Overhead Electrification Systems for 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® ).
This short video (no sound) shows the basic components and set up for the Feedrail® FRS100, 200 & 300 Series.
FRS300 Series Plug-In Service — Design and Construction
Current Carrying Capacity
(Click image for full-size view)Track Rating: 50 amps continuous Plug-In Jack Rating: 15 amps continuous
Voltage
300 VAC, max
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 facory assembled in convenient lengths ready for easy, fool-proof installation on the job.
Buss bars are of hard-drawn copper. They are amply proportioned to carry the specified current of 40 amperes per pole continuously, without overheating. Bus bar connectors assure full current carrying capacity across the joints. Insulators are made of a high insulating and arc-resistent material. They are locked in place on 9-5/8” centers.
A plastic polarization strip is incorporated in the track housing to insure proper insertion of the polarized Plug-In Jack. When inserted, the Plug-In Jack is automatically grounded to the track system for safe operation.
Track Supports
Steel clamp type track hangers for supporting track sections from strap or rod. Track should be supported by a minimum opf two track hangers per section. Track may also be supported on 10' centers at track joints when used with Duplex Track Hangers.
Plug-In Jacks
Plug-In Jacks are available for 2, 3 and 4-pole systems. Plug-In Jacks are available with a galvanized steel outlet box with clamp for fast, easy wiring. The Jack has spring-loaded brass contacts for direct positive contact with the bus bars.
Plug-In Jacks can be inserted into the track slot at any point. A quarter turn, after insertion, makes electrical contact 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 Plug-In Jacks.
Equipment grounding may be made by using the screw on the underside of the Plug-In Jacks or on Jacks having cabinets or boxes by using the grounding screw within the box. Track housing must be grounded through conduit or other suitable means.
Feedrail® FRS 300 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. Plug-In jacks take off current anywhere along the length of the system and supply a stationary source of electric power. Feedrail® FRS300 Series systems have been specifically developed to provide safe electrification for assembly or production lines, lighting, and sewing trade applications.
The Feedrail FRS300 Series systems are made up of standardized units, factory assembled for fast, complete installation and without on-site fabrications.
Busway (track) should have a minimum of two busway hangers per section for support. Additional Busway hangers can be attached at intermediate points. Busway may be supported on up to 10' centers at busway joints when used with duplex track hangers. Please refer to Busway Hanger Section for available styles.
Busway
Busway (track) sections consist of a one-piece streamlined 18-gauge zinc coated steel housing and the enclosed current carrying 4 round bus bars and insulators. Busways are factory assembled in convenient 10 foot lengths and ready for easy, fool-proof on-the-job installation.Bus bars are of hard drawn copper. Designed to carry the specified current of 50 amperes per pole continuously, without overheating. Bus bar coupling sets provide full current carrying capacity across the joints. Insulators are made of high insulating and arc-resistant material.
Plug-Ins
A plastic polarizing guard in the busway housing insures proper insertion and grounding of the polarized plug-in jack. Designed for applications where the frequent movement of a trolley is not required (i.e., sewing rooms, connecting light fixtures, small tools, etc.). Insertion into a busway (track) section can be at any point of busway. After insertion a one quarter turn makes electrical contact with bus bars and locks the plug-in securely in place.
Examples of the methods commonly used for mounting 4 pole system busway runs are shown below. These methods can be used in existing plants as well as in new constructions. Engineers and contractors can 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. Rod or strap supports should not exceed 2 feet in length without sway bracing.
As an aid in planning mountings, the basic dimensions of the Feedrail® 4 pole systems are shown below. These are offered as a guide only.
As an aid in planning mountings, the basic dimensions of the Feedrail® Plug-In system is shown below. These are offered as a guide only.
Mounting Methods
Examples of the methods commonly used for mounting the Feedrail Plug-In system is shown below. These methods can be used in existing plants as well as in new buildings. In every case the mounting should be designed to insure a rigid installation in both horizontal and vertical alignment.
Note: Other bus bar configurations are available on special order. The standard systems shown are preferred for electrical noninterchangeability of track and Plug-In Jacks.
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.
FRS300 SERIES Plug-In Service
The Plug-In Busway System shall be of the metal enclosed type with internally track-supported 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) (4 pole) and a continuous current carrying capacity of (40) (50) Amperes per pole. 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 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. Round copper bus bars, capable of carrying (40) (50) Amperes per pole continuously without overheating, shall be mounted within the steel enclosure on arc-resistant insulators.
A plastic strip bumper guard shall be incorporated in the track housing to insure proper insertion of the polarized Plug-In Jack.
When inserted, the Plug-In Jack is automatically grounded to the track system for safe operation.
Track supported Plug-In Jacks shall be Cat.No._____________________________ as listed in the Feedrail Catalog. The Jack shall have spring-loaded contacts for direct, positive contact 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.
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:
Horsepower and full-load current rating of any electrical motors.
Weight of any equipment to be supported by the system.
Fusing arrangements required.
Number of outlets needed.
Engineering Cooperation
Working out the details of a Feedrail® system installation is not difficult once all the electrical and mechanical requirements have been definitely determined.
Place bus stops (1) over bus bars (2) and push them on all the way. Take the 2 halves of the coupling plate (3) and hook them to the bottom of the busway (track) housing and swing up so the holes are placed over the dimples (4) on the busway housing.
Hold the coupling plate (1) and insert screws (2) to fasten the coupling together. Loosen screws on end plate (3) to allow sliding into position on coupling plate (1). Retighten screws on end plate.
Place cover plate (1) onto coupling plate (2). Insert screws (3) on coupling and the installation of dead end cap is completed.
Place connectors (1) of plastic insulator (2) onto bus bar ends so that the connectors are half way on. Tighten the 4 screws (3) on the connectors to hold the insulator secure. Take the 2 halves of the coupling plate (4) and hook them to the bottom of the busway (track) housing and swing up so the holes are placed over the dimples (5) on the busway housing.
Hold the coupling plate (1) and insert screws (2) to fasten the 2 halves of coupling plate together. Then place end feed box (3) over coupling plate (1) as illustrated. Line up holes in box and coupling (4) and insert and tighten screws (5).
Place cover (1) over box (2) as illustrated. Insert screws (3) and tighten. The end feed box installation is completed.
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.
Build Your Feedrail FRS300 Series Plug-In Service System
All of the components you'll need to build a brand new Feedrail FRS300 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.
Shop for Feedrail FRS300 Series Plug-In Service System Components, Parts & Accessories
All components, parts and accessories for the Feedrail FRS300 Series Plug-In Service System can be found below. Use the product filter menu to narrow your search.
Track Accessories
Track Sections
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. 10' and 5' are standard lengths. Other lengths furnished on special order.
Track Sections, Built-In Center Feed
Supplied with feed box built-in, through which electrical connections to the power supply can be made. Has concentric knockouts for 1" and 1-1/4" conduit. Terminals accommodate No. 14 to No. 6 standard wire.
Track hanger for tie rod. Fits FRS100 & FRS200 Series, also FRS300 Plug-In Series. Allows direct attachment of 3/8" tie rods at any point between track joints. Permits easy leveling of track sections. When used with curved track, field notching of track top flange is required for clearance of clamping bolt. A minimum of two track hangers required for each straight track section.
Track hanger for FRS100 & FRS200 Series, also FRS300 Plug-In Series. For mounting straight track sections. Mounting hole will take 3/8" diameter bolt. They can be attached to straight track at any point between track joints. Not suitable for curved track sections. Minimum of two track hangers required for each straight track section.
Clevis support for tie rod applications. Malleable iron, with 3/8" cross bolt and 3/8"-16 tapped hole for tie rod. Must be used in conjunction with FRS-124 and FRS-105 track hangers.
Hanger (low level). For FRS100 & FRS200 Series, also FRS300 Plug-In Series. Used in place of track hanger FRS-105 where head room is limited. Takes 3/8" diameter bolts. Can be attached to straight track at any point between track joints. Not suitable for curved track. Minimum of two track hangers required for each straight track section.
Place bus stops (1) over bus bars (2) and push them on all the way. Take the 2 halves of the coupling plate (3) and hook them to the bottom of the busway (track) housing and swing up so the holes are placed over the dimples (4) on the busway housing.
Hold the coupling plate (1) and insert screws (2) to fasten the coupling together. Loosen screws on end plate (3) to allow sliding into position on coupling plate (1). Retighten screws on end plate.
Place cover plate (1) onto coupling plate (2). Insert screws (3) on coupling and the installation of dead end cap is completed.
Place connectors (1) of plastic insulator (2) onto bus bar ends so that the connectors are half way on. Tighten the 4 screws (3) on the connectors to hold the insulator secure. Take the 2 halves of the coupling plate (4) and hook them to the bottom of the busway (track) housing and swing up so the holes are placed over the dimples (5) on the busway housing.
Hold the coupling plate (1) and insert screws (2) to fasten the 2 halves of coupling plate together. Then place end feed box (3) over coupling plate (1) as illustrated. Line up holes in box and coupling (4) and insert and tighten screws (5).
Place cover (1) over box (2) as illustrated. Insert screws (3) and tighten. The end feed box installation is completed.
