Foxtronics FOXCART MARK II Operation And Service Manual

FOXCART MARK II

OPERATION AND SERVICE MANUAL

UNIT WEIGHT - ALL MODELS

1200 / 1600 / 2000

APPROX. 600 POUNDS

THE POWER CART WITH MUSCLE

MADE IN THE USA

Revised: August, 2008

FOXTRONICS

LOVE FIELD - DALLAS TEXAS

3448 WEST MOCKINGBIRD LANE

DALLAS, TEXAS

PHONE [phone]
FAX [phone]

TABLE OF CONTENTS

PAGE

1. AN OVERVIEW 1.

2. PURPOSE OF EQUIPMENT 2.

3. MODELS 3.-4.

4. OPTIONS 5.

5. DESCRIPTION 6.

6. PREPARATION FOR USE 7.

7. OPERATION 8.

8. PREVENTIVE MAINTENANCE 9.

9. TROUBLESHOOTING 10.-11.

10. FIGURES / DIAGRAMS 12.
1 1. APPENDIX A

12. APPENDIX B

AN OVERVIEW

This manual provides the operating and maintenance procedures for the Mark II series Foxcart Ground
Power Units. The first part of this manual covers operating procedures that are typical for aircraft
Ground Power Units operating from an alternating current source. Preparation for use and routine
maintenance are also covered. The second part is addressed to trained technical personnel qualified
to perform the detailed process of electrical configuration, problem analysis and repair. Applicable
drawings, charts and schematic wiring diagrams are provided and referenced in the text to identify
components and test points with typical voltage and resistance measurements. Due to the potentially
lethal voltages, it is mandatory that the units described herein be operated and maintained by prop­erly trained and qualified personnel only.

NOTE: The Foxcart is designed to meet Underwriter’s requirements of safety , utility and plac-

ards, even though “UL” specifications are not directed to this type of device.

-1-

PURPOSE OF EQUIPMENT

The Foxcart ground power unit is designed to provide smooth, high current DC power to aircraft
during engine starts or ground maintenance. The Foxcart, when used as an external DC source,
eliminates or minimizes excessive current drain from the aircraft’s battery and battery relay contacts.
It is also designed as a low profile unit that requires minimum ventilation and is easily moved in a
crowded hangar by one person.

-2-

MODELS

All units are provided in functional configuration with standard 15 Ft. DC cables, DC plug and 50 Ft.
AC cable with Hubbell 460P7W AC plug.

MODEL 1200

This is a single-phase power input unit and should only be considered if three-phase
power is not available. It will deliver the rated DC power, but with less efficiency and
regulation than the other models. It can handle starts on helicopters and other light
aircraft and will greatly assist a battery start on heavier aircraft.

OUTPUT VOLTS: 28 VDC
PEAK DC OUT: 1200 AMPS
CONTINUOUS DC OUT: 600 AMPS
INPUT POWER REQUIRED: 208-240 VOLTS SINGLE PHASE

200 AMPS SERVICE

MODEL 1600

This is our mid-line power unit requiring three-phase power input.
OUTPUT VOLTS: 28 VDC

PEAK DC OUT: 1600 AMPS
CONTINUOUS DC OUT: 800 AMPS
INPUT POWER REQUIRED: 208-240 VOLTS PEAK *

THREE PHASE 70 AMPS/PER PHASE
380-480 VOLTS PEAK *
THREE PHASE 50 AMPS/PER PHASE
100 AMPS SERVICE

* OTHER VOLTAGES AVAILABLE UPON REQUEST.

-3-

MODEL 2000

This is our HI-LINE unit that delivers maximum power output.
OUTPUT VOLTS: 28 VDC

PEAK DC OUT: 2000 AMPS
CONTINUOUS DC OUT: 1000 AMPS
INPUT POWER REQUIRED: 208-240 VOLTS PEAK *

THREE PHASE 100 AMPS/PER PHASE
380-480 VOLTS PEAK *
THREE PHASE 70 AMPS/PER PHASE
100 AMPS SERVICE

* OTHER VOLTAGES AVAILABLE UPON REQUEST.

60 cycle AC input current per leg at peak load for 30 seconds maximum.

MODELS

1200 1600 2000

VOL TAGE SINGLE PHASE 3 PHASE 3 PHASE

208 230 115 167
230 218 109 158
240 200 100 145

380 63 91
440 54 79
480 50 72
500 44 63
580 41 60

-4-

OPTIONS

1. EXTRA LENGTH OF AC CABLE

2. EXTRA LENGTH OF DC CABLE Lengths over 25’

not recommended.

3. SOFTSTA RT Limits Starting Current to 1100 AMPS to protect
engine starters and starter drive that require this
feature

4. SHIPPING CRATE

5. WEATHER PROOFING Extra protection from rain and snow

6. REVERSE CURRENT DIODES Prevents aircraft batteries from draining into the
Foxcart if power is shut off and the Foxcart is not
disconnected

7. WALL BOX RECEPTACLE KIT Wall plug to match cable plug

8. EXTRA SIZE WHEELS For rough terrain and snow

9. 14/28 VDC SWITCHING KIT Used for starting 14 or 28-volt aircraft.

10. 115 VAC UTILITY OUTLET Standard on units operating from 200-250 VAC
power source. Units operating from a higher
power source must have a step-down transformer

-5-

DESCRIPTION

The Foxcart is enclosed in an all-steel chassis frame with a three-piece steel box siding. The power
cables can be wrapped around the handles or coiled on top for storage. The wheels can be locked in
place to prevent movement. Both power cables are clamped internally to the frame for strain relief.
Location and identification of the controls are shown in Figure 2. The controls marked “optional” are
not included in the standard Foxcart unless ordered by the customer.

DIMENSIONS INCLUDING HANDLES: See FIGURE 1

STANDARD FOXCART: Length 39.00”

Width 21.50”
Height 16.50”

WITH TERRAIN WHEELS: Length 39.00”

Width 21.50”
Height 21.50”

-6-

PREPARATION FOR USE

The Foxcart is shipped completely assembled except for the handles. Attaching hardware is in­serted into the mounting holes where the handles are to be mounted for your convenience.
Verification of Options and Strapping should be checked before use. Incorrect Primary Supply
Volt age or Strapping could cause damage or improper DC Output.

CAUTION: WHEN THE FOXCART IS PLUGGED INTO THE AC OUTLET, ALL OF THE

STRAPPING TERMINALS ARE “HOT”. CAUTION MUST BE USED TO PRE­VENT SHORTS OR ELECTRICAL SHOCK.

Figure 3 shows how strapping should be for different input source voltages. Select the appropriate
chart that is the same as your hangar power and compare it with the chart. If it is strapped differ­ently correct the strapping.

The “X, Y and Z” posts are for output to the utility plug on the front of the Foxcart. To set correct
strapping, the unit must be plugged into the power source and a voltage measurement taken from
each post to case ground.

CAUTION: BEFORE RE-STRAPPING, DISCONNECT THE AC CABLE FROM THE POWER

SOURCE.

Select the post closest to 115 VAC and strap it to post “W” (See FIGURE 3)
If your Foxcart is 380 V AC or more, the Stepdown Transformer should be installed. If not, your utility
outlet voltage will be high and could cause damage to equipment.

CAUTION: TERMINALS “X AND Y” WILL BE HIGH VOLTAGE.

CAUTION: IF TERMINALS “X AND Y” DO NOT READ NEAR 115 VAC, DO NOT USE THE

UTILITY PLUG. CONTACT AUTHORIZED FACTORY REPRESENTATIVE FOR
CORRECTION.

-7-

OPERATION

1. Move the Foxcart into position and set the wheel brakes.

2. Ensure that 14/28-volt selector switch is in the same voltage range as the Aircraft. (If cart is so

equipped with this optional feature).

3. Plug the Foxcart Input Power Cable into the AC Outlet.

4. Switch the Foxcart ON/OFF breaker to “ON” and rotate the Step Switch to adjust the Voltme-

ter to the desired voltage.

5. Switch the Foxcart ON/OFF breaker to “OFF” and plug the DC cable into the Aircraft DC

receptacle.

6. Switch the Foxcart ON/OFF breaker to “ON” and re-adjust the Step Switch to the desired

voltage. Ideally, there will be no current draw until the aircraft system is activated. Some
aircraft such as early Lear Jets have a direct connection between the external connection and
the battery. An internal current draw of 100 Amperes may be observed on the ammeter of the
FOXCART. This current will decrease as the batteries are charged. On this type of Aircraft,
the batteries should be allowed to charge before energizing the Aircraft electrical system.

7. Perform normal start or maintenance.

8. After starting or completion of maintenance, switch the Foxcart ON/OFF breaker to “OFF”

and disconnect the Power Cable from the Aircraft. Move the FOXCART to a safe distance
and set the brake locks to prevent movement due to Jet or Prop blast.

SOFTSTART OPERATION

Softstart provided current limiting during engine starts to prevent over-torquing starter motors and
starter drive mechanism during starts. Use this option only if your aircraft requires it.
During a Softstart, the Foxcart produces about 20% or more of the current needed for a start and the
Aircraft batteries supply the remaining current. If the Aircraft design maintains the ship’s batteries on
line, the FOXCART will supply all the power. After start, if the FOXCART is left on line long enough,
it will recharge the Aircraft batteries.

-8-

PREVENTIVE MAINTENANCE

Routine maintenance should be performed periodically. Since the wheels and fan motor are the
only moving parts on the Foxcart, maintenance is kept to a minimum.

1. Oil fan motor and all other moveable parts.

2. Using compressed air and a dry cloth, clean accumulated dust and grime from unit.

3. Perform visual inspection and tighten any loose nuts and bolts.

4. Inspect cables and plugs for cuts, cracks or deterioration.

-9-

TROUBLESHOOTING

If the Foxcart does not deliver the proper DC output, check the strapping using the procedure
outlined on Page 7.

If the Foxcart has been operational for a period of time and has failed, use the following steps to
assist in isolating the problem. If the problem cannot be isolated, please call Foxtronics for
assistance. The phone number is [phone]. Replacement parts may be ordered from the
same number.

1. Test the wall receptacle for proper voltage.

2. Using DMM, measure the voltage at the end of the DC Cable. Does the measure­ment agree with for Foxcart voltmeter?

3. Remove the Strapboard Access Cover. (See Figure 2, Item 4.)

CAUTION, SHOCK HAZARD: WHEN THE INPUT CABLE IS PLUGGED INTO THE WALL
RECEPTACLE, HIGH VOLTAGES ARE PRESENT AT THE STRAPPING TERMINALS.
THESE VOLTAGES MAY BE LETHAL.

A. Plug the AC cable into wall recept acle.
B. Turn on Foxcart power.
C. Test the voltage between Terminal “A to C and “A to E” and “C to E”. All

should be the same voltage. The voltage should also be the same as your
wall voltage.

D. If step C is incorrect, the problem is between the wall and the input

strapboard.
E. Turn OFF the Foxcart power.
F. Remove the AC cable from the wall receptacle.
G. Using DMM, measure the resistance between the AC plug and the input

strapboard. All readings should be INFINITE.
H. With the AC plug still removed from the wall receptacle, turn on main

Foxcart circuit breaker. Measure resist ance between AC plug and input

strap board. Resistance should be close to zero. The ground pin should

read continuity to the Foxcart chassis.

4. If problem is still not found:

ENSURE FOXCART IS DISCONNECTED FROM THE WALL RECEPTACLE.

A. Remove top cover.

-10-

B. Inspect the interior of the Foxcart for any signs of arcing or burning, such

as wires or connections.
C. Remove rectifier bus bars and any attaching wiring.
D. Using a DMM Diode Tester , test all the diodes. All readings should be

similar in the forward direction and infinite in the reverse direction.
E. Remove buss bars and attaching wires from reverse current diodes. Test

as in step D. Note, the reverse current diodes are the opposite polarity .
F. Inspect the blue filter capacitors and wiring for leakage or burnt wires.
G. Reassemble the Foxcart.

-1 1-

FIGURES / DIAGRAMS

FIGURE 1 FOXCART DIMENTIONS
FIGURE 2 FRONT PANEL COMPONENTS
FIGURE 3 STRAPPING CHART
FIGURE 4 MAJOR COMPONENTS
FIGURE 5 MODEL 1200B w/REVERSE CURRENT
FIGURE 6 MODEL 1600B/2000B w/REVERSE CURRENT &

SOTFSTART
FIGURE 7 MODEL 1600B/2000B w/14/28VDC OPTION
FIGURE 8 MODEL 1600B/2000B w/STEPDOWN

TRANSFORMER
FIGURE 9 AC CONNECTOR WIRE HOOK-UP
FIGURE 10 460P7W HUBBELL PLUG DIMENTIONS

-12-

DIMENSIONS

HANDLE HEIGHT
ABOVE GROUND

BOX HEIGHT

FOXCART MARK II

50.5

DIMENSIONS ACROSS HANDLES

31.0

BOX DIMENSION

25.5

31.5

20.0

BOX DIMENSION

30.0

OUTSIDE WHEELS DIMENSION

UNIT WEIGHT − ALL MODELS

1200/1600/2000

APPROX. 600 POUNDS

21.0

BOX DIMENSION

GROUND LEVEL

FIGURE 1.

17

NORMAL

OUTPUT
LOAD

SOFT
START

13

16

18

DC

14

VOLTAGE

11

DC

VOLTS

6

7

10

2

4

FIGURE 2.

ADJUST

15

12

9

DC

AMPHRES

HILO

AMPMETER RANGE

8

3

5

1

POWER SWITCH & BREAKER

18

14/28 VOLT OPTION

17

NAME PLATE

16
15

VOLT STEP SWITCH

14

OPTION, SOFT START SWITCH

13

115 VOLT UTILITY RECEPTACLE

UTILITY 115 VOLT BREAKER

12

14 VOLT "ON" LIGHT, WHITE

11
10

VOLT METER

9

AMPMETER

8

AMPMETER RANGE SWITCH

7

REVERSE DIODES OPTION, RED

GREEN POWER "ON" INDICATOR

6

UTILITY 115 VOLT STRAPPING

5

COVER PLATE

4

15 AMP FUSE

3
2

INPUT POWER STRAPPING

1

INPUT POWER STRAPPING PANEL

ITEM

DESCRIPTION

foxtronics

incorporated

TITLE: FOXCART FRONT PANEL COMPONENTS

DRAWING NO: 400­0001-007
PAGE: 1 OF 1

DRAWN BY: SE

REV: B

APPROVED BY:

3448 W. Mockingbird Ln.
Dallas, TX 75235
PHONE: [phone]
FAX: [phone]

DATE:
10/01/01

208

FOXCART MODEL 1200

1

2

3

1

C

2

3

1

2

3

1

A

2

3

1

C

2

3

1

2

3

230

240

A

B

4

D

4

E

F

4

208V

B

4

D

4

E

F

4

440V

FOXCART MODEL 1600-C ONLY

1

A

2

3

1

2

3

1

1

2

3

1

2

3

1

2

3

1

2

3

2

3

1

A

C

E

225V

B

4

D

4

F

4

A

4

C

4

E

2

3

4

2

3

1

2

3

1

2

3

1

2

B

3

D

F

B

4

C

D

4

E

F

4

208V

A

B

4

C

D D

4

E

F

4

380V

208 TO 250 VAC LINE
15 AMP FUSES

1

2

3

1

2

3

1

2

3

B

A

4

C

D

4

E

F

4

230V

1

A

2

3

1

2

3

1

2

3

B

4

C

4

E

F

4

440V

1

A

2

3

1

2

3

1

4

C

4

E

2

3

4

240V

1

A

2

3

1

2

3

1

4

C

4

E

2

3

4

480V

FOXCART MODEL 1600/2000

UTILITY PLUG SET-UP
PLUG THE INPUT CABLE OF THE FOXCART INTO HANGAR POWER. USING A VOLTMETER, CHECK THE VOLTAGE AT
TERMINALS "X" AND "Y" TO CHASSIS GROUND. SELECT THE MEASUREMENT THAT IS NEAREST TO 120 VAC.
DISCONNECT HANGAR POWER, CONNECT STRAP BETWEEN SELECTED TERMINAL AND POST "W" TIGHTEN NUTS,
RECONNECT POWER AND VERIFY THAT 120 VAC IS AT THE UTILITY PLUG.

NOTE: IF INPUT AC POWER IS 380 VAC OR ABOVE AND STEPDOWN TRANSFORMER IS INSTALLED. TERMINALS W, W,
Y AND Z ARE DISCONNECTED.

B

D

F

B

D

F

480V

3448 W. Mockingbird Ln.

REV: B

APPROVED BY:

Dallas, TX 75235
PHONE: [phone]
FAX: [phone]

DATE: 10/01/01

foxtronics

incorporated

TITLE: FOXCART AC INPUT VOLTAGE STRAPPING

DRAWING NO: 400-0001-003

PAGE: 1 OF 1

DRAWN BY: SE

FIGURE 3.

X

Y

W

Z

LIGHT (WHITE) 14VDC ON

STEP-DOWN TRANSFORMER

272625

INPUT STRAP BOARD

MOUNT FAN

AMPMETER RANGE SWITCH

242322

DATE: 10/01/01

3448 W. Mockingbird Ln.

Dallas, TX 75235

PHONE: [phone]

FAX: [phone]

REV: B

PAGE: 1 OF 1

DIODE

LEFT DIODE PLATE ASSEMBLY

CHOKE

REVERSE DIODES

FAN ASSEMBLY

(CONDENSER) 2 MF CAPACITOR

21

18

1716151413

19

20

RIGHT DIODE PLATE ASSEMBLY

CAPACITOR (40,000 MF)

STABILIZING RESISTOR

SOFT START

SERVICE PLUG CIRCUIT BREAKER

TRANSFORMER

AMMETER SHUNT

10

11

12

SOFT START SWITCH

AMPMETER

AC RECEPTICLE

87654

9

14/28 VDC SWITCH

STEP SWITCH

LIGHT (RED) REVERSE CURRENT

LIGHT (GREEN) POWER ON

ON/OFF BREAKER

VOLT METER

321

incorporated

foxtronics

ITEM DESCRIPTION

DRAWN BY: SE

APPROVED BY:

DRAWING NO: 400-0001-005

TITLE: FOXCART COMPONENT PARTS

10

9

24

5

25

8

7

12

13

27

15

14

4

2

26

1

6

3

16

18

11

FIGURE 4.

22

20

21

17

19

23

3448 W. Mockingbird Ln.

Dallas, TX 75235

PHONE: [phone]

FAX: [phone]

DATE: OCTOBER 8, 2001

METER RANGE SWITCH

NORMAL

-

AMPS

LOW

+

+

-

+

VOLTS

SHUNT

CHOKE

RED

GRN

-

+

-

+

-

+

-

+

-

+

.9

-

CORRECT FAN MOTOR WIRING TO BE

COMPATIABLE WITH EITHER 240/480VAC

INPUT

1

1

foxtronics

THIS DRAWING IS APPLICABLE TO ALL 1200 FOXCARTS

WITH -A S/N's AND 1200B SERIES.

1 K.V.A. MAX

115V SERVICE

REV: B

APPROVED BY:

incorporated

PAGE: 1 OF 1

DRAWN BY: SE

DRAWING NO: 400 0005 002

TITLE: 1200 FOXCART w/REVERSE CURRENT DIODE

E
S

VER
E

T

AL R

EN

N

R
R
U

PTIO

C

O

FAN

230V

240

230

208

100A

BLACK

GREEN

WHITE

7

6

5

4

3

2

1

7

6

5

4

3

2

1

10A

W

X

Z

Y

15A

15A

FIGURE 5.

3448 W. Mockingbird Ln.

Dallas, TX 75235

PHONE: [phone]

FAX: [phone]

DATE: 10/09/01

+

METER RANGE SWITCH

NORMAL

-

-

AMPS

LOW

+

RT
L

A

N

SHUNT

FTSTA

SO

O

OPTI

+

VOLTS

RED

GRN

-

TRANSFORMER ONLY

14V TAPS ON M2000

CORRECT FAN MOTOR WIRING TO BE

COMPATIABLE WITH EITHER 240/480VAC

INPUT

2

1

W/REVERSE CURRENT DIODE

& SOFTSTART

REV: B

APPROVED BY:

400-0005-018/028

1600/2000 FOXCART

incorporated

foxtronics

PAGE: 1 OF 1

DRAWN BY: SE

TITLE:

DRAWING

NO:

SOFTSTART NORMAL

+

40,000 mf

+

FOXCARTS WITH -A S/N's AND 1600B/2000B SERIES.

CHOKE

NT

E

NK

SI

)X

UR(xx

2

0

3

2

2

T1

480

208

240

230

4

5

4

2 3

1

3

6

7

-

B

LEFT

2

2

T2

208

240

230

480

5

4

2

1 2 3 4

1

3

2

6

7

-

1 2 3 4

1

D

DIODES

L REVERSE CURR

A

N

O

OPTI

GHT SINK

RI

115V SERVICE

1 K.V.A. MAX

NOTE:

FOR USE WITH 380VAC INPUT OR ABOVE STEP-DOWN TRANSFORMER IS REQUIRED

2

2

T3

208

240

230

480

5

4

3

6

2

7

1

-

F

10A

W

Z

X

Y

15A

15A

THIS DRAWING IS APPLICABLE TO ALL 1600/2000

FIGURE 6.

4 COND

#6 CABLE

BLACK

RED

WHITE

GREEN

4

A

3

1

2

4

C

1

3

2

4

E

1

3

2

50 OR 60 Hz

FAN

230V

70A FOR 1600

100A FOR 2000

1

3448 W. Mockingbird Ln.

Dallas, TX 75235

PHONE: [phone]

FAX: [phone]

+

METER RANGE SWITCH

NORMAL

-

AMPS

LOW

+

ART

T

SHUNT

S

T

F

O

S

IONAL

OPT

-

+

VOLTS

RED

GRN

-

14V TAPS ON M2000

TRANSFORMER ONLY

INPUT

CORRECT FAN MOTOR WIRING TO BE

COMPATIABLE WITH EITHER 240/480VAC

2

1

14V

28V

WHT

DATE: 10/08/01

W/REVERSE CURRENT DIODE

SOFTSTART & 14/28 SWITCH

REV: B

APPROVED BY:

400-0005-019/029

incorporated

1600/2000 FOXCART

foxtronics

PAGE: 1 OF 1

DRAWN BY: SE

TITLE:

DRAWING NO:

+

SOFTSTART NORMAL

40,000 mf

+

CHOKE

FOXCARTS WITH -A S/N's AND 1600B/2000B SERIES.

THIS DRAWING IS APPLICABLE TO ALL 1600/2000

14V

INK

S

HT

G

RI

OPTIONAL REVERSE CURRENT

DIODES

V

28

K

N

I

FT S

E

)X

2UR(xx

30

2

2

T1

480

208

240

230

4

5

2 3

1

4

6

7

-

B

4

A

3

2

L

115V SERVICE

1 K.V.A. MAX

NOTE:

FOR USE WITH 380VAC INPUT

OR ABOVE STEP-DOWN TRANSFORMER

IS REQUIRED

2

2

T2

208

240

230

480

5

3

2 3 4

2

1

1

4

3

2

6

7

1

-

D

4

C

1

3

1

2

2

2

T3

208

240

230

480

5

4

2 3 4

1

3

6

2

7

1

-

F

4

E

3

1

2

50 OR 60 Hz

10A

W

Z

X

Y

15A

15A

FIGURE 7.

4 COND

#6 CABLE

RED

BLACK

WHITE

GREEN

230V

FAN

70A FOR 1600

100A FOR 2000

1

3448 W. Mockingbird Ln.

Dallas, TX 75235

PHONE: [phone]

FAX: [phone]

DATE: 10/08/01

+

METER RANGE SWITCH

NORMAL

-

AMPS

LOW

+

RT
L

A

N

SHUNT

FTSTA

SO

O

OPTI

-

+

VOLTS

RED

GRN

-

TRANSFORMER ONLY

14V TAPS ON M2000

CORRECT FAN MOTOR WIRING TO BE

COMPATIABLE WITH EITHER 240/480VAC

INPUT

2

1

W/ REV. CURR., SOFTSTART,

STEPDOWN TRANSFORMER

REV: B

APPROVED BY:

incorporated

foxtronics

PAGE: 1 OF 1

DRAWING NO: 400-0005-017/027

DRAWN BY: SE

TITLE: 1600/1200 FOXCART

SOFTSTART NORMAL

CHOKE

+

40,000 mf

+

OPTIONAL

TRANSFORMER

FOXCARTS WITH -A S/N's AND 1600B/2000B SERIES.

THIS DRAWING IS APPLICABLE TO ALL 1600/2000

*

115V SERVICE

NT

E

NK

SI

)X

UR(xx

2

0

3

LEFT

DIODES

L REVERSE CURR

A

N

O

OPTI

GHT SINK

RI

1 K.V.A. MAX

TRANSFORMER IS REQUIRED

NOTE:

FOR USE WITH 380VAC INPUT OR ABOVE STEP-DOWN

FIGURE 8.

10A

X1

2

2

2

2

2

2

X2

*

4 COND

#6 CABLE

H4

T1

480

208

240

230

4

5

4

2 3

1

3

2

6

7

1

-

B

T2

208

240

230

480

5

4

3

2

1 2 3 4

6

7

1

-

D

T3

208

240

230

480

5

4

3

6

1 2 3 4

7

2

1

-

F

H2

15A

H

H3

BLACK

RED

WHITE

GREEN

15A

4

A

1

3

2

4

C

1

3

2

4

E

3

1

2

50 OR 60 Hz

230V

FAN

70A FOR 1600

100A FOR 2000

1

3448 W. Mockingbird Ln.

Dallas, TX 75235

PHONE: [phone]

FAX: [phone]

DATE: 07/30/08

REV: C

APPROVED BY:

incorporated

L3

Z

4/3 CABLE

SINGLE PHASE

(REAR VIEW OF CONNECTOR)

HUBBELL 460P7W WIRE CONNECTIONS

L2

Y

L1

G

X

foxtronics

PAGE: 1 OF 1

DRAWN BY: SE

TITLE: FOXCART AC CONNECTOR WIRING

DRAWING NO: 400-0005-033

FIGURE 9.

WHITE

L3

BLACK

L2

WHITE

Z

Y

L1

RED

G

X

GREEN

GREEN

BLACK

G

L2

Y

SINGLE PHASE

(REAR VIEW OF CONNECTOR)

HUBBELL 3100P6W WIRE CONNECTIONS

L1

X

3 PHASE

6/4 CABLE

4/3 CABLE (ONLY)

WHITE

GREEN

BLACK

3 3/32"

88 MM DIA.

1 11/16"

42.8 MM

3448 W. Mockingbird Ln.

Dallas, TX 75235

PHONE: [phone]

FAX: [phone]

DATE: 10/01/01

REV: 10/01/01

APPROVED BY:

BOX

WALL

END

VIEW

P/N 401-0037-000

incorporated

foxtronics

PAGE: 1 OF 1

DRAWN BY: SE

DRAWING NO: 400-0005-034

TITLE: HUBBELL 460P7W & 460R7W AC PLUGS

P/N 401-0038-000

4 5/64"

HUBBELL 460R7W WALL RECEPTICLE

5 7/64"

129.7 MM

103.5 MM

FIGURE 10.

P/N 401-0006-007

10 9/64"

HUBBELL 460P7W WALL PLUG

257.5 MM

4 1/2"

114.4 MM SQ.

3 7/8"

98.4 MM SQ.

(4 HOLES)

7/32" 5.5 MM DIA.

VIEW

FRONT

4 1/2"

114 MM

ASSEMBLY: MODEL 1200 / 60 Hz

APPENDIX A-1

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY

401-0001-012 412-7-T2 TAP SWITCH 1.0 NO
401-0002-016 3M578 FAN MOT OR 1.0 NO
401-0003-016 2C842-8 / 12” BLADE 1.0 NO
401-0004-016 TRIPLET / DC VOLT METER 0-40VDC 1.0 NO
401-0005-016 DC AMP METER: DUAL 0-800; 0-1600 1.0 NO
401-0006-001 RED-DOTCVR CCD DCI-78440135000 1.0 NO
401-0006-006 CR15-1 IVORY DUPLEX; HUBBELL 1.0 NO
401-0006-012 AC PLUG, 3100P6W 1.0 N O
401-0007-000 AN3161-10/10A-CB 1.0 NO
401-0008-001 219-3-1-62F-89-100 480V/BKR 1.0 NO
401-0009-016 502-3241-102 L T/ASY 1.0 NO
401-0009-017 LAMP. TYPE 313 1.0 NO
401-0010-016 LENSE GREEN 320112300 1.0 NO
401-0012-016 600A/50mv SHUNT; HA600-50 1.0 NO
401-0015-001 75 OHM, 5W, RESIST. PW5-75 1.0 NO
401-0019-016 CGS4030040X4C/40,000MF 40V 5.0 NO
401-0019-017 CLAMP VR12B (3”) 5.0 N O
401-0020-012 CHOKE; MOD – 1200 1.0 NO
401-0021-012 TRANSFORMER/1200 1.0 NO
401-0023-001 FR/PL, PLATE 8”X 8” 1.0 NO
401-0023-005 FRONT PNL (NEW-DWG) 1.0 NO
401-0023-013 CHASSIS FRAME 1.0 NO
401-0023-016 COVER 1.0 NO
401-0023-017 BRACKET, FAN MT 1.0 NO
401-0023-018 PLA TE RE-ENFORCE 2.0 NO
401-0023-019 HANDLE, FOXC 2.0 NO
401-0023-021 REAR PANEL 1.0 NO
401-0025-016 CASTER TP505001SR-B SR = SWBRAKE 2.0 NO
401-0026-001 PILLOW BLK 2X530 x ¾” 2.0 NO
401-0026-002 AXLE ¾ x 29 3/8” 1.0 NO
401-0026-003 SHAFT COLLAR 2 x 570 x ¾” 2.0 NO
401-0027-016 TIRE, 4.10/850-4PN, ¾” BEARING 2.0 NO
401-0041-001 DIAL KNOB # 5152A 1.0 NO
401-0041-002 VOLT-ADJ DECAL 1.0 NO
401-0041-003 5003/1-7/DIAL/IND/PLATE 1.0 NO
401-0052-000 CABLE ASSEMBLY/DC, 15FT/W/PLUG 1.0 NO
401-0068-001 DECAL, FOXCART S/N MODEL, 1200 1.0 NO
401-0068-003 DECAL, FOXCART LOGO 2.0 NO
401-0068-003 DECAL, 115V 1.0 NO
401-0068-006 DECAL, CAUTION 1.0 NO
401-0068-007 DECAL, HI / LO (AMP) 1.0 NO
401-0071-002 SWITCH, TOGGLE #93-4001SPSTON/MO 1.0 NO
402-0045-001 4/3 SEOW AC CABLE 50.0 NO
404-1600-010 LOAD RESISTOR 2.0 YES
404-1600-012 STRAPBOARD MODEL 1200 1.0 YES
404-1600-014 LEFT DIODE PLATE 1200 1.0 YES
404-1600-016 RIGHT DIODE PLATE 1200 1.0 YES

ASSEMBLY: MODEL 1600 / 60 Hz

APPENDIX A-2

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY

401-0001-016 412-7-T2 TAP SWITCH 1.0 NO
401-0002-016 3M578 FAN MOT OR 1.0 NO
401-0003-016 2C842-8 / 12” BLADE 1.0 NO
401-0004-016 TRIPLET / DC VOLT METER 0-40VDC 1.0 NO
401-0005-016 DC AMP METER: DUAL 0-800; 0-1600 1.0 NO
401-0006-001 RED-DOTCVR CCD DCI-78440135000 1.0 NO
401-0006-006 CR15-1 IVORY DUPLEX; HUBBELL 1.0 NO
401-0006-007 AC PLUG, 460P7W 1.0 NO
401-0007-000 AN3161-10/10A-CB 1.0 NO
401-0008-016 70ABK/480V 219-3-1-65F-8-9-70 1.0 NO
401-0009-016 502-3241-102 L T/ASY 1.0 NO
401-0009-017 LAMP. TYPE 313 1.0 NO
401-0010-016 LENSE GREEN 320112300 1.0 NO
401-0012-016 600A/50mv SHUNT; HA600-50 1.0 NO
401-0015-001 75 OHM, 5W, RESIST. PW5-75 1.0 NO
401-0019-016 CGS4030040X4C/40,000MF 40V 2.0 NO
401-0019-017 CLAMP VR12B (3”) 2.0 N O
401-0020-016 CHOKE; MOD – 1600 1.0 NO
401-0021-016 TRANSFORMER/1600 – 50/60Hz 1.0 NO
401-0023-001 FR/PL, PLATE 8”X 8” 1.0 NO
401-0023-005 FRONT PNL (NEW-DWG) 1.0 NO
401-0023-013 CHASSIS FRAME 1.0 NO
401-0023-016 COVER 1.0 NO
401-0023-017 BRACKET, FAN MT 1.0 NO
401-0023-018 PLA TE RE-ENFORCE 2.0 NO
401-0023-019 HANDLE, FOXC 2.0 NO
401-0023-021 REAR PANEL 1.0 NO
401-0025-016 CASTER TP505001SR-B SR = SWBRAKE 2.0 NO
401-0026-001 PILLOW BLK 2X530 x ¾” 2.0 NO
401-0026-002 AXLE ¾ x 29 3/8” 1.0 NO
401-0026-003 SHAFT COLLAR 2 x 570 x ¾” 2.0 NO
401-0027-016 TIRE, 4.10/850-4PN, ¾” BEARING 2.0 NO
401-0041-001 DIAL KNOB # 5152A 1.0 NO
401-0041-002 VOLT-ADJ DECAL 1.0 NO
401-0041-003 5003/1-7/DIAL/IND/PLATE 1.0 NO
401-0052-000 CABLE ASSEMBLY/DC, 15FT/W/PLUG 1.0 NO
401-0068-000 DECAL, FOXCART S/N MODEL, 1600 1.0 NO
401-0068-003 DECAL, FOXCART LOGO 2.0 NO
401-0068-005 DECAL, 115V 1.0 NO
401-0068-006 DECAL, CAUTION 1.0 NO
401-0068-007 DECAL, HI / LO (AMP) 1.0 NO
401-0071-002 SWITCH, TOGGLE #93-4001SPSTON/MO 1.0 NO
402-0045-002 6/4 SEOW AC CABLE 50.0 NO
404-1600-003 STRAPBOARD MODEL 1600 1.0 YES
404-1600-006 LEFT DIODE PLATE 1600 1.0 YES
404-1600-007 RIGHT DIODE PLATE 1600 1.0 YES
404-1600-010 LOAD RESISTOR 1.0 YES

ASSEMBLY: MODEL 2000 / 60 Hz APPENDIX A-3

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBL Y

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY

401-0001-016 412-7-T2 TAP SWITCH 1.0 NO
401-0003-016 2C842-8 / 12” BLADE 1.0 NO
401-0002-016 3M458 FAN MOT OR 50Hz 1.0 NO
401-0004-016 TRIPLET / DC VOL T METER 0-40VDC 1.0 NO
401-0005-020 DC AMP METER: DUAL 0-1000; 0-2000 1.0 NO
401-0006-001 RED-DOTCVR CCD DCI-78440135000 1.0 NO
401-0006-006 CR15-1 IVORY DUPLEX; HUBBELL 1.0 NO
401-0006-007 AC PLUG, 460P7W 1.0 NO
401-0007-000 AN3161-10/10A-CB 1.0 NO
401-0008-001 219-3-1-62F-89-100 480V/BKR 1.0 NO
401-0009-016 502-3241-102 L T/ASY 1.0 NO
401-0009-017 LAMP. TYPE 313 1.0 NO
401-0010-016 LENSE GREEN 320112300 1.0 NO
401-0013-016 700A/50mv SHUNT; HA750-50 1.0 NO
401-0015-001 75 OHM, 5W, RESIST. PW5-75 1.0 NO
401-0019-016 CGS4030040X4C/40,000MF 40V 2.0 NO
401-0019-017 CLAMP VR12B (3”) 2.0 N O
401-0020-020 CHOKE; MOD – 2000 1.0 NO
401-0021-020 TRANSFORMER/2000 1.0 NO
401-0023-001 FR/PL, PLATE 8”X 8” 1.0 NO
401-0023-005 FRONT PNL (NEW-DWG) 1.0 NO
401-0023-013 CHASSIS FRAME 1.0 NO
401-0023-016 COVER 1.0 NO
401-0023-017 BRACKET, FAN MT 1.0 NO
401-0023-018 PLA TE RE-ENFORCE 2.0 NO
401-0023-019 HANDLE, FOXC 2.0 NO
401-0023-021 REAR PANEL 1.0 NO
401-0025-016 CASTER TP505001SR-B SR = SWBRAKE 2.0 NO
401-0026-001 PILLOW BLK 2X530 x ¾” 2.0 NO
401-0026-002 AXLE ¾ x 29 3/8” 1.0 NO
401-0026-003 SHAFT COLLAR 2 x 570 x ¾” 2.0 NO
401-0027-016 TIRE, 4.10/850-4PN, ¾” BEARING 2.0 NO
401-0041-001 DIAL KNOB # 5152A 1.0 NO
401-0041-002 VOLT-ADJ DECAL 1.0 NO
401-0041-003 5003/1-7/DIAL/IND/PLATE 1.0 NO
401-0052-000 CABLE ASSEMBLY/DC, 15FT/W/PLUG 1.0 NO
401-0068-002 DECAL, FOXCART S/N MODEL, 2000 1.0 NO
401-0068-003 DECAL, FOXCART LOGO 2.0 NO
401-0068-005 DECAL, 115V 1.0 NO
401-0068-006 DECAL, CAUTION 1.0 NO
401-0068-007 DECAL, HI / LO (AMP) 1.0 NO
401-0071-002 SWITCH, TOGGLE #93-4001SPSTON/MO 1.0 NO
402-0045-002 6/4 SEOW AC CABLE 50.0 NO
404-1600-003 STRAPBOARD MODEL 1600 1.0 YES
404-1600-010 LOAD RESISTOR 1.0 YES
404-1600-018 LEFT DIODE PLATE 2000 1.0 YES
404-1600-020 RIGHT DIODE PLA TE 2000 1.0 YES

ASSEMBLY: 50 Hz OPTION (Prior to 3-1-07) APPENDIX A-4

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBL Y

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY

401-0003-018 3M459 FAN MOT OR 50Hz 1.0 NO
401-0003-019 3M492 MOUNT 1.0 NO
401-0003-020 SPLIT RING ADAPTOR 1.0 NO

ASSEMBLY: 50 Hz OPTION (After 3-1-07)

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBL Y

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBL Y

401-0002-017 DC FAN 1.0 NO
401-0023-060 FAN BRACKET MOUNT 2.0 NO
401-0090-000 STAND OFF 3.0 NO

ASSEMBLY: SOFTSTART OPTION

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBL Y

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY

401-0045-003 CABLE, (DC) WELDING TYPE 2/0 5.0 NO
401-0068-008 DECAL, SOFT START 1.0 NO
401-0071-004 TOG/SWITCH C/H #8792K3 SOFT-START 1.0 NO
401-1023-000 YELLOW 2/0 322090 (2J1871) 2.0 N O
402-1022-000 YELLOW 2/0 322089 (ZZ251869) 6.0 NO
404-0004-000 SOFT START GRID 1.0 NO

ASSEMBLY: REVERSE CURRENT OPTION

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY

COMPONENTS DESCRIPTION UNITS REQ. ASSEMBLY

401-0009-016 502-3241-102 L T/ASY 2.0 NO
401-0009-017 LAMP TYPE 313 2.0 NO
401-0010-017 LENSE, RED #25F-1576 1.0 NO
401-0015-001 75 OHM, 5W, RESISTOR PW5-75 2.0 NO
401-0016-001 302U10A POS DIODE; REV/CUR 3.0 NO
402-0046-005 18 GA WIRE 5.0 NO
402-1014-000 BLUE #10 36160 2.0 NO
402-1020-002 RED 3/8 31897 1.0 NO

B1 Chart for 1200

B2 Chart for 1600

B3 Chart for 2000

APPENDIX B

20001900

18001700160015001400

1300

145

110

120011001000900800700600500400

90 100

DC AMPERES OUT

70

46

300

TYPICAL MODEL 1200 OUTPUT CURVE USING 240V 60 Hz

35

30

200100

20

25

15

OUTPUT

S

10

5

DC VOLT

0

AC LINE INPUT AMPERES PER LEG at 245 VOLTS USING 50ft 4 COND.+0 CABLE

15

0

20001900

18001700160015001400

1300

145

110

120011001000900800700600500400

90 100

DC AMPERES OUT

70

46

300

TYPICAL MODEL 1600 OUTPUT CURVE USING 440V 60 Hz

for 50 Hz de-rate 15%

35

30

200100

20

25

15

OUTPUT

S

10

5

DC VOLT

0

AC LINE INPUT AMPERES PER LEG at 245 VOLTS USING 50ft 4 COND.+0 CABLE

15

0

20001900

18001700160015001400

1300

145

110

120011001000900800700600500400

90 100

DC AMPERES OUT

70

46

300

TYPICAL MODEL 2000 OUTPUT CURVE USING 440V 60 Hz

for 50 Hz de-rate 15%

35

30

2001000

20

25

15

10

0

5

AC LINE INPUT AMPERES PER LEG at 245 VOLTS USING 50ft 4 COND.+0 CABLE

15

0

DC VOLTS OUTPUT