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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DYNAFLIGHT STEEL CORD BELT
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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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 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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DYNAFLIGHT STEEL CORD BELT
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.
6
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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DYNAFLIGHT STEEL CORD BELT
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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DYNAFLIGHT STEEL CORD BELT
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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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.
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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.
DYNAFLIGHT STEEL CORD BELT
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
DYNAFLIGHT STEEL CORD BELT
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.