FR100 Series (Feedrail® '100') Busway and Crane & Hoist Electrification System for Movable Trolley Service
Track rating 100 Amperes continuous
150 Amperes intermittent
Trolleys rated 20, 30, 40, 60 and 100 Amperes continuous
600 Volts A.C. - 250 Volts D.C.
Made in the U.S.A.
Feedrail® is listed by Underwriter's Laboratories, Inc. (U.L.) under BUSWAYS AND ASSOCIATED FITTINGS (File E11348) rated at 100 amperes continuous service and as a CRANE & HOIST ELECTRIFICATION SYSTEM (File E31188) rated at 100 amperes continuous service and 150 amperes intermittent service (1 minute OFF ¿ 1 minute ON). Feedrail® is also listed by the Canadian Standards Association (C.S.A. under WIREWAYS AND BUSWAYS (File 7907).
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:
1. Track sections - straight, curved, door, expansions, sectionalizing and
transfer sections - enclosing current carrying bus bars.
2. 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.
3. 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
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
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
Designed primarily for indoor service in essentially dry locations.
Malleable iron clevis type for tie rod. Fits all track accessories.
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
"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.
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
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
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
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
Because it eliminates the
dangers and susceptibility to damage inherent in open wiring, and lowers
maintenance costs, Feedrail® "100" is widely used for
powering electric cranes and hoists. As these photos show it is readily
adaptable to all kinds of installations, including those with curves,
switches and transfers.
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.
Install hanger rods or
other supports to which Feedrail® "100" is to be
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.
to supports, making sure adjoining track sections are on the same level
and in correct alignment before the track connecting bars and bus bars
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.
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 1/4 inch.
(Transfer Track sections for use on turntables and slide switches, are not
stock items but are manufactured specifically to conform to given
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
Sections are installed and coupled to adjoining track sections as shown in
Joining Sections With Coupling Plate Set FR-102.
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
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."
Length Settings for Standard 10' Expansion Track
* Distance Represents:
(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 track
"100" Expansion Track Design Data, Usage and
Coefficients of thermal expansion (K) (Inches per foot
per degree F)
To determine expansion (or contraction) of system casing (steel) or bus bars
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 x 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
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.
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.)
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
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
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:
LIFE EXPECTANCY % OF NORMAL
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
* Intermittent Duty Cycle Rating based on one minute "ON", one
Drill out threaded holes in offset ends of bus bars with No. 18 (.169"
Dia.) drill. Couple track sections as shown in 1 and 2 in Joining Sections
With Coupling Plate Set FR-102, lapping ends of adjacent bus bars and
fastening them to the terminal blocks, using screws furnished with the
terminal block. Tighten screws to 15 inch-pound torque.
Hook bottoms of coupling plates into slots in the under edge of the track
housings. Bring the plates together and fasten with bolts as shown.
Remove knockout in top of feed box frame to provide proper size hole for conduit.
Attach feed box frame to coupling plates with the four mounting screws
Mount side covers. When ready to connect to power, remove covers, bring in
conduit through hole in box frame, make connection to the solderless lugs and
replace side covers.
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.
1. Track sections are furnished with two connecting bars
on one end of track housing. Place track
sections end to end so that ends with and without connecting bars are facing.
Bring sections tightly together, lining up the threaded holes in the
connecting bars with the holes in the bottom of the track housing. Tighten
connecting bar fastening screws to 25 inch-pounds torque. Hook bottom of
coupling plates into slots in the under edges of the track housing. Bolt
plates together as shown.
Attach support to coupling plate. (Tie Rod and clevis method of suspending
track is shown.) Connect bus bars, tightening screws to 15 inch-pounds
Slide top of coupling set cover plate into top of opening and press against
track section. A slight downward pressure will seat the cover plate.
For proper assembly of the curved track, the copper bus bar splice plates and
steel track connection bars are required on either the right hand or left
hand end of the curved track section.
Curved track sections are furnished with separate copper bus bar splice
plates and steel track connection bars. They are supplied in a bag strapped
to the track section. The above illustration shows them assembled to the
right hand end of the curved track section.
Before putting the copper bus bar splice plates on to the curved track
section, place the loose insulator (which comes in a cloth bag fastened to
the curved track section) between the curved track end and the first
insulator. (See illustration above).
The below illustrations show to which end the copper bus bar splice plates
and steel track connection bars must be assembled.
If the straight track to be joined to the curved track has this type of end.
The copper bus bar splice plates and steel track connection bars must be
attached to the curved track to form this type of end.
After copper bus bars and steel track casings have been connected, assemble
coupling plate set to track by hooking bottoms of coupling plates into slots
under edges of track casings, bring plates together, insert and tighten
bolts. When complete the joint will look like the above.
If the straight track to be joined to the curved track has the above type of
end, the curved track must have this type of end shown below.
The connection of the straight track to the curved track, as shown above, is
made without the use of the copper bus bar splice plates or the steel track
connection bars. (These are used at the other end of the curved track
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.
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.
For use on Standard and Short Radius Crane and Hoist Type Trolleys without
Receptacles and on Plain Transfer Type Trolleys without Receptacles.
For use on Special Service Trolleys, on Standard and Short Radius Crane and
Hoist Type Trolleys with Receptacles, on Duplex Crane and Hoist Type
Trolleys, on Plain Transfer Type Trolleys with Receptacles and on Duplex
Transfer Type Trolleys.
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
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? How 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 Hangar 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
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,
(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.
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
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 wear.
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® 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
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 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.
Basic Dimensions/Mounting Methods of Feedrail®
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.
The Trolley Busway System
(Crane and Hoist Electrification System) shall be of metal enclosed type with
internally track supported trolleys as manufactured by:
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
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.