Feedrail FR100 Series Trolley Service

FR100 Trolley Series (Feedrail^® “100”) — What It Is and What It Does

Feedrail® “100” is the modern flexible “Trolley Busway System” and “Crane and Hoist Electrification System” for distributing electric power. Basically, it is an electrified track in which the current carrying components are enclosed in a protective steel housing. Smooth riding internally track-supported trolleys take off current and provide power outlets anywhere along the length of the run.

Superior to ordinary wiring methods in safety, convenience and adaptability, it provides a dependable power source for both stationary and moving equipment. Its uses in industry are myriad — from powering hoists and cranes to providing current for portable electric tools, from the electrification of moving test lines to the control of large machine tools and to supplying the current for electrically driven hangar doors.

The Feedrail® “100” system is made up of standardized units, factory assembled for easy, fool-proof installation in the field. Its basic units include: 

Track sections — straight, curved, door, expansions, sectionalizing and transfer sections — enclosing current carrying bus bars.

Accessories — coupling plates for joining track sections; feed boxes for connection of bus bars to the electric power supply; dead end caps for closing the end of track runs.

Trolleys — available in several types to meet a wide range of requirements including fusible and non-fusible types, with and without receptacles — internally track supported to provide current takeoff wherever desired.

Track sections can be supplied to form runs of any required length or contour. Hence it is “tailored-to-fit” the electric power requirements of industry, whether for modernizing an existing plant or for installation in a plant under construction.

Feedrail® “100” operates with equal safety of any required level from ceiling to floor. While the majority of installations are overhead, numerous low-level installations have been made, including some along the base of production lines. All installations have proven entirely satisfactory in operation.

Designed primarily for indoor service in essentially dry locations.

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Feedrail® “100” Bus Bar Arrangements

Center Bus Bar is Omitted for 2 Pole System

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Design & Construction 2 & 3 Pole Systems

Busway and Crane & Hoist Electrification System For Movable Trolley Service

Current Carrying Capacity

Track rating 100 Amperes (continuous); 150 Amperes (intermittent) Trolleys rated 20, 30, 40, 60 and 100 Amperes (continuous).

Voltage

600 Volts A.C. — 250 Volts D.C. 

Track Supports

Malleable iron clevis type for tie rod. Fits all track accessories. 

Track

Track sections consist of a 13-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. The lower horizontal portions of the housing serve as smooth, rigid runways for the trolleys. 

“100” Track sections are available in various types — Plain, Door, Sectionalizing, Transfer, Curved and Expansion Track Sections. 

Bus bars are of hard drawn copper. They are amply proportioned to carry the specified current of 100 amperes per pole continuously, 150 amperes per pole intermittently, without overheating. Insulators are made of a high insulating and arc-resistant material. They are held in place on 9” centers by the casing. 

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 fusible and non-fusible types. 

Basically, all Feedrail® “100” trolleys have a chassis-insulator-contact assembly. The chassis is heavy gauge steel. The trolley wheels and guide wheels are of the ball bearing type. A substantially proportioned insulator block combines the best insulating properties with high arc-resistance. 

The trolleys for the “100” track system are furnished with various types of contacts. Bronze ROLLER contacts rated 20 Amperes, Copper Graphite BRUSH contacts rated 30 Amperes and Silver Tungsten Brush contacts rated 30 and 100 Amperes. 

All Feedrail® trolleys have a polarizing tab on the chassis, which, operating in conjunction with a stop within the door track, permits insertion of the trolley one way only, thereby maintaining the trolley polarity as first wired. Provision for equipment grounding is included on all trolleys. 

Feedrail® “100” system Roller Contact Trolleys generally are for intermittent movement applications where speeds do not exceed 200 feet per minute. Feedrail® “100” system Brush Contact Trolleys are for more frequent moving application such as on cranes and monorails where speeds do not exceed 350 feet per minute. Where continuous movement is required at these speeds, or where low voltage (under 50 volts) or low current (under 1 Amp.) is required, consult technical service group for recommendations. Weights in excess of 40 pounds per trolley are not recommended.

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Cranes and Hoists

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Installing “100” Track

Feedrail® “100” track, trolleys and accessories are designed for ready installation without field alteration. Any qualified electrician can do the job. No special tools are required.

Installation should begin at a transfer or switch point or at an expansion track section if these are included in a track run. Otherwise, start at the feed box (center feed or end feed) and proceed away from that point.

The following four steps should be performed in the order given:

1. Install hanger rods or other supports to which Feedrail® “100” is to be attached.
   
   
2. Assemble Feedrail® components. The illustrations on the following pages show the step by step procedure. In many cases the assembling of Feedrail® “100” can be facilitated by coupling two or more sections prior to rising into position.
   
   
3. Attach Feedrail® to supports, making sure adjoining track sections are on the same level and in correct alignment before the track connecting bars and bus bars are secured.
   
   
4. Connect electrical supply cables to terminals of feed box.

NOTE: Where Feedrail® equipment has been ordered to the job site in advance of actual installation, the equipment should be carefully stored indoors in a clean, dry area. 

Feedrail® “100” is designed primarily for indoor service in essentially dry locations. 

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Installing Transfer Track

Transfer Track sections are similar to Plain Track sections except that one or both ends are flared and have a tapered insulator serving as a guide for entrance of the trolleys.

On installations having transfer points, (turntables, slide or tongue switches, hangar door tail-gates, etc.) the Transfer Track sections should be installed first so that proper gaps can be set. These gaps between Transfer Track sections should not exceed ¼ inch.

(Transfer Track sections for use on turntables and slide switches, are not stock items but are manufactured specifically to conform to given dimensions.)

Where motor propelled hoists are used on runs which include transfer points, it is necessary to use two electrically interconnected trolleys. The two trolleys must be spaced sufficiently so that current is maintained to one trolley while the other crosses the transfer point. Duplex Transfer Type Trolleys have been designed particularly for this application.

Transfer Track sections at transfer points must be aligned accurately, both horizontally and vertically. They must be supported at the transfer ends by an FR-124 Transfer Point Hanger Set. (Hook bottoms of Transfer Point Hanger Set into slots in the under edges of the track housing. Bring the plates together and fasten to support with bolts as shown). 

In every case the mounting of Transfer Track sections should be designed to insure a rigid installation. They should be sway braced to maintain alignment. 

Sections are installed and coupled to adjoining track sections as shown in Joining Sections With Coupling Plate Set FR-102.

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Building 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 joint.

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 and support at each end from coupling plates and from the center support plates. Center support must be on the same side of the building expansion joint as the side of the expansion section stenciled “STATIONARY.”

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“100” Expansion Track Design Data, Usage and Settings

To determine expansion (or contraction) of system casing (steel) or bus bars (copper):

Expansion = K x ΔT x L
     K= Constant (from table above)
     L= Length (in feet)
     ΔT= Temperature change (°F)

A) A straight run of “100” track has sufficient freedom of movement between copper bus bars and steel casing to accommodate an expansion or contraction of 3/8 inch of the copper bus over and above that of the steel casing. Where a Feedrail® installation will be subjected to a high or low temperature, such that the expansion or contraction of the copper bus bars (from nominal 75 °F) will exceed the steel track casing expansion or contraction by 3/8 inch, an expansion section must be used.

Example: In a 250 foot run of “100” Feedrail® track which will be subjected to a low temperature of 15 °F, the difference in contraction between the copper bus bars and the steel track casing due to the 60 °F. temperature drop from a nominal 75 °F. will be 
     .0000348×250 ft. x 60 °F. temp 
     Difference = .522 inches
 

Since this is in excess of the maximum of 3/8 inch (.375”) permitted, an expansion section must be used in the run. 

B) It is recommended that at least one expansion track section be installed in each 400 ft. of track run, even if only minor temperature fluctuations are expected in the area in which the Feedrail® is installed.

C) Expansion track sections must be used wherever an installation is made across a building expansion joint to prevent the building movement from causing undue stresses on the Feedrail® system.

D) The “100” Expansion joint is normally made to a nominal length of 10'-0'' and is designed to operate within the limits of 9'-10'' to 10'-2'' length of the steel casing. In addition to the above movement permitted by the steel casing, the copper bus bars are permitted 50% additional movement with respect to the casing so that the normal difference in expansion or contraction between the casing and bus bars can be accommodated be the expansion joint.

E) The air temperature at the time of the actual installing of a Feedrail® system will influence the setting of a Feedrail® expansion track section. They should be set in accordance with the table in the Building Expansion Track section directly above this section.

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Elevated Temperature Use Of FR-100 System

Below is a data sheet giving the U/L approved temperature usage of Feedrail® 100 systems and the temperature restrictions based on the properties of the materials used in construction of the equipment. 

The U/L approval does not apply to use in ambients over 40°C (104°F.)

ELEVATED TEMPERATURE USE- RESTRICTIONS
Feedrail® FR-100 TRACK SYSTEM
RATED AMP CONTINUOUS- 150 AMP. INTERMITTANT

Feedrail® “100” is listed for its continuous ampacity rating by the Underwriters' Laboratories based on a maximum temperature rise of the bus bars of 54°F (30°C) above 104°F (40°C) ambient temperature. In order that its maximum life under continuous operating conditions might be realized, operation at elevated ambients require operation at lower ampacity as follows:

In the event that the Feedrail® “100” equipment is subject to higher ambient temperature, the following information as to its operating life is offered as a guide:

A) “Rated life” based on insulation life vs. temperature is considered in excess of 100,000 hours (11.4 years) of service at rated Ampacity. (Not applicable to wearing parts such as trolley wheels and contacts).

B) Increasing the system temperature, either by increasing the ambient or the heating effect of the current through the bus bars, will shorten the life of the system by the following estimated amount:

The “100” system should not be operated so as to have any part reach 250°F (121°C). Consult factory for other conditions.

C) Factors which often accompany increased ambients (fumes, corrosion, etc.) contribute to the reduction of the service life of the equipment, often to a greater extent than temperature increases

D) Trolleys used in ambients over 104°F (40°C) should have “sealed” wheels and brush contacts, and use wire suitable for the maximum temperature expected.

* Intermittent Duty Cycle Rating based on one minute “ON”, one minute “OFF”. 

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Coupling Sections With Center Feed Box FR-103

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Mounting End Feed Box FR-109

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Mounting Dead End Cap FR-107

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Installing Sectionalizing 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 Sections With Coupling Plate Set FR-102.

NOTE: The standard sections described 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 device.

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Joining Sections With Coupling Plate Set FR-102

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Joining Curved Track Sections

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Inserting Trolleys

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Mounting of Crane and Hoist Type Trolleys

Trolleys for use on Cranes and Hoists (Crane and Hoist Trolleys) are equipped with a pulling bracket with chain linkage. Brackets must be attached to the hoist or crane bridge in such a manner that the chains are on the center line of the track and the bracket is parallel to the track and 2” below the track. Flexible rubber covered cables must be used for electrical connection to each trolley.

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Mounting of Special Service Trolleys

Special Service Trolleys for use on straight track runs are equipped with a pulling bracket with chain linkage. Brackets must be attached to the hoist or crane bridge in such a manner that the chains are on the center line of the track and the bracket is parallel to the track and 3” below the track. Flexible rubber covered cables must be used for electrical connection to each trolley.

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Mounting Dimensions of Trolley Pulling Rackets

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Installation Planning

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 of the Feedrail® “100” system. Will it be used with existing equipment?
2. What is the voltage of the available power source and type of current (A.C. or D.C.)? If A.C., is it single or three phase?
3. 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

4. Sketch giving number, location, length of crane runways and length of bridge. Show location of building expansion joints, if any.
5. How many conductors will be required on each bridge run? — How many for power? — for control? Ho w much current must each conductor carry?
6. What is the maximum travel speed of the bridge? — of the hoist?
7. 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 Moving Test Lines

4. 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.
5. What type of equipment will be tested?
6. Give weight of units to be supported by the system.
7. What amperage range and what fusing arrangements will be required?

For Hanger Doors

4. Sketch with dimensions to show the location and space available for the Feedrail® system. Indicate range of roof deflection due to snow loads, temperature changes, etc.
5. Plan view showing exact sizes and locations of tailgates. Give location of expansion joints, if any, in the upper door guides and in the hangar roof structure. Indicate size and number of doors and pattern of door movements.
6. List the number of conductors required and give voltage and amperage requirement of each. Give horsepower and full load current rating of the motors.

For Electric Hoists

4. Plan view sketch of the rail system on which the hoists will travel, giving length of run 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.
5. 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 Portable Tool and Conveyor Assembly Lines

4. Sketch with dimensions showing the location and space available for the system. Show location of building expansion joint, if any.
5. What type of portable tools will be used, how many, and what is the horsepower and full-load current rating of each?
6. Is each tool to be fused individually? Give weight of any tools to be supported by the system.
7. List any other equipment that will be operated from the Feedrail® system with the horsepower and full-load current rating of each unit.
8. If power for driving any conveyors is also to be taken from the Feedrail® system, what is the horsepower and full-load current rating of each motor?

For Special Requirements

4. Plan view sketch with all dimensions which are necessary to make clear the location and extent of the Feedrail® “100” system and the radii of any curves it may contain. Show the location of the power source.
5. 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.

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Preventive Maintenance

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.
2. Maintaining electrical continuity by keeping bus bar contact surfaces clean and joints tight.

Mechanical maintenance requires:

1. Preventing excessive wear
2. Replacing parts showing excessive wear.

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

1. 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.
   
   
2. Clean bus bars with Feedrail® Bus Bar Cleaner.
   
   
3. Blow out all foreign particles which have accumulated inside the track.
   
   
4. Check trolleys for free movement within the track.
   
   
5. 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 inspection and main– tenance will be required.

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

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Basic Dimensions/Mounting Methods of Feedrail® ‘100’ Assembly

Examples of the methods commonly used for mounting Feedrail® “100” systems track runs are shown. 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.

As an aid in planning mountings, the basic dimensions of the “100” systems are shown. These are offered as a guide only. 

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Typical Specification

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

Genuine Feedrail®
Industrial Products 

The System shall have a voltage rating of 600 Volts A.C. or 250 Volts D.C. (2 pole) (3 pole) and a continuous current carrying capacity of 100 Amperes per Pole: (When used as a Crane and Hoist Electrification System, the System shall be rated at 100 Amperes continuous service and 150 Amperes intermittent service). The full current carrying capacity of the system shall be maintained throughout.

The System shall permit longitudinal movement of the housing 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, as called for on the plans.

Track sections shall be pressed 13 gauge zinc-coated sheet steel enclosures having a continuous slot in the bottom. Rolled or drawn copper bus bars, capable of carrying 100 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. Spring-loaded roller, (or brush) contacts shall be mounted on arc-resistant insulation. When inserted in Feedrail® track, the contacts shall align with the bus bars at all times.

Trolleys shall be mechanically polarized with respect to door track sections. 

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