Heavy Duty Crane & Hoist Electrification Systems for Movable Trolley Service|
Current Carrying capacity
No. FH2100 225 amperes (continuous); 300 amperes (intermittent). Trolleys rated 225 amperes
No. FH3100 375 amperes (continuous); 425 amperes (intermittent). Trolleys rated 375 amperes
No. FH5100 500 amperes (continuous); 575 amperes (intermittent). Trolleys rated 500 amperes
600 volts A.C. - 250 volts D.C.
Supports are of heavy gauge steel. Two supports are required for each track section
to provide support every five feet.
Track sections consist of a brake pressed one-piece 13-gauge zinc coated steel
housing and the enclosed current carrying bus bars and insulators, all factory
assembeld in convenient lengths ready for easy fool-proof instalation on the job.
The lower horizontal portions of the housing serve as smooth, rigid runways for
Heavy Duty track sections are available in various types - Plain, Door, Sectionalizing,
and Expansion track sections.
Bus Bars are of hard drawn copper. They are amply proprotioned to carry the specified
current or 225 / 375 / 500 amperes per pole continuously, or 300 / 500 / 575 amperes
per pole intermittently, without over-heating.
Bus bar connectors assure full current carrying capacity accross the joints without
interferring with the free travel of the trolley contacts.
Insulators are made of a high insulating and arc-resistant material.
Basically, all Feedrail® heavy Duty 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. A substantially proprotioned insulator block combines
the best insulation properties with high arc resistance.
Feedrail® Heavy Duty trolleys are furnished with silver alloy BRUSH CONTACTS for
movement up to 500 feet per minute. For rate of travel or conditions other than
above please consult technical service group.
A polarizing tab on the chassis, operating in conjunctin 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 40 pounds per trolley
are not recommended.
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
Equipment grounding may be made by using the grounding lug within the box. track
housing must be grounded through conduit or other suitable means.
Feedrail® Heavy Duty systems are designed primarily for indoor services 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-supported trolleys take off current and provide electric power for crane
and hoist or other types of electrification systems.
The Feedrail® Heavy Duty systems have been specifically developed to provide safe
electrification for crane bridges, monorail-hoist installations, test lines, machine
tools and similar applications.
The Feedrail® Heavy Duty Systems are made up of standardized units, factory assembled
for fast, complete installation without on-site fabrications.
Heavy Duty Feedrail® systems find new applications daily wherever convenient
movable power sources of 225, 375 or 500 amperes are needed. There is virtually
no limit to thier use. A few applications are illustrated here.
Furniture Photographic Studios
Overhaed Travelling Cranes
Welding Transformers on Welding Cranes
Sections with Coupling Plate
|1. Track sections must be placed so that the diamond match marks
are on the same side. Fasten the two steel connection bars to the
inside of the lower channel-shaped groove of the track housing so
that the bars extend halfway out.
||2. Bring the ends of the adjoining track sections together in horizontal
and vertical alignment. Attach track connection bars.
Fasten the copper splice bars across the bus bar joints with the
hex head locking screw as shown. (Use only locking screws
Hook bottoms of coupling plates into slots under edge of the track
housing. Hold plates in position, put cover in place and fasten.
|Mounting Reversible End Feed Box
|1. Bolt positive pressure type solderless terminals to bus bars. Lugs
should be up if power is to be brought in from top; down if
brought in from the bottom.|
|2. Hook side plates into slots under edges of track housing. Attach
end feed box frame to side plates so that conduit hole is at top or
bottom to match position at which power will be brought in.
|3. Connect power source to terminals. (Power supply cables should
not put strain on terminals.) Fasten cover to end feed box.
|Mounting Dead End
|1. Hook dead end cap side plates into slots under edges of track
housing. Hold plates in position and fasten end cap in place.
Mount top cover.|
|Coupling Sections with Center Feed Box
|1. Join track as shown in steps 1 and 2 in Joining Straight Sections with Coupling Plate. Attach positive
type solderless terminals to bus bars.|
|2. Hook bottom of feed box side plates into slots under edges of
track housing. Place center feed box frame in place and attach to
the side plates.
|3. Connect power source to terminals. (Power supply cables should
not put strain on terminals.) Mount the two cover plates to the center
feed box frame.
|1. Assemble two piece hanger set over the track section and attach
to mounting bracket or other support. (Two hanger sets should be
used for each 10 foot track section on approximately 5 foot centers.)|
|Installing Sectionalized Track
|Sectionalizing Track sections are used to electrically isolate parts of a
track run while permitting movement of the trolleys through that portion
of the track.|
All Sectionalizing Track sections are coupled in the same manner as
Plain Track, shown in Joining Straight Sections with Coupling Plate.
Note: The standard sections described in Sectionalizing Track have internal insulators
of a size which do not prevent the interrupting of the current to
the trolley. The current is not only maintained through the trolley but the
circuits on both sides are electrically tied together through the trolley
contacts as the trolley passes the sectionalizing insulator.
Other special sectionalizing track sections which are used in particular
applications do break the current to the trolley. In these cases, two
electrically connected trolleys must be used. They must be spaced
sufficiently apart so that the contacts of one will be on the bus bars
while the contacts of the other are passing the insulator. Unless connected
in this manner, power will not be maintained to the trolley contacts
as they cross the insulators and arcing at the trolley contacts will
occur. Sectionalizing track sections must not be used as a circuit interrupting
|Installing Expansion Track
At least one Expansion Track section should be installed in
each 400 ft. of track run to compensate for the cumulative
differences in expansion and contraction between the steel
casings and copper bus bars. Additional Expansion Track
sections may be required if the installation is subjected to a
wide range of temperature changes.
Expansion Track sections must be used wherever an
installation is made across a building or structural expansion
The standard 10' Expansion Track section is designed to
provide 2" of expansion and 2" of contraction above and
below the normal 10' length, at 75°F. At the time of installation,
the length of the Expansion Track section must be set
in accordance with the table below.
When used at points other than a building or structural
expansion joint to compensate for unequal expansion or
contraction between the steel track housing and copper
bus bars, support the Expansion Track section by the coupling
plates at each end and by the center support plates
from suitable support brackets. When used across a building
expansion joint, center the Expansion Track section
across the building expansion joint.
Settings for Standard 10' Expansion Track
in Feet *
(1) Footage between expansion track sections on installation having
more than one expansion track section.
(2) Overall length of run on installation having only one expansion
|Mounting of Heavy Duty Trolleys
|(1) Press latch pins on bottom of door track section together
and open doors.
(2) Insert trolley. If trolley hits polarizing stop, remove, reverse
180° and reinsert. Close track doors.
(3) Mount drive bracket in a horizontal plane as shown below.
Chains must be parallel with and on the center line of the
When wiring trolleys, a looped flexible wire cable should be
used (not rigid or flexible conduit). The flexible cable should
be attached to the trolley so no strain is placed on the trolley
by the cable. Trolleys should be allowed to travel freely in the
225 Amp. Trolley
|Before a Feedrail® Heavy Duty 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
Basic for All
1. Describe in detail the purpose of the
Feedrail® Heavy Duty System. 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,
NOTE: Basic dimensions of the Feedrail
Heavy Duty System and various methods
of mounting and supporting the system
are given on page 82 and 84.
For Electric Cranes
5. Sketch giving number, location, length
of crane runways and length of bridge.
Show location of building expansion
joints, if any.
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
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 crane rail 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 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
requirement of each. Give horsepower
and full load current rating of
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
Heavy Duty. Show the location of the
6. Full details about equipment which
will be operated from the system,
(a) Horsepower and full-load current rating
of any electrical motors.
(c) Fusing arrangements required.
(d) Number of outlets needed.
|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 tight.
Mechanical Maintenance requires
(1) preventing excessive wear and
(2) replacing parts showing excessive
The following Preventive Maintenance
procedure, periodically performed is
(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® Track
(c) Blow out all foreign particles which
have accumulated inside the track.
(d) Check trolleys for free movement
within the track.
(2) Check all track supports, track joints,
bus bar and feed connections for
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 inspection and
maintenance will be required.
Before additional electrical loads are
added to the system it should be determined
that sufficient capacity is available.
|FH Series (Feedrail® HD) – Basic Dimensions/Mounting Methods
Basic Dimensions of Feedrail
Heavy Duty Systems
The following are the basic dimensions of the Heavy Duty
Feedrail® System. These are offered as a guide only.
Examples of the methods commonly used for mounting Feedrail® Heavy Duty Systems
track runs are 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.
Rod or strap supports should not exceed 2 feet in length without sway bracing.
No. FH2100 Shown
Click Image for full view.