Feedrail® FRS300 Series Overhead Electrification Systems for Stationary Plug-In Service
2,3,4 poles; 300V
Plug-in jacks rated 15 amperes
Made in the U.S.A.
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 quick video (no sound) shows the basic components and set up for the Feedrail® 300 Series.
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.
Bus 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"
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.
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
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.
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
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.
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
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.
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.
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®
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:
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
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
1. Describe in detail the purpose for which the Feedrail system will be
used. Will it be used with existing equipment?
2. How many conductors will be required?
3. What voltage and current is to be applied to each conductor? Where is
the power source located?
4. 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
5. 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.
6. How many conductors will be required on each bridge run? How many for
power? For control? How much current must each conductor carry?
7. What is the maximum travel speed of the bridge? of the hoist?
8. 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
5. 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.
6. 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
5. 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.
6. What type of equipment will be tested.
7. Give weight of units to be supported by the system.
8. What amperage range and what fusing arrangements will be required.?
For Production Machines
5. Plan view sketch with dimensions showing the location of the Feedrail®
6. Indicate the number of conductors required and give voltage and amperage
requirements of each. Give horsepower and full load current rating of each
7. List any other equipment that will be powered by the Feedrail and give
its full load current rating.
For Special Requirements
5. 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.
6. Full details about equipment which will be operated from the system,
(a) Horsepower and full-load current rating of any electrical motors
(b) Weight of any equipment to be supported by the system.
(c) Fusing arrangements required.
(d) Number of outlets needed.
Working out the details of a Feedrail® system installation is not difficult
once all the electrical and mechanical requirements have been definitely
straight track sections (1), making sure plastic polarizing strips (2) of
both sections are on the same side. Back off the 8 set screws (3) in terminal
block (4). Slip terminal block connectors (5) on to bus bars (6). Tighten
set screws (3) to bus bars. Insert bus bars (6) into terminal block (4),
bringing track casings together and tighten set screws (3).
the 2 halves of the coupling plate (7) and hook them to the bottom of the
track housing and swing up so the holes are placed over the dimples (8)
on the track housing. Hold the coupling plate (7) and insert screws (9)
to fasten them together (Do not tighten all the way).
screws (9) on coupling plate. Place cover plate (10) onto coupling plate
(7), and insert screws (11) and tighten. The joining of sections is complete.
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.
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.
cover plate (1) onto coupling plate (2). Insert screws (3) on coupling and
the installation of dead end cap is completed.
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.
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).
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 (1) keeping the system dry and clean to
prevent electrical leakage or "shorts" across the insulation, and (2) maintaining
electrical continuity by keeping bus bar contact surfaces clean and joints
Mechanical Maintenance requires (1) preventing excessive wear and (2) replacing
parts showing excessive wear.
The following Preventive Maintenance procedure, periodically performed,
(a) 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.
(b) Clean bus bars with Feedrail® Bus Bar Cleaner.
(c) Blow out all foreign particles which have accumulated inside the track.
(d) Check trolleys for free movement within the track.
(e) 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®
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.