Dyna Flight 08

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DYNAFLIGHT

STEEL CORD BELT


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DYNAFLIGHT STEEL CORD BELT

Custom Designed Means anIdeal Match for Your Needs

Fenner Dunlop understands the importance

of reliable conveyor belting operations. We

are the worlds leader in supplying the right

belt to do the best job, whether the belt is

loading coal into a ship or lifting copper ore

from an open pit mine. Every belt we make

is backed by our experience and reputation.

DynaFlight Steel Cord Belting is made to

withstand the toughest applications. These

belts deliver real performance carrying the

roughest loads, over the longest distances,

and at the highest tensions.

DynaFlight is manufactured with specially

designed and coated cables to maximize

adhesion and minimize corrosion. These

features are necessary to withstand the rigorsof heavy duty, bulk material handling.

DynaFlight is ideally suited for high

tension/low-stretch applications such as

overland conveying systems. DynaFlight

Steel Cord Belts are carefully constructed

and pre-tensioned to ensure the best

possible tracking on long hauls of bulk

material.

Dynacord Breakers are a special featureavailable upon request. Dynacord Breakers

provide active rip and penetration protection

and extends belt life.

For additional protection, Fenner Dunlop offers

two highly advanced Electronic Rip Detection

Systems. The Rip Ranger and EyeQ systems will

give you confidence and comfort knowing

your belt line is protected and unexpected

damage will be kept to a minimum

Your Best Investment For LongHauls Of Bulk Material

Quality is at the core of Fenner Dunlops

reliability. Carefully selected raw materials for

DynaFlight Steel Cord Belting are processed

on the most advanced equipment available.

These components are assembled into a

precisely engineered belt which is inspected

at every stage of production to make sure

that there is strict adherence to our stringent

specifications and ISO 9001:2000 certification.

Fenner Dunlop knows that the service you

get from your belt begins with our attention

to precise dimensional tolerances, equal

cord tensioning and the highest quality

materials. This assures a durable finished belt

that tracks straight and is problem-free.

Experience You Can Trust

Conveyor belt recommendations made by

Fenner Dunlop are based on in-depth

technical knowledge of conveyor operations

and belting designs. Fenner Dunlop brings a

century of experience with the benefits of

the latest computer technology to assure

optimum belt design. Cord construction,

cord diameter, cord pitch, cover thickness,

belt style, safety factors and Dynacord

Breakers are carefully selected to matchtension, impact, spliceability, and geometrical

demands of the conveyor system.

Furthermore, Fenner Dunlop gives special

consideration to material costs and load

demands to produce the highest quality belt

at the most economical price. Combine this

with our history of product quality, technical

expertise and hands-on experience and you

can see why we promise that you will have

confidence in DynaFlight

Steel Cord Belting.


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Consider These Advantages

High Capacity- High belt speeds and

deep troughing keep materials moving.

Straight Tracking- Belts are pre-

tensioned during manufacture with

alternating S and Z twists cords.

Minimum Load Disturbance - High tensile

strength means transfer points are reduced

or eliminated and loads are conveyed

smoothly, without surges, over the idlers.

Maximum Impact Resistance - The strength

of steel is combined with the toughness of

highest quality cover compounds.

Unsurpassed Durability- Careful

construction using corrosion resistant

zinc coated cords, tightly adhering cord

bonding rubber, all protected with a hard

wearing cover means extra long belt life

on the job.

Choose The Cover Best SuitedTo Your Operation

Fenner Dunlop covers are engineered to meet

the service requirements of any operation, and

deliver the best possible performance. Each

cover has carefully defined properties, which

make it an outstanding choice for its intended

service. Careful cover selection is essential tomaximize belt life. Fenner Dunlop will help

you select the cover, which provides the best

protection for your belting needs.

High Impact Service

Matchless

(-40 C to 93 C / -40 F to 200 F)

RMA Grade I cover compound with excellent

resistance to the effects of combined cuttin

gouging and heavy impact. Recommended

conveying large-lump ores (iron, copper, and

molybdenum), overburden, traprock, quartz

ores, granite and similar materials.

Matchless Plus

(-46 C to 93 C / -50 F to 200 F)

Premium RMA Grade I cover compound wi

outstanding resistance to the effects of

combined cutting, gouging and heavy impa

Recommended for applications similar to

Matchless, but where loading conditions are

usually severe.

Heavy Duty Abrasive Service

Granite

(-40 C to 93 C / -40 F to 200 F)

RMA Grade II cover compound with

outstanding resistance to heavy continuous

abrasion. Recommended for the majority of

above-ground applications carrying coal, coa

mine refuse, crushed ores and rock, slag,

limestone, potash, salt, sand, aggregates andother abrasive materials.

Titanium (Super Abrasion Resistant)

(-40 C to 93 C / -40 F to 200 F)

Premium RMA Grade II cover abrasion

resistant compound, which provides increas

service life without increasing cover thicknes

Service life is approximately 30% greater tha

Giant depending on severity of the

applications running environment.

High Temperature Service

Sahara

(-40 C to 150 C/ -40 F to 300 F)

Premium high temperature cover compoun

with excellent resistance to the effects of

combined heat and abrasion. Recommende

for iron ore pellets and concentrate, hot cok

and similar materials.4


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Sahara SAR

(-40 C to 150 C/ -40 F to 300 F)Premium high temperature cover compound,that provides superior abrasion resistance inelevated temperature environments.

Low TemperatureOil Resistant Service

CWOR

(-46 C to 93 C / -50 F to 200 F)Outstanding resistance to the very difficultcombined effects of cold, abrasion andpetroleum products. Recommended forconveying tar sands, bitumen, oil-sprayed coaland similar products.

Fire Performance ServiceFenner Dunlop is able to supply covers, whichmeet the fire performance requirements ofseveral regulatory authorities:

CSA- Canadian Standards Associationspecifications

MSHA- US Department of Laborspecifications

NCB/BC - British Coal specifications

MSHA-FFAR, MSHA-SFAR and

CSA-FFAR

Excellent abrasion resistant cover compoundsfor mining and industrial applications whereMSHA and CSA specifications are required.

Recommended for conveying coal, potash,salt and other materials underground. Alsorecommended for above ground use in coalpreparation plants and coal fired steam plantswhere fire performance is required.

The exact belt construction recommendationwill be the result of studying the demands of

the individual conveyor system. The FennerDunlop Engineering Group utilizing the highlyadvanced Belt Wizard conveyor program willfactor in such specifics as impact conditions,conveyor cycle time, pulley diameters andspliceability. Material costs are also consideredto make sure Fenner Dunlop DynaFlight SteelCord Belting is not only the best suited for theapplication, but is also the most economicalfor the operation.

DynaFlight Cord Cord Carcass Operating Belt Minimum

Diameter Pitch Weight Tension Modulus Covers

Belt Style mm inches mm inches kg/m2 lb/ft2 kN/m piw kN/m piw mm inches

ST 500 3.1 0.122 18.5 0.729 5.4 1.11 75 430 36000 206000 4 5/32

ST 630 3.1 0.122 15.0 0.591 5.8 1.19 94 535 46000 259000 4 5/32

ST 800 3.6 0.142 17.3 0.682 6.8 1.40 120 685 58000 329000 4 5/32

ST 1000 3.6 0.142 14.0 0.552 7.4 1.52 150 860 72000 411000 4 5/32

ST 1250 4.4 0.174 15.9 0.626 9.2 1.89 187 1070 90000 514000 4 5/32

ST 1400 4.4 0.174 14.3 0.563 9.6 1.97 209 1195 103000 576000 4 5/32

ST 1600 5.4 0.213 18.0 0.709 11.3 2.32 240 1370 116000 658000 5 3/16

ST 1800 5.4 0.213 16.3 0.642 12.0 2.46 269 1535 130000 740000 5 3/16

ST 2000 5.4 0.213 14.0 0.552 12.8 2.63 300 1720 144000 822000 5 3/16

ST 2250 5.4 0.213 12.7 0.500 13.5 2.77 336 1920 162000 925000 5 3/16ST 2500 6.7 0.264 15.9 0.626 15.9 3.26 375 2140 180000 1030000 5 3/16

ST 2800 8.6 0.339 19.6 0.771 21.0 4.30 418 2390 202000 1151000 6 1/4

ST 3150 8.6 0.339 18.5 0.729 21.5 4.40 471 2690 227000 1295000 6 1/4

ST 3500 8.6 0.339 17.1 0.673 22.4 4.59 523 2985 252000 1439000 6 1/4

ST 4000 9.3 0.367 19.2 0.756 24.7 5.06 600 3440 288000 1640000 7 9/32

ST 4500 9.3 0.367 16.3 0.642 27.2 5.57 672 3840 324000 1850000 7 9/32

ST 5000 10.7 0.422 18.7 0.737 30.2 6.19 750 4280 360000 2060000 8 5/16

ST 5400 12.4 0.488 24.9 0.980 33.5 6.86 807 4605 390000 2220000 9 11/32

DynaFlightSteel Cord Belting Specifications

Cover Compound Matchless Matchless Titanium Granite Sahara Sahara MSHA-FF MSHA- CWORPlus SAR CSA-FFAR FFAR

Cover Weight:

kg/m_ per mm 1.15 1.12 1.15 1.15 1.15 1.15 1.32 1.19 1.15

lbs/ft_ per 1/32 in. 0.187 0.182 0.187 0.187 0.187 0.187 0.215 0.194 0.187


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Dynacord BreakersExtend Belt Life

When a belt gets added abuse because of

severe loading conditions or difficulty in

maintaining good housekeeping, Dynacord

Breakers protect the belt from crushing

impacts or penetration by sharp objects. By

increasing rip and penetration resistance,

Dynacord Breakers pay for themselves in

extended belt life.

Troughability, Sagand Load Support

DynaFlight Steel Cord Belting with "all-

rubber" construction has a high transverse

flexibility and will trough on 45-degree idlers

at widths as narrow as 24" (610mm) for

ST500. Optional Dynacord Breakers add

stiffness to the extent that the minimum belt

width increases to 30" (762mm) with one

breaker or 36" (914mm) with two breakers.

They will also provide added stiffness to belts

on deep trough systems over 60" (1524mm)

wide, which require improved load support.

Transverse flexibility is also influenced by t

cord pitch/diameter ratio and cover

thickness. Larger cords, smaller pitches and

heavier covers all contribute to greater

stiffness. Each of these factors is considerewhen designing a belt.

To further enhance the performance of

DynaFlight Steel Cord Belting, idler design

and spacing should be selected to suite th

following criteria:

1. The gap between idler rolls should not

exceed 15mm to avoid pinching and

wear of the belt at the idler junction.

2. Carry idler spacing should be set to lim

belt sag to 1-1/2% in the case of -8"

lumps and 1% for over 8" lumps. This

avoids increased belt tension due to

excessive flexing and reduces wear due

to load shifting and impact against the

idler. Too much sag will accelerate

bottom cover wear at the belt edges a

may cause the belt to bounce on 45-

degree idlers.

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Idler Trough Angle

20 35 45

(inches) (mm) (inches) (mm) (inches) (mm)

ST 500 24 610 24 610 24 610

ST 630 24 610 24 610 24 610

ST 800 24 610 24 610 30 762

ST 1000 24 610 24 610 30 762

ST 1250 24 610 30 762 36 914

ST 1400 24 610 30 762 36 914

ST 1600 24 610 30 762 36 914

ST 1800 30 762 30 762 36 914

ST 2000 30 762 30 762 36 914

ST 2250 30 762 30 914 36 914

ST 2500 30 762 30 914 36 914

ST 2800 30 762 30 914 36 914

ST 3150 30 762 36 914 36 914

ST 3500 30 762 36 914 36 914

ST 4000 36 914 36 914 42 1067

ST 4500 36 914 36 914 42 1067

ST 5000 36 914 42 1067 48 1219

ST 5400 36 914 42 1067 48 1219

Belt Style

Minimum Belt Width for Troughing Empty


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Select The Right Pulley

DynaFlight Steel Cord Belting requires straight-faced,engineered-class pulleys (no crown).

The minimum pulley diameters have been chosento limit cord pressure on the pulley and bendingstress in the cords.

Reverse bending in a high-tension position requirespulley diameters 6" (150mm) greater than thoselisted.

Pulleys should be rubber lagged to increase pulleylife, improve coefficient of friction, and minimizematerial build-up, which can damage the pulley andthe belt.

% of Operating Tension

81-100 61-80 1-60

(inches) (mm) (inches) (mm) (inches) (mm) (inches) (m

DynaFlight ST 500 24 610 20 508 16 406 14 35

DynaFlight ST 630 24 610 20 508 16 406 14 35

DynaFlight ST 800 36 914 30 762 18 457 16 40

DynaFlight ST 1000 36 914 30 762 18 457 16 40

DynaFlight ST 1250 42 1067 36 914 20 508 18 45

DynaFlight ST 1400 42 1067 36 914 20 508 18 45

DynaFlight ST 1600 48 1219 36 914 24 610 20 50

DynaFlight ST 1800 48 1219 36 914 24 610 20 50

DynaFlight ST 2000 48 1219 36 914 24 610 20 50

DynaFlight ST 2250 48 1219 36 914 24 610 20 50

DynaFlight ST 2500 54 1372 42 1067 36 914 30 76

DynaFlight ST 2800 54 1372 42 1067 36 914 30 76

DynaFlight ST 3150 54 1372 42 1067 36 914 30 76

DynaFlight ST 3500 54 1372 42 1067 36 914 30 76

DynaFlight ST 4000 60 1524 48 1219 42 1067 36 91

DynaFlight ST 4500 66 1676 54 1372 48 1219 48 10

DynaFlight ST 5000 72 1829 60 1524 54 1372 48 12

DynaFlight ST 5400 78 1981 66 1676 54 1372 48 12

Belt StyleLow Tensio

Snub

Minimum Recommended Pulley Diameters

Belt Condition Monitoring ForPeace of Mind

With the emergence of new technologies,Fenner Dunlop Americas continually searchesfor innovative ways to provide total solutions-based service programs for the end-user.Fenner Dunlop offers diagnostic and belt

scanning/monitoring services that will detectand alert customers of potential belt damageand failure in steel cord belting.

EyeQ, The Intelligent BeltMonitoring System

EyeQ is the mostadvanced combined ripdetection andcontinuous beltmonitoring system in theworld. Called EyeQ

because it utilizes asophisticated computer

system giving users instant access to informationabout the conveyor belt condition and works inconcert with the conveyors control system tosound an alarm or stop the belt should anysignificant damage occur. The system is based onthe principle of magnetic flux leakage.

The EyeQ system uses panels of smalldiameter steel cord mounted in the belt at auniform spacing. The belt scanning system candetect when these panels are ripped and can

shut the conveyor system down.

The benefits of installing EyeQ can beenormous. Continuous belt monitoring givesoperators much tighter control over finances byenabling them to recognize potential troublespots and take affirmative action before costly,and in some cases, unnecessary damage occurs.

rEscan Technology

Fenner Dunlops newest business unit, rEscan,provides monitoringsystems and servicesfor the detection ofearly splice failure,cord/strand breaks,cord corrosion andcarcass defects in steel cord belting. rEscanmonitoring systems use a combination ofspecially developed software, purpose builthardware and NDT methodologies including;magnetic flux leakage, ultrasonics, laser and

inductive methods for the monitoring anddetection of conveyor belt defects.

Pulsed Digital X-ray Service

Fenner Dunlop performs Pulsed Digital X-rayinspections to visualize and quantify anomaliesfound in a scan. Clear images displayed inreal time at 16, 383 levels of gray allow forclose inspection to determine the best courseof action. Unlimited x-rays can be done andstored for later comparison. No hazardous

chemicals are used.


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Splicing

DynaFlight Steel Cord Belting is made endles

with a hot vulcanized splice. Curing pressure

must be at least 160 psi. Cords from each end

of the belt are singled and overlapped in a

symmetrical pattern, which unites them to for

a strong continuous unit. The pattern of overla

is determined by the cord diameter and pitch

There are three commonly used splice pattern

1-Step, 2-Step and 3-Step.

Fenner Dunlop recommends DynaFlight Stee

Cord Belting constructions which can be splic

by the simplest (1-step or 2-step) patterns,

whenever possible. High strength belts, (ST450

and greater) must be spliced using the 3-step

method.

Our Splicing and Repair Manual gives full deta

on splicing methods. Ask for copy.

Certified Splicing Program

Value added services continue to make the

difference in winning and maintaining

customer business in a competitive market.

Fenner Dunlop Americas has established a

Certified Splicing Program geared to educate

its distributor network. The Fenner Dunlop

Splice Management Team customizes each

training session to ensure that participants

increase their skill level and knowledge base

in the areas needed to improve their level of

service to their customers.

Highly skilled Certified Splice Technicians areon call to assist and to supply the end-users

with the latest technology, materials and full

endorsement from Fenner Dunlop when

proper procedures, techniques and materials

are used.

One Step Splice Layout

DynaFlight belt designs emphasize maximum spliceability with the simplest possible splice pattern t

finish at the belt edges with full-length cords, without the need for pattern modification.

ST 500 to ST 1800 belts use a 1-step splice pattern. The belts have an even number of cords and th

space between cords in a splice is at least 2.2mm.8


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Two Step Splice Layout

Belts over ST 1800 and up to ST 4000 use a 2-step splice pattern. These belts have an uneven number

of cords with the additional following parameter: (No. of cords minus 1, then divided by 2, is also an

uneven integral number). The minimum space between cords in a splice is 2.4mm.

Three Step Splice Layout

Belts over ST 4000 and up to ST 5500 use a 3-step splice pattern. These belts have an uneven number

of cords with the additional following parameter: (No. of cords minus 2, then divided by 4, is also an

uneven integral number). The minimum space between cords in a splice is 2.6mm.

Belts over ST 5500 are handled on a case by case basis.


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Transition Distances

Transitions occur wherever a belt changes at

a terminal pulley from a flat shape to a

troughed shape, or vice versa. Transitions

force a disproportionate share of the full

width tension to the edges of the belt. If the

share is excessive at the head pulley, where

full width tension is high, the belt edges will

be damaged. At the tail pulley, where full

width tension is low, center buckling may

cause damage to the splice or pinching at

the idler gaps.

These risks may be avoided by making surethat transitions distances are long enough to

avoid sudden changes in belt shape.

Minimum transition distances are affected by

belt tension at the point of transition, trough

angle and the level of the terminal pulley in

relation to the last full-troughing idler.

When belt tension is low the "Full Trough"

position, where the top surface of the pul

is tangent to the top of the troughing idler

is the most common arrangement.

The "Half Trough" position is used where

belt tension is high. This position allows fo

shorter transitions with less potential for

spillage, but large lump materials may hit t

pulley and cause damage.

The following transition distances are

expressed as multiples of the belt width. If

specific application will not accommodate

these distances, contact Fenner Dunlop

Design and Applications personnel for

assistance.


Idler Trough Angle

w = Belt Width

20 35 45

91 - 100 3.3(w) 5.5(w) 6.7(w)

81 - 90 3.0(w) 5.1(w) 6.2(w)

71 - 80 2.7(w) 4.5(w) 5.5(w)

61 - 70 2.4(w) 4.1(w) 5.0(w)

1 - 60 2.3(w) 3.9(w) 4.8(w)

91 - 100 1.7(w) 2.8(w) 3.4(w)

81 - 90 1.5(w) 2.6(w) 3.1(w)

71 - 80 1.4(w) 2.3(w) 2.8(w)

61 - 70 1.3(w) 2.1(w) 2.5(w)

1 - 60 1.2(w) 2.0(w) 2.4(w)

% ofOperatingTension

TerminalPulley

Position

FullTrough

HalfTrough

These minimum transition distances limit edge tension to 130%of rated tension during steady operating conditions and temporary

non-steady conditions such as starting and stopping.

Suggested MinimumTransition Distances

10


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Take-up Travel

DynaFlight Steel Cord Belting will operate

satisfactorily with a take-up travel as small as

0.25% of the conveyor center distance. To

allow this absolute minimum, which will

accommodate 0.05% permanent stretch plus

0.15% elastic elongation plus 0.05% thermal

expansion and contraction, careful attention

must be given to belt slack during

installation, take-up pulley positioning, and

starting and stopping conditions. This

minimum may allow no provisions for re-splicing, if the belt should be accidentally

damaged.

To avoid this possibility, Fenner Dunlop

recommends these allowances:

Take-ups should be automatic, either

counterweighted or wench operated.

When the conveyor center distance is very

long, the total take-up travel requirement

may be split between two separate take-ups,

one automatic and one static


500 150 0.80

1000 300 0.70

1500 450 0.60

2500 750 0.50

4500 1350 0.40

6500 1950 0.30

9500 2850 0.25

Conveyor CenterDistance

FT M

Take-Up Travel% of C-C

Minimum Take-up Travel 0.25% of C-C

Recommended Take-up Travel


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ISO

9001:2000

Certified

To find where you can

purchase DynaFlight

Steel Cord Belt, please visit

www.fennerdunlopamericas.com

or call our sales service

department at:

Mining Sales:

(800) 537-4483

(419) 635-4068

Export and

Steel Cord Sales:

(800) 661-2358

(705) 645-2228 Fenner Dunlop Conveyor Belting Americas

21 Laredo Drive

Scottdale, Georgia 30079-0865

Telephone: (404) 294-5272

Fax: (404) 297-3174

Internet: www.fennerdunlopamericas.com

Fenner Dunlop Americas does provide information, w

and verbal, relative to its products which it considers

accurate and reliable. Such information is offered as a se

only and is not an expression of warranty and Fenner Du

Americas does not assume any liability whatsoever in re

to its use. The buyer of Fenner Dunlop Americas pro

should determine for itself the suitability of such produc

the particular purpose of the buyer or the specific us

which the product will be applied.

Dyna Flight 08

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