Foxtronics FOXCART MARK II Manuale operativo
FOXCARTMARKII
OPERATIONANDSERVICEMANUAL
THE POWER CART WITH MUSCLE
Revised: August, 2008
FOXTRONICS
LOVEFIELD - DALLASTEXAS
PHONE(214)358-4425
FAX(214)358-1519
3448 WEST MOCKINGBIRD LANE
DALLAS,TEXAS
MADE IN THE USA
UNIT WEIGHT - ALL MODELS
1200/ 1600 / 2000
APPROX.600 POUNDS
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
ThismanualprovidestheoperatingandmaintenanceproceduresfortheMarkIIseriesFoxcartGround
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 prop-
erly 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
VOLTAGE 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. 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
powersourcemusthaveastep-downtransformer
-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 in-
serted 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 PRE-
VENT 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 differ-
ently 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)
IfyourFoxcartis380VAC or more, the StepdownTransformer should be installed.Ifnot,yourutility
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-
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