DYNAFLIGHT STEEL CORD BELT

DYNAFLIGHT STEEL CORD BELT

Custom Designed Means an Ideal 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 rigors of 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 feature available 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 Long Hauls 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 match tension, 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.

DYNAFLIGHT STEEL CORD BELT

Consider These Advantages

High Capacity - High belt speeds and

deep troughing keep materials moving.

Straight Tracking - Belts are pre-

resistance to the effects of combined cutting, gouging and heavy impact. Recommended for 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 with outstanding resistance to the effects of combined cutting, gouging and heavy impacts. Recommended for applications similar to Matchless, but where loading conditions are usually severe.

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

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, coal mine refuse, crushed ores and rock, slag, limestone, potash, salt, sand, aggregates and other 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 increased service life without increasing cover thickness. Service life is approximately 30% greater than Giant depending on severity of the applications running environment.

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 Suited To 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 to maximize belt life. Fenner Dunlop will help you select the cover, which provides the best protection for your belting needs.

High Temperature Service

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

High Impact Service

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

RMA Grade I cover compound with excellent

Premium high temperature cover compound, with excellent resistance to the effects of combined heat and abrasion. Recommended for iron ore pellets and concentrate, hot coke and 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 in elevated temperature environments.

NCB/BC - British Coal specifications MSHA-FFAR, MSHA-SFAR and CSA-FFAR Excellent abrasion resistant cover compounds for mining and industrial applications where MSHA and CSA specifications are required. Recommended for conveying coal, potash, salt and other materials underground. Also recommended for above ground use in coal preparation plants and coal fired steam plants where fire performance is required. The exact belt construction recommendation will be the result of studying the demands of the individual conveyor system. The Fenner Dunlop Engineering Group utilizing the highly advanced Belt Wizard conveyor program will factor in such specifics as impact conditions, conveyor cycle time, pulley diameters and spliceability. Material costs are also considered to make sure Fenner Dunlop DynaFlight Steel Cord Belting is not only the best suited for the application, but is also the most economical for the operation.

Low Temperature Oil Resistant Service

CWOR (-46 C to 93 C / -50 F to 200 F) Outstanding resistance to the very difficult combined effects of cold, abrasion and petroleum products. Recommended for conveying tar sands, bitumen, oil-sprayed coal and similar products.

Fire Performance Service

Fenner Dunlop is able to supply covers, which meet the fire performance requirements of several regulatory authorities: CSA - Canadian Standards Association specifications MSHA - US Department of Labor specifications

DynaFlight Steel Cord Belting Specifications

DynaFlight Belt Style ST 500 ST 630 ST 800 ST 1000 ST 1250 ST 1400 ST 1600 ST 1800 ST 2000 ST 2250 ST 2500 ST 2800 ST 3150 ST 3500 ST 4000 ST 4500 ST 5000 ST 5400
Cover Compound Cover Weight: kg/m_ per mm lbs/ft_ per 1/32 in. 1.15 0.187 1.12 0.182 1.15 0.187 1.15 0.187 1.15 0.187 1.15 0.187 1.32 0.215 1.19 0.194 1.15 0.187

Cord Diameter mm 3.1 3.1 3.6 3.6 4.4 4.4 5.4 5.4 5.4 5.4 6.7 8.6 8.6 8.6 9.3 9.3 10.7 12.4 inches 0.122 0.122 0.142 0.142 0.174 0.174 0.213 0.213 0.213 0.213 0.264 0.339 0.339 0.339 0.367 0.367 0.422 0.488 mm 18.5 15.0 17.3 14.0 15.9 14.3 18.0 16.3 14.0 12.7 15.9 19.6 18.5 17.1 19.2 16.3 18.7 24.9

Cord Pitch inches 0.729 0.591 0.682 0.552 0.626 0.563 0.709 0.642 0.552 0.500 0.626 0.771 0.729 0.673 0.756 0.642 0.737 0.980
Titanium

Carcass Weight kg/m2 5.4 5.8 6.8 7.4 9.2 9.6 11.3 12.0 12.8 13.5 15.9 21.0 21.5 22.4 24.7 27.2 30.2 33.5
Granite

Operating Tension kN/m 75 94 120 150 187 209 240 269 300 336 375 418 471 523 600 672 750 807 piw 430 535 685 860 1070 1195 1370 1535 1720 1920 2140 2390 2690 2985 3440 3840 4280 4605
Sahara

Belt Modulus kN/m 36000 46000 58000 72000 90000 103000 116000 130000 144000 162000 180000 202000 227000 252000 288000 324000 360000 390000
MSHA-FF CSA-FFAR

Minimum Covers mm inches 4 5/32 4 4 4 4 4 5 5 5 5 5 6 6 6 7 7 8 9

CWOR

lb/ft2 1.11 1.19 1.40 1.52 1.89 1.97 2.32 2.46 2.63 2.77 3.26 4.30 4.40 4.59 5.06 5.57 6.19 6.86

piw 206000 259000 329000 411000 514000 576000 658000 740000 822000 925000 1030000 1151000 1295000 1439000 1640000 1850000 2060000 2220000
MSHAFFAR

5/32 5/32 5/32 5/32 5/32 3/16 3/16 3/16 3/16 3/16 1/4 1/4 1/4 9/32 9/32 5/16 11/32

Matchless Plus

Matchless

Sahara SAR

DYNAFLIGHT STEEL CORD BELT

Dynacord Breakers Extend 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.

Transverse flexibility is also influenced by the cord pitch/diameter ratio and cover thickness. Larger cords, smaller pitches and heavier covers all contribute to greater stiffness. Each of these factors is considered when designing a belt. To further enhance the performance of DynaFlight Steel Cord Belting, idler design and spacing should be selected to suite the 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 limit 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 and may cause the belt to bounce on 45degree idlers.

Troughability, Sag and Load Support

DynaFlight Steel Cord Belting with "allrubber" 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.

Minimum Belt Width for Troughing Empty

Belt Style ST 500 ST 630 ST 800 ST 1000 ST 1250 ST 1400 ST 1600 ST 1800 ST 2000 ST 2250 ST 2500 ST 2800 ST 3150 ST 3500 ST 4000 ST 4500 ST 5000 ST 5400 Idler Trough Angle 20 35 45 (inches) (mm) (inches) (mm) (inches) (mm) 24 24 24 24 24 24 24 30 30 30 30 30 30 30 36 36 36 36 610 610 610 610 610 610 610 762 762 762 762 762 762 762 914 914 914 914 24 24 24 24 30 30 30 30 30 30 30 30 36 36 36 36 42 42 610 610 610 610 762 762 762 762 762 914 914 914 914 914 914 914 1067 1067 24 24 30 30 36 36 36 36 36 36 36 36 36 36 42 42 48 48 610 610 762 762 914 914 914 914 914 914 914 914 914 914 1067 1067 1219 1219

DYNAFLIGHT STEEL CORD BELT

Minimum Recommended Pulley Diameters Select The Right Pulley
DynaFlight Steel Cord Belting requires straight-faced, engineered-class pulleys (no crown). The minimum pulley diameters have been chosen to limit cord pressure on the pulley and bending stress in the cords. Reverse bending in a high-tension position requires pulley diameters 6" (150mm) greater than those listed. Pulleys should be rubber lagged to increase pulley life, improve coefficient of friction, and minimize material build-up, which can damage the pulley and the belt.
Belt Style DynaFlight ST 500 DynaFlight ST 630 DynaFlight ST 800 DynaFlight ST 1000 DynaFlight ST 1250 DynaFlight ST 1400 DynaFlight ST 1600 DynaFlight ST 1800 DynaFlight ST 2000 DynaFlight ST 2250 DynaFlight ST 2500 DynaFlight ST 2800 DynaFlight ST 3150 DynaFlight ST 3500 DynaFlight ST 4000 DynaFlight ST 4500 DynaFlight ST 5000 DynaFlight ST 5400 % of Operating Tension Low Tension Snub 81-100 61-80 1-60 (inches) (mm) (inches) (mm) (inches) (mm) (inches) (mm) 24 24 36 36 42 42 48 48 48 48 54 54 54 54 60 66 72 78 610 610 914 914 1067 1067 1219 1219 1219 1219 1372 1372 1372 1372 1524 1676 1829 1981 20 20 30 30 36 36 36 36 36 36 42 42 42 42 48 54 60 66 508 508 762 762 914 914 914 914 914 914 1067 1067 1067 1067 1219 1372 1524 1676 16 16 18 18 20 20 24 24 24 24 36 36 36 36 42 48 54 54 406 406 457 457 508 508 610 610 610 610 914 914 914 914 1067 1219 1372 1372 14 14 16 16 18 18 20 20 20 20 30 30 30 30 36 48 48 48 356 356 406 406 457 457 508 508 508 508 762 762 762 762 914 1067 1219 1219

Belt Condition Monitoring For Peace of Mind

With the emergence of new technologies, Fenner Dunlop Americas continually searches for innovative ways to provide total solutionsbased service programs for the end-user. Fenner Dunlop offers diagnostic and belt scanning/monitoring services that will detect and alert customers of potential belt damage and failure in steel cord belting.

The benefits of installing EyeQ can be enormous. Continuous belt monitoring gives operators much tighter control over finances by enabling them to recognize potential trouble spots and take affirmative action before costly, and in some cases, unnecessary damage occurs.

rEscan Technology
Fenner Dunlops newest business unit, rEscan, provides monitoring systems and services for the detection of early splice failure, cord/strand breaks, cord corrosion and carcass defects in steel cord belting. rEscan monitoring systems use a combination of specially developed software, purpose built hardware and NDT methodologies including; magnetic flux leakage, ultrasonics, laser and inductive methods for the monitoring and detection of conveyor belt defects.

EyeQ, The Intelligent Belt Monitoring System

EyeQ is the most advanced combined rip detection and continuous belt monitoring system in the world. Called EyeQ because it utilizes a sophisticated computer system giving users instant access to information about the conveyor belt condition and works in concert with the conveyors control system to sound an alarm or stop the belt should any significant damage occur. The system is based on the principle of magnetic flux leakage. The EyeQ system uses panels of small diameter steel cord mounted in the belt at a uniform spacing. The belt scanning system can detect when these panels are ripped and can shut the conveyor system down.

Pulsed Digital X-ray Service

Fenner Dunlop performs Pulsed Digital X-ray inspections to visualize and quantify anomalies found in a scan. Clear images displayed in real time at 16, 383 levels of gray allow for close inspection to determine the best course of action. Unlimited x-rays can be done and stored for later comparison. No hazardous chemicals are used.

DYNAFLIGHT STEEL CORD BELT

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 are on 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.

Splicing
DynaFlight Steel Cord Belting is made endless 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 form a strong continuous unit. The pattern of overlap is determined by the cord diameter and pitch. There are three commonly 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 that 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 the space 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 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.

DYNAFLIGHT STEEL CORD BELT

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 sure that 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 pulley is tangent to the top of the troughing idlers, is the most common arrangement. The "Half Trough" position is used where belt tension is high. This position allows for shorter transitions with less potential for spillage, but large lump materials may hit the pulley and cause damage. The following transition distances are expressed as multiples of the belt width. If a specific application will not accommodate these distances, contact Fenner Dunlop Design and Applications personnel for assistance.

Suggested Minimum Transition Distances

Terminal Pulley Position % of Operating Tension 91 - 100 Full Trough 81 - 90 71 - 80 61 - 70 1 - 60 91 - 100 81 - 90 71 - 80 61 - 70 1 - 60 20 3.3(w) 3.0(w) 2.7(w) 2.4(w) 2.3(w) 1.7(w) 1.5(w) 1.4(w) 1.3(w) 1.2(w) Idler Trough Angle w = Belt Width 35 5.5(w) 5.1(w) 4.5(w) 4.1(w) 3.9(w) 2.8(w) 2.6(w) 2.3(w) 2.1(w) 2.0(w) 45 6.7(w) 6.2(w) 5.5(w) 5.0(w) 4.8(w) 3.4(w) 3.1(w) 2.8(w) 2.5(w) 2.4(w)

Half Trough

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.

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DYNAFLIGHT STEEL CORD BELT

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 resplicing, 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

Recommended Take-up Travel

Conveyor Center Distance FT M 500 1000 1500 2500 4500 6500 9500 150 300 450 750 1350 1950 2850 Take-Up Travel % of C-C 0.80 0.70 0.60 0.50 0.40 0.30 0.25

Minimum Take-up Travel 0.25% of C-C

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

02.11.08