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FOXCART MARK II

OPERATION AND SERVICE MANUAL

UNIT WEIGHT - ALL MODELS


1200 / 1600 / 2000
APPROX. 600 POUNDS

THE POWER CART WITH MUSCLE

FOXTRONICS
LOVE FIELD - DALLAS TEXAS

MADE IN THE USA

3448 WEST MOCKINGBIRD LANE


DALLAS, TEXAS

Revised: August, 2008

PHONE (214) 358-4425


FAX (214) 358-1519

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.

11. 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 Underwriters requirements of safety, utility and placards, 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 aircrafts 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:
PEAK DC OUT:
CONTINUOUS DC OUT:
INPUT POWER REQUIRED:

28 VDC
1200 AMPS
600 AMPS
208-240 VOLTS SINGLE PHASE
200 AMPS SERVICE

MODEL 1600
This is our mid-line power unit requiring three-phase power input.
OUTPUT VOLTS:
PEAK DC OUT:
CONTINUOUS DC OUT:
INPUT POWER REQUIRED:

28 VDC
1600 AMPS
800 AMPS
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:
PEAK DC OUT:
CONTINUOUS DC OUT:
INPUT POWER REQUIRED:

28 VDC
2000 AMPS
1000 AMPS
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

VOLTAGE
208
230
240

1200

1600

2000

SINGLE PHASE
230
218
200

3 PHASE
115
109
100

3 PHASE
167
158
145

63
54
50
44
41

91
79
72
63
60

380
440
480
500
580

-4-

OPTIONS
1.

EXTRA LENGTH OF AC CABLE

2.

EXTRA LENGTH OF DC CABLE

Lengths over 25 not recommended.

3.

SOFTSTART

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:

WITH TERRAIN WHEELS:

Length

39.00

Width
Height

21.50
16.50

Length

39.00

Width
Height

21.50
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
Voltage 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 VAC 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.
4.

Plug the Foxcart Input Power Cable into the AC Outlet.


Switch the Foxcart ON/OFF breaker to ON and rotate the Step Switch to adjust the Voltme-

5.

ter to the desired voltage.


Switch the Foxcart ON/OFF breaker to OFF and plug the DC cable into the Aircraft DC

6.

receptacle.
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,

7.
8.

the batteries should be allowed to charge before energizing the Aircraft electrical system.
Perform normal start or maintenance.
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 ships 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.
2.

Oil fan motor and all other moveable parts.


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

3.
4.

Perform visual inspection and tighten any loose nuts and bolts.
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 (214) 358-4425. Replacement parts may be ordered from the
same number.
1.
2.

Test the wall receptacle for proper voltage.


Using DMM, measure the voltage at the end of the DC Cable. Does the measure-

3.

ment agree with for Foxcart voltmeter?


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.
B.

Plug the AC cable into wall receptacle.


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

D.

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

E.

strapboard.
Turn OFF the Foxcart power.

F.
G.

Remove the AC cable from the wall receptacle.


Using DMM, measure the resistance between the AC plug and the input

H.

strapboard. All readings should be INFINITE.


With the AC plug still removed from the wall receptacle, turn on main
Foxcart circuit breaker. Measure resistance 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

C.

as wires or connections.
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.
G.

Inspect the blue filter capacitors and wiring for leakage or burnt wires.
Reassemble the Foxcart.

-11-

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-

FOXCART MARK II

DIMENSIONS
50.5
DIMENSIONS ACROSS HANDLES

HANDLE HEIGHT
ABOVE GROUND

31.0
BOX DIMENSION
31.5

20.0
BOX DIMENSION

25.5

BOX HEIGHT

21.0
BOX DIMENSION

30.0
OUTSIDE WHEELS DIMENSION

GROUND LEVEL

UNIT WEIGHT ALL MODELS


1200/1600/2000
APPROX. 600 POUNDS

FIGURE 1.

17
OUTPUT
LOAD
NORMAL

SOFT
START

16
18

DC
VOLTAGE
ADJUST

13

14

15

12

11

9
6

DC
VOLTS

DC
AMPHRES

LO

10

HI

AMPMETER RANGE

18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
ITEM

POWER SWITCH & BREAKER


14/28 VOLT OPTION
NAME PLATE
VOLT STEP SWITCH
OPTION, SOFT START SWITCH
115 VOLT UTILITY RECEPTACLE
UTILITY 115 VOLT BREAKER
14 VOLT "ON" LIGHT, WHITE
VOLT METER
AMPMETER
AMPMETER RANGE SWITCH
REVERSE DIODES OPTION, RED
GREEN POWER "ON" INDICATOR
UTILITY 115 VOLT STRAPPING
COVER PLATE
15 AMP FUSE
INPUT POWER STRAPPING
INPUT POWER STRAPPING PANEL
DESCRIPTION
3448 W. Mockingbird Ln.
Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

foxtronics
incorporated

1
4

FIGURE 2.

TITLE: FOXCART FRONT PANEL COMPONENTS


DRAWING NO: 4000001-007
PAGE: 1 OF 1

REV: B

DRAWN BY: SE

APPROVED BY:

DATE:
10/01/01

230

208

240

2
4

3
1

2
4

1
2

3
1

4
E

REV: B

DRAWN BY: SE

APPROVED BY:

4
E

2
4

3
480V

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

W
Z

DATE: 10/01/01

PAGE: 1 OF 1

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.

208 TO 250 VAC LINE


15 AMP FUSES

TITLE: FOXCART AC INPUT VOLTAGE STRAPPING


DRAWING NO: 400-0001-003

FOXCART MODEL 1600/2000

X
3448 W. Mockingbird Ln.
Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

440V

480V

incorporated

4
E

FOXCART MODEL 1600-C ONLY

foxtronics

1
2

240V

3
F

380V

440V

3
F

1
2

B
4

3
4

2
4

225V

4
E

2
4

2
4
208V

230V

208V

1
2
3

B
4

1
2

4
E

1
2

FOXCART MODEL 1200

FIGURE 3.

23

19

18

17

21

16

20

22

FIGURE 4.

11

14

15

27

26

13

12

7
8

25

24

10

ON/OFF BREAKER

DRAWN BY: SE

APPROVED BY:

DRAWING NO: 400-0001-005

PAGE: 1 OF 1

REV: B

DATE: 10/01/01

3448 W. Mockingbird Ln.


Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

DESCRIPTION

TITLE: FOXCART COMPONENT PARTS

incorporated

foxtronics

ITEM

VOLT METER

3
1

STEP SWITCH
LIGHT (GREEN) POWER ON

14/28 VDC SWITCH


LIGHT (RED) REVERSE CURRENT

SOFT START SWITCH

7
6

AC RECEPTICLE

SERVICE PLUG CIRCUIT BREAKER


AMPMETER

TRANSFORMER

10

RIGHT DIODE PLATE ASSEMBLY

13
11

STABILIZING RESISTOR

14

AMMETER SHUNT

SOFT START

15

12

REVERSE DIODES
CAPACITOR (40,000 MF)

16

FAN ASSEMBLY

17

18

CHOKE
(CONDENSER) 2 MF CAPACITOR

20
19

DIODE
LEFT DIODE PLATE ASSEMBLY

MOUNT FAN

23
21

AMPMETER RANGE SWITCH

24
22

INPUT STRAP BOARD

LIGHT (WHITE) 14VDC ON

STEP-DOWN TRANSFORMER

25

26

27

GREEN

WHITE

BLACK

100A

4
5
6
7

15A

4
5

208

230

240

15A

6
7

FAN
230V

X
W

10A

FIGURE 5.

OPTIONAL REVERSE
CURRENT

115V SERVICE
1 K.V.A. MAX

+
-

THIS DRAWING IS APPLICABLE TO ALL 1200 FOXCARTS


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

.9

CHOKE

GRN

incorporated

foxtronics

APPROVED BY:
DRAWN BY: SE

DATE: OCTOBER 8, 2001


REV: B

PAGE: 1 OF 1

DRAWING NO: 400 0005 002

3448 W. Mockingbird Ln.


Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

CORRECT FAN MOTOR WIRING TO BE


COMPATIABLE WITH EITHER 240/480VAC
INPUT

NORMAL

METER RANGE SWITCH

TITLE: 1200 FOXCART w/REVERSE CURRENT DIODE

RED

+
VOLTS

SHUNT

LOW

AMPS

70A FOR 1600


100A FOR 2000

230V
FAN

50 OR 60 Hz

15A

15A

X
W

480
240
230
208

480
240
230
208

T3

T2

T1

480
240
230
208

GREEN
WHITE
BLACK
RED

10A

4 COND
#6 CABLE

OPTIONAL REVERSE CURRENT


DIODES

FIGURE 6.

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

115V SERVICE
1 K.V.A. MAX

302UR(xx)X
LEFT SINK
RIGHT SINK

+
40,000 mf

+
GRN

NORMAL

THIS DRAWING IS APPLICABLE TO ALL 1600/2000


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

CHOKE

SOFTSTART

OPTIONAL
SOFTSTART
RED

APPROVED BY:
DRAWN BY: SE

DATE: 10/09/01

W/REVERSE CURRENT DIODE


& SOFTSTART

REV: B

400-0005-018/028

1600/2000 FOXCART

3448 W. Mockingbird Ln.


Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

14V TAPS ON M2000


TRANSFORMER ONLY

CORRECT FAN MOTOR WIRING TO BE


COMPATIABLE WITH EITHER 240/480VAC
INPUT

PAGE: 1 OF 1

DRAWING
NO:

TITLE:

incorporated

NORMAL

METER RANGE SWITCH

foxtronics

VOLTS

LOW

AMPS

SHUNT

70A FOR 1600


100A FOR 2000

230V
FAN

50 OR 60 Hz

15A

15A

T2

T3

480
240
230
208

480
240
230
208

T1

10A

4 COND
#6 CABLE

FIGURE 7.

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

115V SERVICE
1 K.V.A. MAX

302UR(xx)X
LEFT SINK
28V

480
240
230
208

GREEN
WHITE
BLACK
RED

RIGHT SINK
14V
OPTIONAL REVERSE CURRENT
DIODES

40,000 mf

+
GRN

NORMAL

THIS DRAWING IS APPLICABLE TO ALL 1600/2000


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

CHOKE

SOFTSTART

RED

WHT

OPTIONAL
SOFTSTART

LOW

AMPS

14V TAPS ON M2000


TRANSFORMER ONLY

incorporated

APPROVED BY:
DRAWN BY: SE

DATE: 10/08/01

W/REVERSE CURRENT DIODE


SOFTSTART & 14/28 SWITCH

REV: B

400-0005-019/029
PAGE: 1 OF 1

DRAWING NO:

3448 W. Mockingbird Ln.


Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

CORRECT FAN MOTOR WIRING TO BE


COMPATIABLE WITH EITHER 240/480VAC
INPUT

foxtronics

METER RANGE SWITCH

NORMAL

TITLE: 1600/2000 FOXCART

28V

14V

VOLTS

SHUNT

70A FOR 1600


100A FOR 2000

230V
FAN

50 OR 60 Hz

15A

15A

480
240
230
208

480
240
230
208

T3

T2

T1

480
240
230
208

GREEN
WHITE
BLACK
RED

H3

H2

H4

4 COND
#6 CABLE

X2

X1
10A

302UR(xx)X
LEFT SINK

FIGURE 8.

RIGHT SINK

40,000 mf

OPTIONAL
TRANSFORMER

+
+

GRN

NORMAL

THIS DRAWING IS APPLICABLE TO ALL 1600/2000


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

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

115V SERVICE
1 K.V.A. MAX

CHOKE

SOFTSTART

OPTIONAL
SOFTSTART
OPTIONAL REVERSE CURRENT
DIODES

RED

REV: B
APPROVED BY:

PAGE: 1 OF 1
DRAWN BY: SE

DATE: 10/08/01

W/ REV. CURR., SOFTSTART,


STEPDOWN TRANSFORMER

3448 W. Mockingbird Ln.


Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

14V TAPS ON M2000


TRANSFORMER ONLY

DRAWING NO: 400-0005-017/027

TITLE: 1600/1200 FOXCART

CORRECT FAN MOTOR WIRING TO BE


COMPATIABLE WITH EITHER 240/480VAC
INPUT

incorporated

NORMAL

METER RANGE SWITCH

foxtronics

VOLTS

LOW

AMPS

SHUNT

GREEN

BLACK

WHITE

RED

GREEN

WHITE

SINGLE PHASE

(REAR VIEW OF CONNECTOR)

L1

L2

HUBBELL 3100P6W WIRE CONNECTIONS

4/3 CABLE (ONLY)

3 PHASE
6/4 CABLE

L1

L2

L3

BLACK

GREEN

BLACK

WHITE

FIGURE 9.

L1

(REAR VIEW OF CONNECTOR)

L2

REV: C
APPROVED BY:
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DATE: 07/30/08

3448 W. Mockingbird Ln.


Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

PAGE: 1 OF 1

DRAWING NO: 400-0005-033

TITLE: FOXCART AC CONNECTOR WIRING

incorporated

foxtronics

L3

4/3 CABLE
SINGLE PHASE

HUBBELL 460P7W WIRE CONNECTIONS

114 MM

4 1/2"

3 7/8"
98.4 MM SQ.

FRONT
VIEW

7/32" 5.5 MM DIA.


(4 HOLES)

4 1/2"
114.4 MM SQ.

257.5 MM

10 9/64"

P/N 401-0006-007

HUBBELL 460P7W WALL PLUG

5 7/64"
129.7 MM

4 5/64"
END
VIEW

FIGURE 10.

103.5 MM

1 11/16"

REV: 10/01/01
APPROVED BY:
DRAWN BY: SE

DATE: 10/01/01

3448 W. Mockingbird Ln.


Dallas, TX 75235
PHONE: 214/358-4425
FAX: 214/358-1519

PAGE: 1 OF 1

DRAWING NO: 400-0005-034

3 3/32"
88 MM DIA.

42.8 MM

TITLE: HUBBELL 460P7W & 460R7W AC PLUGS

incorporated

foxtronics

P/N 401-0037-000

WALL
BOX

P/N 401-0038-000

HUBBELL 460R7W WALL RECEPTICLE

ASSEMBLY: MODEL 1200 / 60 Hz


COMPONENTS
COMPONENTS
401-0001-012
401-0002-016
401-0003-016
401-0004-016
401-0005-016
401-0006-001
401-0006-006
401-0006-012
401-0007-000
401-0008-001
401-0009-016
401-0009-017
401-0010-016
401-0012-016
401-0015-001
401-0019-016
401-0019-017
401-0020-012
401-0021-012
401-0023-001
401-0023-005
401-0023-013
401-0023-016
401-0023-017
401-0023-018
401-0023-019
401-0023-021
401-0025-016
401-0026-001
401-0026-002
401-0026-003
401-0027-016
401-0041-001
401-0041-002
401-0041-003
401-0052-000
401-0068-001
401-0068-003
401-0068-003
401-0068-006
401-0068-007
401-0071-002
402-0045-001
404-1600-010
404-1600-012
404-1600-014
404-1600-016

APPENDIX A-1
DESCRIPTION
UNITS REQ. ASSEMBLY
DESCRIPTION
UNITS REQ. ASSEMBLY
412-7-T2 TAP SWITCH
1.0
NO
3M578 FAN MOTOR
1.0
NO
2C842-8 / 12 BLADE
1.0
NO
TRIPLET / DC VOLT METER 0-40VDC
1.0
NO
DC AMP METER: DUAL 0-800; 0-1600
1.0
NO
RED-DOTCVR CCD DCI-78440135000
1.0
NO
CR15-1 IVORY DUPLEX; HUBBELL
1.0
NO
AC PLUG, 3100P6W
1.0
NO
AN3161-10/10A-CB
1.0
NO
219-3-1-62F-89-100 480V/BKR
1.0
NO
502-3241-102 LT/ASY
1.0
NO
LAMP. TYPE 313
1.0
NO
LENSE GREEN 320112300
1.0
NO
600A/50mv SHUNT; HA600-50
1.0
NO
75 OHM, 5W, RESIST. PW5-75
1.0
NO
CGS4030040X4C/40,000MF 40V
5.0
NO
CLAMP VR12B (3)
5.0
NO
CHOKE; MOD 1200
1.0
NO
TRANSFORMER/1200
1.0
NO
FR/PL, PLATE 8X 8
1.0
NO
FRONT PNL (NEW-DWG)
1.0
NO
CHASSIS FRAME
1.0
NO
COVER
1.0
NO
BRACKET, FAN MT
1.0
NO
PLATE RE-ENFORCE
2.0
NO
HANDLE, FOXC
2.0
NO
REAR PANEL
1.0
NO
CASTER TP505001SR-B SR = SWBRAKE
2.0
NO
PILLOW BLK 2X530 x
2.0
NO
AXLE x 29 3/8
1.0
NO
SHAFT COLLAR 2 x 570 x
2.0
NO
TIRE, 4.10/850-4PN, BEARING
2.0
NO
DIAL KNOB # 5152A
1.0
NO
VOLT-ADJ DECAL
1.0
NO
5003/1-7/DIAL/IND/PLATE
1.0
NO
CABLE ASSEMBLY/DC, 15FT/W/PLUG
1.0
NO
DECAL, FOXCART S/N MODEL, 1200
1.0
NO
DECAL, FOXCART LOGO
2.0
NO
DECAL, 115V
1.0
NO
DECAL, CAUTION
1.0
NO
DECAL, HI / LO (AMP)
1.0
NO
SWITCH, TOGGLE #93-4001SPSTON/MO
1.0
NO
4/3 SEOW AC CABLE
50.0
NO
LOAD RESISTOR
2.0
YES
STRAPBOARD MODEL 1200
1.0
YES
LEFT DIODE PLATE 1200
1.0
YES
RIGHT DIODE PLATE 1200
1.0
YES

ASSEMBLY: MODEL 1600 / 60 Hz


COMPONENTS
COMPONENTS
401-0001-016
401-0002-016
401-0003-016
401-0004-016
401-0005-016
401-0006-001
401-0006-006
401-0006-007
401-0007-000
401-0008-016
401-0009-016
401-0009-017
401-0010-016
401-0012-016
401-0015-001
401-0019-016
401-0019-017
401-0020-016
401-0021-016
401-0023-001
401-0023-005
401-0023-013
401-0023-016
401-0023-017
401-0023-018
401-0023-019
401-0023-021
401-0025-016
401-0026-001
401-0026-002
401-0026-003
401-0027-016
401-0041-001
401-0041-002
401-0041-003
401-0052-000
401-0068-000
401-0068-003
401-0068-005
401-0068-006
401-0068-007
401-0071-002
402-0045-002
404-1600-003
404-1600-006
404-1600-007
404-1600-010

APPENDIX A-2
DESCRIPTION
UNITS REQ. ASSEMBLY
DESCRIPTION
UNITS REQ. ASSEMBLY
412-7-T2 TAP SWITCH
1.0
NO
3M578 FAN MOTOR
1.0
NO
2C842-8 / 12 BLADE
1.0
NO
TRIPLET / DC VOLT METER 0-40VDC
1.0
NO
DC AMP METER: DUAL 0-800; 0-1600
1.0
NO
RED-DOTCVR CCD DCI-78440135000
1.0
NO
CR15-1 IVORY DUPLEX; HUBBELL
1.0
NO
AC PLUG, 460P7W
1.0
NO
AN3161-10/10A-CB
1.0
NO
70ABK/480V 219-3-1-65F-8-9-70
1.0
NO
502-3241-102 LT/ASY
1.0
NO
LAMP. TYPE 313
1.0
NO
LENSE GREEN 320112300
1.0
NO
600A/50mv SHUNT; HA600-50
1.0
NO
75 OHM, 5W, RESIST. PW5-75
1.0
NO
CGS4030040X4C/40,000MF 40V
2.0
NO
CLAMP VR12B (3)
2.0
NO
CHOKE; MOD 1600
1.0
NO
TRANSFORMER/1600 50/60Hz
1.0
NO
FR/PL, PLATE 8X 8
1.0
NO
FRONT PNL (NEW-DWG)
1.0
NO
CHASSIS FRAME
1.0
NO
COVER
1.0
NO
BRACKET, FAN MT
1.0
NO
PLATE RE-ENFORCE
2.0
NO
HANDLE, FOXC
2.0
NO
REAR PANEL
1.0
NO
CASTER TP505001SR-B SR = SWBRAKE
2.0
NO
PILLOW BLK 2X530 x
2.0
NO
AXLE x 29 3/8
1.0
NO
SHAFT COLLAR 2 x 570 x
2.0
NO
TIRE, 4.10/850-4PN, BEARING
2.0
NO
DIAL KNOB # 5152A
1.0
NO
VOLT-ADJ DECAL
1.0
NO
5003/1-7/DIAL/IND/PLATE
1.0
NO
CABLE ASSEMBLY/DC, 15FT/W/PLUG
1.0
NO
DECAL, FOXCART S/N MODEL, 1600
1.0
NO
DECAL, FOXCART LOGO
2.0
NO
DECAL, 115V
1.0
NO
DECAL, CAUTION
1.0
NO
DECAL, HI / LO (AMP)
1.0
NO
SWITCH, TOGGLE #93-4001SPSTON/MO
1.0
NO
6/4 SEOW AC CABLE
50.0
NO
STRAPBOARD MODEL 1600
1.0
YES
LEFT DIODE PLATE 1600
1.0
YES
RIGHT DIODE PLATE 1600
1.0
YES
LOAD RESISTOR
1.0
YES

ASSEMBLY: MODEL 2000 / 60 Hz


COMPONENTS
COMPONENTS
401-0001-016
401-0003-016
401-0002-016
401-0004-016
401-0005-020
401-0006-001
401-0006-006
401-0006-007
401-0007-000
401-0008-001
401-0009-016
401-0009-017
401-0010-016
401-0013-016
401-0015-001
401-0019-016
401-0019-017
401-0020-020
401-0021-020
401-0023-001
401-0023-005
401-0023-013
401-0023-016
401-0023-017
401-0023-018
401-0023-019
401-0023-021
401-0025-016
401-0026-001
401-0026-002
401-0026-003
401-0027-016
401-0041-001
401-0041-002
401-0041-003
401-0052-000
401-0068-002
401-0068-003
401-0068-005
401-0068-006
401-0068-007
401-0071-002
402-0045-002
404-1600-003
404-1600-010
404-1600-018
404-1600-020

APPENDIX A-3

DESCRIPTION
UNITS REQ.
ASSEMBLY
DESCRIPTION
UNITS REQ. ASSEMBLY
412-7-T2 TAP SWITCH
1.0
NO
2C842-8 / 12 BLADE
1.0
NO
3M458 FAN MOTOR 50Hz
1.0
NO
TRIPLET / DC VOLT METER 0-40VDC
1.0
NO
DC AMP METER: DUAL 0-1000; 0-2000
1.0
NO
RED-DOTCVR CCD DCI-78440135000
1.0
NO
CR15-1 IVORY DUPLEX; HUBBELL
1.0
NO
AC PLUG, 460P7W
1.0
NO
AN3161-10/10A-CB
1.0
NO
219-3-1-62F-89-100 480V/BKR
1.0
NO
502-3241-102 LT/ASY
1.0
NO
LAMP. TYPE 313
1.0
NO
LENSE GREEN 320112300
1.0
NO
700A/50mv SHUNT; HA750-50
1.0
NO
75 OHM, 5W, RESIST. PW5-75
1.0
NO
CGS4030040X4C/40,000MF 40V
2.0
NO
CLAMP VR12B (3)
2.0
NO
CHOKE; MOD 2000
1.0
NO
TRANSFORMER/2000
1.0
NO
FR/PL, PLATE 8X 8
1.0
NO
FRONT PNL (NEW-DWG)
1.0
NO
CHASSIS FRAME
1.0
NO
COVER
1.0
NO
BRACKET, FAN MT
1.0
NO
PLATE RE-ENFORCE
2.0
NO
HANDLE, FOXC
2.0
NO
REAR PANEL
1.0
NO
CASTER TP505001SR-B SR = SWBRAKE
2.0
NO
PILLOW BLK 2X530 x
2.0
NO
AXLE x 29 3/8
1.0
NO
SHAFT COLLAR 2 x 570 x
2.0
NO
TIRE, 4.10/850-4PN, BEARING
2.0
NO
DIAL KNOB # 5152A
1.0
NO
VOLT-ADJ DECAL
1.0
NO
5003/1-7/DIAL/IND/PLATE
1.0
NO
CABLE ASSEMBLY/DC, 15FT/W/PLUG
1.0
NO
DECAL, FOXCART S/N MODEL, 2000
1.0
NO
DECAL, FOXCART LOGO
2.0
NO
DECAL, 115V
1.0
NO
DECAL, CAUTION
1.0
NO
DECAL, HI / LO (AMP)
1.0
NO
SWITCH, TOGGLE #93-4001SPSTON/MO
1.0
NO
6/4 SEOW AC CABLE
50.0
NO
STRAPBOARD MODEL 1600
1.0
YES
LOAD RESISTOR
1.0
YES
LEFT DIODE PLATE 2000
1.0
YES
RIGHT DIODE PLATE 2000
1.0
YES

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


COMPONENTS
COMPONENTS
401-0003-018
401-0003-019
401-0003-020

DESCRIPTION
DESCRIPTION
3M459 FAN MOTOR 50Hz
3M492 MOUNT
SPLIT RING ADAPTOR

APPENDIX A-4
UNITS REQ.

ASSEMBLY
UNITS REQ. ASSEMBLY
1.0
NO
1.0
NO
1.0
NO

UNITS REQ.

ASSEMBLY
UNITS REQ. ASSEMBLY
1.0
NO
2.0
NO
3.0
NO

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


COMPONENTS
COMPONENTS
401-0002-017
401-0023-060
401-0090-000

DESCRIPTION
DESCRIPTION
DC FAN
FAN BRACKET MOUNT
STAND OFF

ASSEMBLY: SOFTSTART OPTION


COMPONENTS
COMPONENTS
401-0045-003
401-0068-008
401-0071-004
401-1023-000
402-1022-000
404-0004-000

DESCRIPTION
UNITS REQ.
ASSEMBLY
DESCRIPTION
UNITS REQ. ASSEMBLY
CABLE, (DC) WELDING TYPE 2/0
5.0
NO
DECAL, SOFT START
1.0
NO
TOG/SWITCH C/H #8792K3 SOFT-START
1.0
NO
YELLOW 2/0 322090 (2J1871)
2.0
NO
YELLOW 2/0 322089 (ZZ251869)
6.0
NO
SOFT START GRID
1.0
NO

ASSEMBLY: REVERSE CURRENT OPTION


COMPONENTS
COMPONENTS
401-0009-016
401-0009-017
401-0010-017
401-0015-001
401-0016-001
402-0046-005
402-1014-000
402-1020-002

DESCRIPTION
DESCRIPTION
502-3241-102 LT/ASY
LAMP TYPE 313
LENSE, RED #25F-1576
75 OHM, 5W, RESISTOR PW5-75
302U10A POS DIODE; REV/CUR
18 GA WIRE
BLUE #10 36160
RED 3/8 31897

UNITS REQ.

ASSEMBLY
UNITS REQ. ASSEMBLY
2.0
NO
2.0
NO
1.0
NO
2.0
NO
3.0
NO
5.0
NO
2.0
NO
1.0
NO

APPENDIX B

B1

Chart for 1200

B2

Chart for 1600

B3

Chart for 2000

DC VOLTS OUTPUT

10

15

20

25

30

35

15

100
300

400

500

46

600

700

800

1000

1100

70

DC AMPERES OUT

900

90

1200

1300

100

1400

1500

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

200

TYPICAL MODEL 1200 OUTPUT CURVE USING 240V 60 Hz

110

1600

1700

1800

1900

145

2000

DC VOLTS OUTPUT

10

15

20

25

30

35

15

100
300

400

500

46

600

700

800

1000

1100

70

DC AMPERES OUT

900

90

1200

1300

100

1400

1500

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

200

TYPICAL MODEL 1600 OUTPUT CURVE USING 440V 60 Hz


for 50 Hz de-rate 15%

110

1600

1700

1800

1900

145

2000

DC VOLTS OUTPUT

10

15

20

25

30

35

100

15

300

400

500

46

600

700

800

1000

1100

70

DC AMPERES OUT

900

90

1200

1300

100

1400

1500

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

200

TYPICAL MODEL 2000 OUTPUT CURVE USING 440V 60 Hz


for 50 Hz de-rate 15%

110

1600

1700

1800

1900

145

2000