MILLENNIUM H100B14/28VDC FOXCART

OPERATION AND SERVICE MANUAL

UNIT WEIGHT - APPROX. 500 POUNDS

THE POWER CART WITH MUSCLE

FOXTRONICSLOVE FIELD - DALLAS TEXAS

MADE IN THE USA3448 WEST MOCKINGBIRD LANE

DALLAS, TEXAS 75235

PHONE (214) 358-4425FAX (214) 358-1519

Revised: AUGUST, 2009

TABLE OF CONTENTS

SECTION PAGE

1. AN OVERVIEW 2

2. PURPOSE OF EQUIPMENT 3

3. DESCRIPTION 4

4. PREPARATION FOR USE 4

5. OPERATION 5

6. SPECIFICATIONS 6

7. FIGURES & DIAGRAMS 7-10

8. PREVENTATIVE MAINTENANCE 11

9. TROUBLESHOOTING 12

10. H100B MILLENNIUM ACCEPTANCE DATA SHEET 13

11. APPENDIX 14-15

1. AN OVERVIEW

This manual provides the operating and maintenance procecures for the Millennium series

Foxcart Ground Power Units. The Millennium H100B manual covers operating procedures

that are typical for aircraft Ground Power Units operating from an alternating current source.

Preparation for use in routine maintenance are also covered. Information is also provided for

trained technical personnel qualified to preform the detailed 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 Millennium H100B is designed to meet Underwriter’s requirements of safety,

utility and placards, even though “UL” specifications are not directed to this

type of device.

CAUTION: Before using the 115 VAC Utility Outlet, check voltage with voltmeter. If not

close to 115 VAC contact the factory before using.

Page 2.

2. PURPOSE OF EQUIPMENT

The Millennium H100B is specifically designed for light aircraft, avionics installations and

flight line maintenance ground power. The Millennium H100B was introduced at the Helicopter

Association International (HAI) meeting in February 2008.

The Millennium H100B ground power unit is designed to provide DC power to aircraft for

ground maintenance and avionics installations. The Millennium H100B, when used as an

external DC source, eliminates or minimizes excessive current drain from the aricraft’s battery

and battery relay contacts. It is also desinged as a low profile unit that requires minimum

ventilation and is easily moved in a crowded hangar by one person.

The H100B is a single-phase 208-240 VAC input ground power unit (GPU), capable of 100

AMPS at 28 or 14 Volts DC and with two(2) internal 12 Volt sealed lead acid batteries assist

with loads over 100 AMPS.

Page 3.

3. DESCRIPTION

The Millennium H100B is designed to provide the Aircraft with 28 Volts DC from a single

phase 208-240 Volts AC.

It is designed for 100 AMPS DC continuous at 28 Volts DC to power the aircraft during

maintenance. The two(2) internal batteries, with the AC rectifier on, will provide assist when

loads exceed 100 Amps. The display control panel contains standard analog DC Volt and

Amp meters with AC and DC Power “ON” lights. Also a three(3) position DC Power Switch

actuates between 28 or 14 Volts DC to the aircraft. A 115 Volt utility outlet, supplying AC

power for power tools, lights, etc, is located on the rear panel.

The Millennium H100B is enclosed in an all-steel chassis frame and weather tolerant powder

coat paint with a lift up cover. A steel tow bar is used to pull the unit around. The power cables

can be coiled on top for storage. The DC power cable is clamped internally to the frame for

strain relief.

DIMENSIONS:

Length 35.00” Width 21.50”

Height 21.50” Weight 400 lbs

4. PREPARATION FOR USE

The Millennium H100B is shipped completely assembled and requires no special preparation

before use.

CAUTION: This unit is a single phase AC - 208-240 Volts AC input only. Incorrect

Primary Supply Voltage could cause improper DC Output and / or

internal battery damage.

Page 4.

5. OPERATION

1. Move the H100B Power Cart into position.

2. Plug DC Power Cable in aircraft.

3. Plug Input Power Cable into Power Cart.

4. Plug input Power Cable into AC Outlet.

5. Select either 14 or 28 VDC with toggle switch.

6. Switch AC “ON/OFF” circuit breaker to “ON” position.

7. Turn DC “ON/OFF” switch to “ON” position.

8. Perform normal maintenance.

9. After maintenance is completed, turn DC “ON/OFF” switch to “OFF” position.

10. Turn AC power circuit breaker to “OFF” position.

11. Disconnect DC Power Cable from aircraft.

12. Disconnect unit from AC outlet.

NOTE:The battery/batteries used in the Millennium H100B is/are maintenance free

and should be re-charged after using for start assist. Charging time will depend

on the condition of the battery/batteries. (See Section 8. (4.) PREVENTATIVE

MAINTENANCE).

Page 5.

6. SPECIFICATIONS

Output Volts: 14 or 28 Volts DC

Peak DC Out: 100 AMPS *

Continuous DC Out: 100 AMPS *

Input Power Requirements: 208-240 Volts AC

AC Input Current: 35 AMPS at 100 AMPS DC Output

AC Cable: 75 Feet

DC Cable: 15 Feet

* With AC Power

Page 6.

7. FIGURES / DIAGRAMS

FIGURE 1 MILLINNIUM H100B WIRING DIAGRAM

FIGURE 2 HUBBELL PLUG (9452C) / (CS6364C)

FIGURE 3-4 TYPICAL OUTPUT CURVE

Page 7.

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8. PREVENTATIVE MAINTENANCE

I. CAUTION: Harmful Voltages are present inside this cart, even when AC power is

DISCONNECTED.

II. CAUTION: Prior to performing any maintenance on this unit, DISCONNECT

BATTERIES

MAINTENANCE

1. Grease wheel bearings as required.

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

3. Perform visual inspection, tighten and loose nuts and bolts, etc.

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

5. Inspect batteries for corrosion, signs of cracking, leaking etc.

6. Battery Charging: The internal battery in the H100B may be charged by connecting

the unit to a “Hot” power source and the main AC Breaker turned ON. Foxctonics

warrants each new Millennium Foxcart to be free of defects in material and workmanship

under normal use and service for a period of two (2) years from date of shipment.

EXCEPTION: The manufactures warranty supersedes any and all other warranties of

Aircraft Batteries supplied by Foxtronics to be operated in the Millennium series Foxcart.

NOTE: The battery/batteries used in the Millennium H100B is/are maintenance free

and should be re-charged after using for start assist. Charging time will depend on the

condition of the battery.

Page 11.

9. TROUBLESHOOTING

I. CAUTION: Harmful Voltages are present inside this cart, even when AC power is

DISCONNECTED.

II. CAUTION: Prior to performing any maintenance on this unit, the blue capacitors

must be discharged. This can be accomplished by:

1. Remove battery connector from battery.

2. While monitoring voltage across capacitor with DC Voltmeter,

place a high wattage 10 ohm (approx) resistor to the terminals of

the capacitors.

3. After capacitors are drained, remove resistor.

Before Reconnecting Battery:

1. Plug power cart into AC coltage source.

2. Turn ON power cart AC Power.

3. After approximately 30 seconds, turn OFF AC power.

4. Connect battery.

III. CAUTION: If input cable is plugged into hot AC outlet, lethal voltages will be present.

1. UNIT OVERHEATING: Allow unit to cool. Ensure Cooling Fan is

operating.

2. OUTPUT VOLTAGE INCORRECT: Verify input voltage is correct.

check battery voltage. If low, recharge or replace battery as

applicable. Contact Foxtronics, Inc for in-depth trouble shooting.

Page 12.

10. H100B MILLENNIUM ACCEPTANCE DATA SHEET

W/O# S/N

CUSTOMER ORDER TAKEN BY

CONTACT/BUYER ASSEMBLED BY

PURCHASE ORDER

PHONE INSPECTOR

ORDER DATE DATE

INPUT TEST VOLTS 245 VOLTS AC

BATTERY CHARGED

OUTPUT VOLTS TEST

28VAC MODE

DC AMP OUTPUT DC VOLTS OUT AC INPUT AMPS

0 27.9 4A

25 27.2 7A

50 26.9 10A

75 26.6 13A

100 26.4 18A

150 25.5 24A

200 22.8 26A

14VDC MODE

0 13.8 4A

25 12.7 7A

50 12.5 7A

75 12.3 8A

100 12.1 10A

(TYPICAL TEST DATA)

Page 13.

11. APPENDIX A-1

ASSEMBLY: MODEL H100B

COMPONENTS DESCRIPTION UNITS ASSEMBLY

401-0019-016 40,000MF Capicator 2.0 N

401-0026-001 Pillow Block 2.0 N

401-0026-002 Axel 1.0 N

401-0027-018 Wheel Assyembly/Large 1.0 Y

401-0027-019 Caster Wheel; Swivel 1.0 N

401-0038-001 Angle Plug #9452C Hubbell; 4 Cond. 1.0 N

401-0052-000 15 Ft. DC Cable w/Molded AC Conn 1.0 N

401-0250-001 Main Frame 1.0 N

401-0250-002 Cover Drg. 1.0 N

401-0250-003 Towbar 1.0 N

401-0250-104 Transformer 60 Hz 1.0 N

401-0250-006 Capacitor 38K D6630 Mallory 1.0 N

401-0250-007 AC Receptacle Hub CS6375 1.0 N

401-0250-008 Plug HubCS6364C 1.0 N

401-0250-009 Circuit Bkr Heinemann 1.0 N

401-0250-023 Contactor CT300A24D10 2.0 N

401-0250-085 Fan Guard 1.0 N

401-0250-027 Shunt (1000 Amp) 1.0 N

401-0012-016 Shunt (1600 Amp) 1.0 N

401-0250-028 Name Plate - H100B 1.0 N

401-0250-029 Lrg. Decal 6.5 X 12.0 2.0 N

401-0250-031 Bolt, Axel 7” 1.0 N

401-0250-032 Cable; 75 Ft. 8/3 1.0 N

401-0250-045 Pipe Clamp Z703-2 1.0 N

404-0100-016 Load Resistor Assy 1.0 Y

401-0250-010 Hawker Sealed Cell 2.0 N

401-0016-001 Reverse Current Diode 2.0 N

401-0250-065 DC Amp Meter (1000 Amp) 1.0 N

401-0005-016 DC Amp Meter (1600 Amp) 1.0 N

401-0004-016 DC Volt Meter (28V) 1.0 N

404-0100-002 Panel Meter Assembly 1.0 Y

404-0100-006 Load Resistor Assembly 1.0 Y

Page 14.

11. APPENDIX A-1

PANEL METER ASSEMBLY; MODEL H100B

P/N 404-0250-101

COMPONENTS DESCRIPTION UNITS REQUIRED

401-0004-016 DC Volt Meter 1.0

401-0250-037 Yellow Lamp 1.0

401-0250-051 Red Lamp 1.0

401-0250-105 On Switch (14/28 Select) 1.0

401-0250-106 Alumn. Panel Display 1.0

401-0250-065 AMP Meter 0-1000 AMPS 1.0

401-0005-016 AMP Meter 0-1600 AMPS 1.0

401-0250-067 Zero Volt Relay Lockout 1.0

Molex 6 Pin Connector(Male) 1.0

Molex 6 Pin Connector(Female) 1.0

Molex Male Pins 6.0

Molex Female Pins 6.0

PANEL METER ASSEMBLY; MODEL H100B

P/N 404-0250-102

COMPONENTS DESCRIPTION UNITS REQUIRED

401-0017-018 Neg Diode, Stud Type 4.0

401-0016-001 Reverse Current Diode, Stud Type 2.0

401-0250-015 Heatsink Fin 2.0

401-0250-016 Top Cover Plate 1.0

401-0250-092 Load Resistor 1.0

401-0250-093 Load Resistor Insulator Plate 1.0

401-0250-094 Load Resistor Mount Bracket 2.0

Page 15.