboratory or production line use. |
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They can have fixed or variable output voltage and frequences. Using highly reliable semiconductor technology, outputs can tolerate phase unbalances up to 100% and large transient overloads for equipment with high start up demands. The outputs can be monitored on a LCD digital display, indicating all phase voltages and frequencies, output power and effective power factors. These displays can be locked for simplified use. Together with clear information lights giving the unit status, this makes these units very simple to use. |
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Aircraft interlocks in both Military and Commercial variants are available with override facilities to provide compatibility with a wide range of airframes.
These units can be provided in both a static and mobile formats. Static units can be free standing, bridge, or skid mounted for more permanent installation, whereas the portable units are trolley mounted enabling complete maneuverability behind field vehicles.
Compact and lightweigth static frequency and voltage converters can be produced for any insutrial or marine application, offering both multiple / variable voltage and frequency input and output.
These units are in current use by NATO military and can be supplied in military or other colours to order. |
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These units are typically used for :
1)Ramp or field power during aircraft turnround.
2)Hanger or ramp power for servicing and diagnostics; used for avionics, lighting, ventilation & climate control, kitchen & gallery.
3)Service power for lighting and ancillaries during domestic cleaning, maintenance, training or demonstration purposes. |
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SnakeCam portable inspection and search equipment : |
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SnakeCam is a remarkable, high quality, low cost, inspection tool.
SnakeCam combines user flexibility with quality equipment, at a very competitive price.
SnakeCam is waterproof to 50 ft, 15 metres depth.
SnakeCam can be supplied in an 'Immediate Use' case for rapid deployment.
This completely portable system combines a miniature CCD camera with a hand held TFT display that delivers crystal clear colour pictures. |
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The standard inspection camera has inbuilt cold LED lights and can operate in complete darkness.
The very compact display unit has a rotating screen so that, regardless of the camera orientation, the picture can always be viewed "head up".
Camera cables can be up to 100 metres and are supplied in modular lengths. The TFT screen is protected by a lexan outer cover.
Images can be downloaded for record purposes or for onward transmission to manufacturers.
SnakeCam can be easily attached to any model of borescope or fibrescope for reaching through small apertures.
SnakeCam is cost effective for technicians, inspectors and investigators to use this tool to save time and money in a wide range of applications. |
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Also available for SnakeCam is the very small digital audio and video recorder. The recorder is about half the size of a deck of cards and can record up to 15 hours of audio and visual data without recharging. |
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"YOUR PROBLEM OUR SOLUTION" |
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Quality and Support |
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Managed under ISO 9001 and with some products built to military requirements, the design and quality enable our power packs to be used fro tough operations. Red Box also provides is depth technical support and operational advice to our customers. We offer world-wide after sales and service locations. |
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Red box authorization : |
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