Feedrail FRS100 & FRS200 Plug-In & Trolley Series

Overhead Electrification Systems for Movable Trolley or Stationary Plug-In Service

General Information:

Feedrail^® systems are capable of providing multi-purpose trolleys or stationary plug-ins for installations requiring a source of electrical power which can be reconfigured without rewiring.

These systems provide moveable outlets for electrical power along their entire length. The systems are especially suited for use where conventional wire systems would be cumbersome and costly.

Plug-in Jacks with stationary power take-offs, are available for all Feedrail^® systems.

The busway-supported outlets called “trolleys” (Feedrail^® 60 system only) make contact with the enclosed bus bars and provide a continuous moveable connection for electrical devices. The trolleys are easily inserted and removed through door-busway sections.

As additional outlets are needed, trolleys (Feedrail^® 60 System only) or stationary plug-ins can be quickly and efficiently inserted, their numbers being limited only by the current-carrying capacity of the busway and the capacity of each outlet.

Reliable design assures uniform contact pressure, limiting work stoppages due to electrical and mechanical interruptions in supplying power.

Advantages of these systems include low installation costs with complete re-usability; ease of adding outlets as required; electrical and personnel safety; compactness; dependability and minimum maintenance expense.

All “busway (track) sections” are factory assembled for ease in handling and rapid installation. No special tools are required.

Systems are designed for indoor use in non-hazardous, non-corrosive, dry atmosphere.

UL & CSA Listed

Feedrail^® is listed by Underwriter's Laboratories, Inc. (U.L.) under BUSWAYS AND ASSOCIATED FITTINGS (File E11348 for Feedrail^® / File E165922 for Electro-Rail^® ) and as a CRANE AND HOIST ELECTRIFICATION SYSTEM (File E31188 for Feedrail^® ). Feedrail^® is also listed by the Canadian Standards Association (C.S.A.) under WIREWAYS AND BUSWAYS (File LL-7907 for Feedrail^® / File LL 103287-1 for Electro-Rail^® ).

Basic Information:

60 Amps Continuous
90 Amps Intermittent
2, 3 Poles; 300 Volts
Trolleys to 30 Amp
Plug-In Jacks Rated 15 Amperes
Made in the U.S.A.

More Information:

FRS100 & FRS200 Series Service — Design and Construction
Typical Electrical Systems for Various Applications
Installation Planning
Installation Procedure
Preventative Maintenance
Basic Dimensions/Mounting Methods
Typical Specification

This short video (no sound) shows the basic components and set up for the Feedrail^® FRS100, 200 & 300 Series.

Current Carrying Capacity

(Click image for full-size view)Track Rating: 60 amps continuous
Trolley Rating: 5, 15, 20 or 30 amps continuous
Plug-In Jack Rating: 15 amps continuous.

Voltage

300 VAC, 300 VDC

Track

Track sections consist of a one-piece streamlined 18-gauge zinc coated steel housing and the enclosed current carrying bus bars and insulators, all factory assembled in convenient lengths ready for easy, fool-proof installation on the job. No special tools required. The lower horizontal portions of the housing serve as smooth, rigid runways for the trolleys.

FRS100 & FRS200 Series Track sections are available in various types — Straight, Door, Sectionalizing and Transfer Track sections.

Bus bars are of hard-drawn copper. They are amply proportioned to carry the specified current of 60 amperes per pole continuously, 90 amperes per pole intermittently, without overheating. Bus bar connectors assure full current carrying capacity across the joints without interfering with the free travel of the trolley contacts.

Insulators are made of a high insulating and arc-resistant material. The are locked in place on 9-5/8” centers.

Track Supports

Steel clamp type track hangers for supporting track sections from strap or rod. Track may be supported on up to 10' centers at track joints when used with Duplex Track Hangers. Additional track hangers can be attached at intermediate points. Track should be supported by a minimum of two track hangers per section.

Trolleys

Feedrail^{^®} trolleys are designed to provide stable clean power; arcing and hot spots are essentially eliminated. Stable clean power is required for trouble free operation of today’s computer controlled equipment and machinery.

Trolleys are available in both fusible and non-fusible types.

All Feedrail^{^®} 2 and 3 Pole trolleys have a chassis-insulator contact assembly. The chassis is of heavy gauge steel. The trolley wheels and guide wheels are of the ball bearing type.

Horizontally mounted ball bearing guide wheels prevent slewing when running in the track. A substantially proportioned insulator block combines the best insulating properties with high arc resistance.

FRS100 and FRS200 Series 2 and 3 Pole trolleys are furnished with three types of contacts:

COPPER GRAPHITE ROLLER CONTACTS for intermittent movement no in excess of 150 feet per minute
COPPER GRAPHITE BRUSH CONTACTS for movement up to 250 feet per minute
BRONZE BRUSH CONTACTS for stationary service

A polarizing tab on the chassis operating in conjunction with a stop in the door track section permits insertion of the trolleys only one way. Equipment grounding may be made through the trolleys. Weights in excess of 20 pounds per trolley are not recommended for moving applications.

Plug-In Jacks

Plug-in Jacks are designed for applications where the mobility of trolleys is not required, such as in some sewing rooms or for connecting lighting fixtures and small tools to Feedrail^® track. They can be inserted into the track section at any point. A quarter turn after insertion makes electrical contact with the bus bars and locks the jack in place.

Grounding

For the safety of personnel, the track casings of the Feedrail^® system may be used as an equipment grounding conductor for grounding equipment through the individual trolleys and plug-in jacks.

Equipment grounding may be made by using the screw on the underside of the trolley chassis or plug-in jacks or on trolleys or jacks having cabinets of boxes by using the grounding screw within the box. Track housing must be grounded through conduit or other suitable means.

FRS100 & FRS200 Series systems are designed for indoor service in essentially dry locations. Feedrail^® systems are electrified tracks in which the current carrying components are enclosed in protective steel housings. Smooth riding internally track supporting trolleys or plug-in jacks take off current and provide electric power for crane and hoist or other types of electrification systems.

The FRS100 & FRS200 Series systems have been specifically developed to provide safe electrification for sewing machines, cloth cutting machines, cloth laying and inspection machines, silk screen printing and drying machines, monorail hoists, light duty cranes and stackers, book binding machines, portable tools on assembly and production lines, radio, TV and appliance test lines, lights for offices, stores, factories, etc.

The FRS100 and FRS200 Series systems are made up of standardized units, factory assembled for fast, complete installation without on-site fabrications. These 2 and 3 pole systems may be used to provide both power and control. They are ideally suited for use on control circuits where other standard Feedrail^® systems supply heavier electrification requirements.

Bus Bar Arrangement

Applications	Electrical System	Connections-Grounding
For Single Phase Cutting Machines Sewing Machines Cloth Laying Machines Hot Melt Adhesive Machines Heaters Portable Tools Fans Lighting Systems Electric Irons	Single Phase 2P, 3W 110V, 208V, 220V or 277V Equipment ground wire thru casing
	Single Phase 2P, 3W 110V, 208V, 220V or 220V with one bus for equipment ground
	Single Phase 3P, 4W 110V & 220V Equipment ground wire thru casing
Applications	Electrical System	Connections-Grounding
For Three Phase Sewing Machines Cloth Laying Machines Lighting Systems Machine Tools Heaters	Three Phase 3P, 4W 208V or 220V Equipment ground wire thru casing

Before a Feedrail^{^®} system can be planned or an estimate of the cost prepared, the electrical and mechanical requirements that the system must meet should be known. The following outlines list the basic data needed for all applications and the additional data required for various specific applications.

Basic For All

Describe in detail the purpose for which the Feedrail system will be used. Will it be used with existing equipment?
How many conductors will be required?
What voltage and current is to be applied to each conductor? Where is the power source located?
Details about any special requirements or conditions which the installation must meet such as moisture, corrosive fumes, high or low temperatures, etc.

For Electric Cranes

Sketch giving number, location, length of crane runways and length of bridge. Show location of building expansion joints or expansion joints in the structure from which the Feedrail^{^®} will be supported.
How many conductors will be required on each bridge run? How many for power? For control? How much current must each conductor carry?
What is the maximum travel speed of the bridge? of the hoist?
List of the crane’s motors — main hoist, auxiliary hoist, bridge travel, trolley travel — giving the type (D.C., wound rotor, squirrel cage, etc.) of each motor and its horsepower and full-load ampere rating.

For Electric Hoists

Plan view sketch of the rail system on which the hoists will travel, giving the length of run, of straight sections, radii of any curves and dimensions of any switches. What is the minimum distance from Feedrail to monorail in order to clear hoist? Show location of building expansion joints or expansion joints in the structure from which the Feedrail^{^®} will be supported.
How many hoists will be used and what is the horsepower and full load current rating of each? Include horsepower and full load current rating of travel motors of any of the hoists that are motor propelled. What are the maximum travel speeds?

For Moving Test Lines

Plan view sketch with dimensions showing the length of straight sections and radii of any curves, indicate the number of outlets required. If there are any sections along the run where test current will not be required, indicate their location and extent.
What type of equipment will be tested.
Give weight of units to be supported by the system.
What amperage range and what fusing arrangements will be required?

For Production Machines

Plan view sketch with dimensions showing the location of the Feedrail^{^®} system.
Indicate the number of conductors required and give voltage and amperage requirements of each. Give horsepower and full load current rating of each motor.
List any other equipment that will be powered by the Feedrail and give its full load current rating.

For Special Requirements

Plan view sketch with all dimensions which are necessary to make clear the location and extent of the Feedrail system, and the radii of any curves it may contain. Show the location of the power source.
Full details about equipment which will be operated from the system, including
1. Horsepower and full-load current rating of any electrical motors
2. Weight of any equipment to be supported by the system.
3. Fusing arrangements required.
4. Number of outlets needed.

Joining Straight to Straight Sections with Coupling Plate (Cat. No. FRS-102)

1. Place sections end to end so that ends with and without connectors are facing. Loosen set screws in unattached ends of bus bar connectors to clear openings. Bring track sections together, aligning ends of bars in section being installed with end of the track casing, shifting bus bars slightly if necessary. (Up 1/32” to gap may be left in bus bar joint to permit this alignment.) Bus bar connectors should be center in the casing cutout of the two track sections. Tighten connector set screws.

2. Hook bottoms of side plates of coupling into underside of track housings and swing up into position so that holes engage studs on sides of housing. Insert clamping screws as shown and screw in tightly. The two track sections are now securely coupled together permitting an uninterrupted path for the trolley travel.

3. Place coupling cover in position on top of coupling plates. Insert the two fastening screws and the coupling is complete.

NOTE: Bus Bar Connectors shown above are not provided with track section. Order Catalog No. FRS-102.

Mounting Center Feed Box (Cat. No. FRS-103)

1. Replace plain copper bus bar connectors in one track section with terminal connectors of center feed. Place sections end to end so ends with and without connectors are facing. Loosen screws in unattached ends of terminal connectors to clear openings. Slide bus bars into connectors (Up to 1/32” gap may be left in bus bar joint.) Tighten connector set screws.

Feed set will take standard 2-1/8” deep 4” octagonal extension ring or outlet box or FRS-110 junction box.

Mounting End Feed Box (Cat. No. FRS-106)

1. Slip terminal connectors of end feed on to ends of bus bars and tighten screws. Attach end insulator to terminal connectors.

2. Mount side plates and end plate-bumper assembly. Mount cover on side plates with two fastening screws. Place the two feed terminal spacers around feed-in terminals and fasten by four holding screws.

Feed set will take standard 2-1/8” deep 4” octagonal extension ring or outlet box or FRS-110 junction box.

Mounting Dead End Cap (Cat. No. FRS-107)

1. Mount end insulator by inserting prongs into ends of bus bar connectors as far as they will go and tighten set screws. Hook on dead end cap side plates so that holes engage studs on track housing. Bring plates together as shown. Insert and fasten clamping screws.

2. Loosen clip on end plate-bumper assembly sufficiently to permit sliding into position as shown. Tighten screws. Place dead end cover in position. Insert the two fastening screws and tighten.

Installation of Trolleys

1. Press pins together on underside of door section and swing door open.

2. Insert trolley as shown. If trolley hits polarizing strip, remove, reverse 180° and reinsert. Close track doors.

At all times Feedrail^{^®} equipment should be so protected and maintained as to be kept clean and dry.

Before the Feedrail^{^®} system is placed in operation, it should be thoroughly checked for horizontal and vertical alignment, adequate track support and free movement of trolley travel throughout the entire track run. All track, bus bar and feed connections should be mechanically tight. The system should be checked for possible grounds or short circuits. Any paint, grease, or other foreign matter accumulated during construction should be removed from the bus bars, insulation and track interior. Blow out all dust and other loose particles from inside the track.

Expansion sections, when used, must be properly adjusted, located and supported in accordance with installation instructions. Check bus bars and casing for accurate alignment.

Feedrail^{^®} is both an electrical and a moving mechanical system and therefore should be included as a part of your Preventive Maintenance Program.

Electrical Maintenance requires:

Keeping the system dry and clean to prevent electrical leakage or “shorts” across the insulation.
Maintaining electrical continuity by keeping bus bar contact surfaces clean and joints tight.

Mechanical Maintenance requires:

Preventing excessive wear.
Replacing parts showing excessive wear.

The following Preventive Maintenance procedure, periodically performed, is recommended:

Remove, thoroughly clean all trolleys and lubricate the wheels. Feedrail^{^®} recommends Grade #1 Bearing Grease. This is softer grease than #2 and allows the grease to penetrate the bearings easier. Inspect contacts for excessive wear. Replace worn wheels and contacts.
Clean bus bars with Feedrail^{^®} Bus Bar Cleaner.
Blow out all foreign particles which have accumulated inside the track.
Check trolleys for free movement within the track.
Check all track supports, track joints, bus bar and feed connections for tightness. This procedure should be repeated at regular intervals, consistent with the severity of the operations and usage of the system. Plants operating two or three shifts will require more frequent inspection of the Feedrail^{^®} equipment.

Feedrail^{^®} is not normally recommended for installations subject to vibration, frequent electrical overload, corrosive fumes and other abnormal conditions. However, should such conditions exist, more frequent inspections and maintenance will be required.

Before additional electrical loads are added to the system, it should be determined that sufficient capacity is available.

Basic Dimensions

As an aid in planning mountings, the basic dimensions of the Feedrail^{^®} 60 system is shown below. These are offered as a guide only.

Mounting Methods

Examples of the methods commonly used for mounting the Feedrail^® '60' system is shown below. These methods can be used in existing plants as well as in new buildings. Engineers and contractors will readily be able to devise other methods to suit special installations. In every case the mounting should be designed to insure a rigid installation in both horizontal and vertical alignment.

(Click image for full-size view)

As an aid to preparing specifications for a Feedrail^® installation, the following wording is suggested. You will note this specification contains the primary electrical and mechanical features of the Genuine Feedrail^® System.

FRS100 & FRS200 Series (Feedrail^® '60')

The Trolley and Plug-in Busway System (Crane and Hoist Electrification System) shall be of the metal enclosed type with internally track-supported trolleys and plug-in jacks as manufactured by:

Genuine Feedrail^{^®}
Industrial Products

The System shall have a voltage rating 300 Volts A.C. or D.C. (2 Pole) (3 Pole) and a continuous current carrying capacity of 60 Amperes per Pole. (When used as a Crane and Hoist Electrification System, the System shall be rated at 60 Amperes continuous service and 90 Amperes intermittent service). The full current carrying capacity of the system shall be maintained throughout. The system shall permit longitudinal movement of the housings and bus bars, independent of each other, in order to allow for unequal expansion and contraction as a result of temperature changes. The System shall consist of standardized, interchangeable, Feedrail^® units — track sections, coupling sets, dead end caps, track hangers and power takeoff trolleys and jacks, as called for on the plans.

Track sections shall be one piece, 18 gauge, rolled, zinc-coated sheet steel enclosures having a continuous slot in the bottom and a heavy keystone shaped rib in the top. Rolled or drawn copper bus bars, capable of carrying 60 Amperes per pole continuously without overheating, shall be mounted within the steel enclosure on arc-resistant insulators.

Door track sections shall include two hinged doors in the bottom for insertion and removal of trolleys. Door openings shall have a mechanical polarization to insure proper polarity of the trolleys.

Track supported trolleys shall be Cat. No._______________________ as listed in the Feedrail^® Catalog. They shall have a zinc-plated sheet steel chassis with metal wheels for support. Horizontal guide wheels shall run in the slot of the Feedrail^® track to prevent slewing and maintain alignment.

Springloaded roller (or brush) contacts shall be mounted on arc-resistant insulation. When inserted in the Feedrail^® track, the contacts shall align with the bus bars at all times.

Trolleys shall be mechanically polarized withcontact with the bus bars.

Plug-In Jacks can be inserted in the track slot at any point. A quarter turn, after insertion, makes electrical contact and locks the Jack in place.

All of the components you’ll need to build a brand new Feedrail FRS100 or FRS200 Series system have been organized below by category. It is recommended that you start with Track Sections and work your way through each category in the order they’re presented. If you have any questions, please contact us and one of our highly trained Feedrail specialists will respond shortly.