C O N V E Y O R B E L T I N G A M E R I C A S

DYNAFLIGHT ®

STEEL CORD BELT

DYNAFLIGHT® STEEL CORD BELT

Custom Designed Means anIdeal Match for Your Needs

Fenner Dunlop understands the importanceof reliable conveyor belting operations. Weare the world’s leader in supplying the rightbelt to do the best job, whether the belt isloading coal into a ship or lifting copper orefrom an open pit mine. Every belt we makeis backed by our experience and reputation.

DynaFlight® Steel Cord Belting is made towithstand the toughest applications. Thesebelts deliver real performance carrying theroughest loads, over the longest distances,and at the highest tensions.

DynaFlight® is manufactured with speciallydesigned and coated cables to maximizeadhesion and minimize corrosion. Thesefeatures are necessary to withstand the rigorsof heavy duty, bulk material handling.DynaFlight® is ideally suited for hightension/low-stretch applications such asoverland conveying systems. DynaFlight®

Steel Cord Belts are carefully constructedand pre-tensioned to ensure the bestpossible tracking on long hauls of bulkmaterial.

Dynacord Breakers are a special featureavailable upon request. Dynacord Breakersprovide active rip and penetration protectionand extends belt life.

For additional protection, Fenner Dunlop offerstwo highly advanced Electronic Rip DetectionSystems. The Rip Ranger and EyeQ systems willgive you confidence and comfort knowingyour belt line is protected and unexpecteddamage will be kept to a minimum

Your Best Investment For LongHauls Of Bulk Material

Quality is at the core of Fenner Dunlop’sreliability. Carefully selected raw materials forDynaFlight® Steel Cord Belting are processedon the most advanced equipment available.These components are assembled into aprecisely engineered belt which is inspectedat every stage of production to make surethat there is strict adherence to our stringentspecifications and ISO 9001:2000 certification.

Fenner Dunlop knows that the service youget from your belt begins with our attentionto precise dimensional tolerances, equalcord tensioning and the highest qualitymaterials. This assures a durable finished beltthat tracks straight and is problem-free.

Experience You Can Trust

Conveyor belt recommendations made byFenner Dunlop are based on in-depthtechnical knowledge of conveyor operationsand belting designs. Fenner Dunlop brings acentury of experience with the benefits ofthe latest computer technology to assureoptimum belt design. Cord construction,cord diameter, cord pitch, cover thickness,belt style, safety factors and DynacordBreakers are carefully selected to matchtension, impact, spliceability, and geometricaldemands of the conveyor system.Furthermore, Fenner Dunlop gives specialconsideration to material costs and loaddemands to produce the highest quality beltat the most economical price. Combine thiswith our history of product quality, technicalexpertise and hands-on experience and youcan see why we promise that you will haveconfidence in DynaFlight® Steel Cord Belting.

C O N V E Y O R B E L T I N G A M E R I C A S

DYNAFLIGHT® STEEL CORD BELT

Consider These Advantages

■ High Capacity - High belt speeds anddeep troughing keep materials moving.

■ Straight Tracking - Belts are pre-tensioned during manufacture withalternating S and Z twists cords.

■ Minimum Load Disturbance - High tensilestrength means transfer points are reducedor eliminated and loads are conveyedsmoothly, without surges, over the idlers.

■ Maximum Impact Resistance - The strengthof steel is combined with the toughness ofhighest quality cover compounds.

■ Unsurpassed Durability - Carefulconstruction using corrosion resistantzinc coated cords, tightly adhering cordbonding rubber, all protected with a hardwearing cover means extra long belt lifeon the job.

Choose The Cover Best SuitedTo Your Operation

Fenner Dunlop covers are engineered to meetthe service requirements of any operation, anddeliver the best possible performance. Eachcover has carefully defined properties, whichmake it an outstanding choice for its intendedservice. Careful cover selection is essential tomaximize belt life. Fenner Dunlop will helpyou select the cover, which provides the bestprotection for your belting needs.

High Impact Service

Matchless™

(45° C t6 95° C/-50° F to 200° F)

RMA Grade I cover compound with excellent

resistance to the effects of combined cutting,gouging and heavy impact. Recommended forconveying large-lump ores (iron, copper, andmolybdenum), overburden, traprock, quartzores, granite and similar materials.

Matchless™ Plus

(-45° C t6 95° C/-50° F to 200° F)

Premium RMA Grade I cover compound withoutstanding resistance to the effects ofcombined cutting, gouging and heavy impacts.Recommended for applications similar toMatchless, but where loading conditions areusually severe.

Heavy Duty Abrasive Service

Giant®

(-40° C to 95° C/-40° F to 200° F)

RMA Grade II cover compound withoutstanding resistance to heavy continuousabrasion. Recommended for the majority ofabove-ground applications carrying coal, coalmine refuse, crushed ores and rock, slag,limestone, potash, salt, sand, aggregates andother abrasive materials.

Giant® SAR (Super Abrasion Resistant)

(-40° C to 95° C/-40° F to 200° F)

Premium RMA Grade II cover abrasionresistant compound, which provides increasedservice life without increasing cover thickness.Service life is approximately 30% greater thanGiant depending on severity of theapplications running environment.

High Temperature Service

Sahara™

(-40° C to 150° C/ -40° F to 300° F)

Premium high temperature cover compound,with excellent resistance to the effects ofcombined heat and abrasion. Recommendedfor iron ore pellets and concentrate, hot cokeand similar materials.

DYNAFLIGHT® STEEL CORD BELT

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 Temperature Oil Resistant Service

MCWOR(-45° C to 95° 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 Service

Fenner 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, 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 ofthe 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 inchesST 500 3.1 0.122 18.5 0.729 5.4 1.11 75 430 36000 206000 4 5/32ST 630 3.1 0.122 15.0 0.591 5.8 1.19 94 535 46000 259000 4 5/32ST 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 5/32ST 1250 4.4 0.174 15.9 0.626 9.2 1.89 187 1070 90000 514000 4 5/32ST 1400 4.4 0.174 14.3 0.563 9.6 1.97 209 1195 103000 576000 4 5/32ST 1600 5.4 0.213 18.0 0.709 11.3 2.32 240 1370 116000 658000 5 3/16ST 1800 5.4 0.213 16.3 0.642 12.0 2.46 269 1535 130000 740000 5 3/16ST 2000 5.4 0.213 14.0 0.552 12.8 2.63 300 1720 144000 822000 5 3/16ST 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 3/16ST 2800 8.6 0.339 19.6 0.771 21.0 4.30 418 2390 202000 1151000 6 1/4ST 3150 8.6 0.339 18.5 0.729 21.5 4.40 471 2690 227000 1295000 6 1/4ST 3500 8.6 0.339 17.1 0.673 22.4 4.59 523 2985 252000 1439000 6 1/4ST 4000 9.3 0.367 19.2 0.756 24.7 5.06 600 3440 288000 1640000 7 9/32ST 4500 9.3 0.367 16.3 0.642 27.2 5.57 672 3840 324000 1850000 7 9/32ST 5000 10.7 0.422 18.7 0.737 30.2 6.19 750 4280 360000 2060000 8 5/16ST 5400 12.4 0.488 24.9 0.980 33.5 6.86 807 4605 390000 2220000 9 11/32

DynaFlight® Steel Cord Belting Specifications

Cover Compound Matchless Matchless Giant Giant Sahara Sahara MSHA FF MSHA MCWORPlus SAR SAR CSA C CSA C FFAR FFAR

Cover Weight:

kg/m_ per mm1.15 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

DYNAFLIGHT® STEEL CORD BELT

Dynacord Breakers Extend Belt Life

When a belt gets added abuse because ofsevere loading conditions or difficulty inmaintaining good housekeeping, DynacordBreakers protect the belt from crushingimpacts or penetration by sharp objects. Byincreasing rip and penetration resistance,Dynacord Breakers pay for themselves inextended belt life.

Electronic Rip Detection

The Rip Ranger system incorporatesinductive coils in the belt cover that arespaced at regular intervals and monitored by acomputer control unit for integrity. Thecontrol unit will detect a break and shut theconveyor down, should an object penetrateand rip the belt or break a coil. The potentialfor widespread and costly damage issignificantly reduced.

EyeQ is the most advanced combined ripdetection andcontinuous beltmonitoring system inthe world. The EyeQname was arrived atbecause it utilizes asophisticatedcomputer systemthat gives usersinstant access toinformation aboutthe belt condition.EyeQ works inconcert with theconveyor’s controlsystem to sound analarm or stop thebelt should significantdamage occur. EyeQ

can also provide a continuous visual display ofthe belt condition, in real time. Rip detectionpanels stop the belt immediately upondetection of a longitudinal rip and act as aphysical barrier to contain damage betweenthe panels. EyeQ is the intelligent steel cordbelt monitoring system; an extra pair of eyesto help you safeguard your belt.

Select The Right Pulley

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

The minimum pulley diameters have beenchosen to limit cord pressure on the pulleyand bending stress in the cords.

Reverse bending in a high-tension positionrequires pulley diameters 6" (150mm) greaterthan those listed.

Pulleys should be rubber lagged to increasepulley life, improve coefficient of friction, andminimize material build-up, which candamage the pulley and the belt.

% of Operating Tension81-100 61-80 1-60

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

DynaFlight® ST 500 24 610 20 508 16 406 14 356DynaFlight® ST 630 24 610 20 508 16 406 14 356DynaFlight® ST 800 36 914 30 762 18 457 16 406DynaFlight® ST 1000 36 914 30 762 18 457 16 406DynaFlight® ST 1250 42 1067 36 914 20 508 18 457DynaFlight® ST 1400 42 1067 36 914 20 508 18 457DynaFlight® ST 1600 48 1219 36 914 24 610 20 508DynaFlight® ST 1800 48 1219 36 914 24 610 20 508DynaFlight® ST 2000 48 1219 36 914 24 610 20 508DynaFlight® ST 2250 48 1219 36 914 24 610 20 508DynaFlight® ST 2500 54 1372 42 1067 36 914 30 762DynaFlight® ST 2800 54 1372 42 1067 36 914 30 762DynaFlight® ST 3150 54 1372 42 1067 36 914 30 762DynaFlight® ST 3500 54 1372 42 1067 36 914 30 762DynaFlight® ST 4000 60 1524 48 1219 42 1067 36 914DynaFlight® ST 4500 66 1676 54 1372 48 1219 48 1067DynaFlight® ST 5000 72 1829 60 1524 54 1372 48 1219DynaFlight® ST 5400 78 1981 66 1676 54 1372 48 1219

Belt StyleLow Tension

Snub

Minimum Recommended Pulley Diameters

DYNAFLIGHT® STEEL CORD BELT

Troughability, Sag and Load Support

DynaFlight® Steel Cord Belting with "all-rubber" construction has a high transverseflexibility and will trough on 45-degree idlersat widths as narrow as 24" (610mm) forST500. Optional Dynacord Breakers addstiffness to the extent that the minimum beltwidth increases to 30" (762mm) with onebreaker or 36" (914mm) with two breakers.They will also provide added stiffness to beltson deep trough systems over 60" (1524mm)wide, which require improved load support.

Transverse flexibility is also influenced by thecord pitch/diameter ratio and coverthickness. Larger cords, smaller pitches andheavier covers all contribute to greaterstiffness. Each of these factors is consideredwhen designing a belt.

To further enhance the performance ofDynaFlight® Steel Cord Belting, idler designand spacing should be selected to suite thefollowing criteria:

1. The gap between idler rolls should notexceed 15mm to avoid pinching andwear of the belt at the idler junction.

2. Carry idler spacing should be set to limitbelt sag to 1-1/2% in the case of -8"lumps and 1% for over 8" lumps. Thisavoids increased belt tension due toexcessive flexing and reduces wear dueto load shifting and impact against theidler. Too much sag will acceleratebottom cover wear at the belt edges andmay cause the belt to bounce on 45-degree idlers.

Idler Trough Angle20° 35° 45°

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

ST 500 24 610 24 610 24 610ST 630 24 610 24 610 24 610ST 800 24 610 24 610 30 762ST 1000 24 610 24 610 30 762ST 1250 24 610 30 762 36 914ST 1400 24 610 30 762 36 914ST 1600 24 610 30 762 36 914ST 1800 30 762 30 762 36 914ST 2000 30 762 30 762 36 914ST 2250 30 762 30 914 36 914ST 2500 30 762 30 914 36 914ST 2800 30 762 30 914 36 914

ST 3150 30 762 36 914 36 914ST 3500 30 762 36 914 36 914ST 4000 36 914 36 914 42 1067ST 4500 36 914 36 914 42 1067ST 5000 36 914 42 1067 48 1219ST 5400 36 914 42 1067 48 1219

Belt Style

Minimum Belt Width for Troughing Empty

DYNAFLIGHT® STEEL CORD BELT

Splicing

DynaFlight® Steel Cord Belting is madeendless with a hot vulcanized splice. Curingpressure must be at least 160 psi. Cords fromeach end of the belt are singled andoverlapped in a symmetrical pattern, whichunites them to form a strong continuousunit. The pattern of overlap is determined bythe cord diameter and pitch. There are threecommonly used splice patterns, 1-Step, 2-Step and 3-Step.

Fenner Dunlop recommends DynaFlight®

Steel Cord Belting constructions which can

be spliced by the simplest (1-step or 2-step)

patterns, whenever possible. High strength

belts, (ST4500 and greater) must be spliced

using the 3-step method.

Our Splicing and Repair Manual gives full

details on splicing methods. Ask for copy.

One Step Splice Layout

• DynaFlight® belt designs emphasize maximum spliceability with the simplest possible splice pattern thatfinish 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 thespace between cords in a splice is at least 2.2mm.

DYNAFLIGHT® STEEL CORD BELT

Two Step Splice Layout

• Belts over ST 1800 and up to ST 4000 use a 2-step splice pattern. These belts have an uneven numberof cords with the additional following parameter: (No. of cords minus 1, then divided by 2, is also anuneven 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 numberof cords with the additional following parameter: (No. of cords minus 2, then divided by 4, is also anuneven 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.

Transition Distances

Transitions occur wherever a belt changes ata terminal pulley from a flat shape to atroughed shape, or vice versa. Transitionsforce a disproportionate share of the fullwidth tension to the edges of the belt. If theshare is excessive at the head pulley, wherefull width tension is high, the belt edges willbe damaged. At the tail pulley, where fullwidth tension is low, center buckling maycause damage to the splice or pinching atthe idler gaps.

These risks may be avoided by making surethat transitions distances are long enough toavoid sudden changes in belt shape.Minimum transition distances are affected bybelt tension at the point of transition, trough

angle and the level of the terminal pulley inrelation to the last full-troughing idler.

When belt tension is low the "Full Trough"position, where the top surface of the pulleyis tangent to the top of the troughing idlers,is the most common arrangement.

The "Half Trough" position is used wherebelt tension is high. This position allows forshorter transitions with less potential forspillage, but large lump materials may hit thepulley and cause damage.

The following transition distances areexpressed as multiples of the belt width. If aspecific application will not accommodatethese distances, contact Fenner DunlopDesign and Applications personnel forassistance.

DYNAFLIGHT® STEEL CORD BELT

Idler Trough Anglew = 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

Full Trough

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 Minimum Transition Distances

Take-up Travel

DynaFlight® Steel Cord Belting will operatesatisfactorily with a take-up travel as small as0.25% of the conveyor center distance. Toallow this absolute minimum, which willaccommodate 0.05% permanent stretch plus0.15% elastic elongation plus 0.05% thermalexpansion and contraction, careful attentionmust be given to belt slack duringinstallation, take-up pulley positioning, andstarting and stopping conditions. Thisminimum may allow no provisions for re-splicing, if the belt should be accidentallydamaged.

To avoid this possibility, Fenner Dunloprecommends these allowances:

Take-ups should be automatic, eithercounterweighted or wench operated.

When the conveyor center distance is verylong, the total take-up travel requirementmay be split between two separate take-ups,one automatic and one static

DYNAFLIGHT® STEEL CORD BELT

500 150 0.801000 300 0.701500 450 0.602500 750 0.504500 1350 0.406500 1950 0.309500 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

ISO 9001:2000 Certified

To find where you canpurchase DynaFlight® SteelCord Belt, please visit www.fennerdunlopamericas.com or call our sales servicedepartment at:

Mining Sales:

(800) 537-4483

(419) 635-4068

Export and

Steel Cord Sales:

(800) 661-2358

(705) 645-2228 Fenner Dunlop Conveyor Belting Americas21 Laredo DriveScottdale, Georgia 30079-0865

Telephone: (404) 294-5272Fax: (404) 297-3174Internet: www.fennerdunlopamericas.com

09.13.04

Fenner Dunlop Americas does provide information, written

and verbal, relative to its products which it considers to be

accurate and reliable. Such information is offered as a service

only and is not an expression of warranty and Fenner Dunlop

Americas does not assume any liability whatsoever in regard

to its use. The buyer of Fenner Dunlop Americas’ products

should determine for itself the suitability of such products for

the particular purpose of the buyer or the specific uses to

which the product will be applied.