Index Page

DYNAFLIGHT ®
STEEL CORD BELT

C O N V E Y O R B E L T I N G A M E R I C A S
Index Page

DYNAFLIGHT STEEL CORD BELT®
C O N V E Y O R B E L T I N G
Custom Designed Means an
Ideal Match for Your Needs
Fenner Dunlop understands the importance
of reliable conveyor belting operations. We
are the world’s 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
Index Page
A M E R I C A S
Your Best Investment For Long
Hauls Of Bulk Material
Quality is at the core of Fenner Dunlop’s
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-
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 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 Impact Service
Matchless™
(45° C t6 95° C/-50° F to 200° F)
RMA Grade I cover compound with excellent
Index Page
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
(-45° C t6 95° 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.
Heavy Duty Abrasive Service
Giant®
(-40° C to 95° 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.
Giant® SAR (Super Abrasion Resistant)
(-40° C to 95° 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.
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 of
combined heat and abrasion. Recommended
for iron ore pellets and concentrate, hot coke
and similar materials.
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DYNAFLIGHT ® STEEL CORD BELT

Sahara™ SAR NCB/BC - British Coal specifications

(-40° C to 150° C/ -40° F to 300° F)
Premium high temperature cover compound, MSHA FFAR, SFAR and CSA FFAR
that provides superior abrasion resistance in
elevated temperature environments. Excellent abrasion resistant cover compounds
for mining and industrial applications where
Low Temperature MSHA and CSA specifications are required.
Oil Resistant Service
Recommended for conveying coal, potash,
MCWOR salt and other materials underground. Also
(-45° C to 95° C/-50° F to 200° F)
recommended for above ground use in coal
Outstanding resistance to the very difficult
preparation plants and coal fired steam plants
combined effects of cold, abrasion and
where fire performance is required.
petroleum products. Recommended for
conveying tar sands, bitumen, oil-sprayed coal
and similar products. The exact belt construction recommendation
will be the result of studying the demands of
Fire Performance Service the individual conveyor system. The Fenner
Dunlop Engineering Group utilizing the highly
Fenner Dunlop is able to supply covers, which advanced Belt Wizard conveyor program will
meet the fire performance requirements of factor in such specifics as impact conditions,
several regulatory authorities: conveyor cycle time, pulley diameters and
spliceability. Material costs are also considered
CSA - Canadian Standards Association
to make sure Fenner Dunlop DynaFlight® Steel
specifications
Cord Belting is not only the best suited for the
MSHA - US Department of Labor application, but is also the most economical
specifications for the operation.

DynaFlight® Steel Cord Belting Specifications

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 3/16
ST 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
Cover Compound Matchless Matchless Giant Giant Sahara Sahara MSHA FF MSHA MCWOR
Plus 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
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DYNAFLIGHT ® STEEL CORD BELT

Dynacord Breakers can also provide a continuous visual display of

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.
Electronic Rip Detection
the belt condition, in real time. Rip detection
panels stop the belt immediately upon
detection of a longitudinal rip and act as a
physical barrier to contain damage between
the panels. EyeQ is the intelligent steel cord
belt monitoring system; an extra pair of eyes
to help you safeguard your belt.
Select The Right Pulley
DynaFlight® Steel Cord Belting requires straight-
faced, engineered-class pulleys (no crown).

The Rip Ranger system incorporates The minimum pulley diameters have been
inductive coils in the belt cover that are chosen to limit cord pressure on the pulley
spaced at regular intervals and monitored by a and bending stress in the cords.
computer control unit for integrity. The
control unit will detect a break and shut the Reverse bending in a high-tension position
conveyor down, should an object penetrate requires pulley diameters 6" (150mm) greater
and rip the belt or break a coil. The potential than those listed.
for widespread and costly damage is
significantly reduced. Pulleys should be rubber lagged to increase
pulley life, improve coefficient of friction, and
EyeQ is the most advanced combined rip minimize material build-up, which can
detection and damage the pulley and the belt.
continuous belt Minimum Recommended Pulley Diameters
monitoring system in % of Operating Tension Low Tension
the world. The EyeQ Belt Style 81-100 61-80 1-60 Snub
(inches) (mm) (inches) (mm) (inches) (mm) (inches) (mm)
name was arrived at ®
DynaFlight ST 500 24 610 20 508 16 406 14 356
because it utilizes a ®
DynaFlight ST 630 24 610 20 508 16 406 14 356
sophisticated ®
DynaFlight ST 800 36 914 30 762 18 457 16 406
®
computer system DynaFlight ST 1000 36 914 30 762 18 457 16 406
®
DynaFlight ST 1250 42 1067 36 914 20 508 18 457
that gives users ®
DynaFlight ST 1400 42 1067 36 914 20 508 18 457
instant access to ®
DynaFlight ST 1600 48 1219 36 914 24 610 20 508
information about ®
DynaFlight ST 1800 48 1219 36 914 24 610 20 508
®
the belt condition. DynaFlight ST 2000 48 1219 36 914 24 610 20 508
®
DynaFlight ST 2250 48 1219 36 914 24 610 20 508
EyeQ works in ®
DynaFlight ST 2500 54 1372 42 1067 36 914 30 762
concert with the ®
DynaFlight ST 2800 54 1372 42 1067 36 914 30 762
conveyor’s control ®
DynaFlight ST 3150 54 1372 42 1067 36 914 30 762
®
system to sound an DynaFlight ST 3500 54 1372 42 1067 36 914 30 762
®
DynaFlight ST 4000 60 1524 48 1219 42 1067 36 914
alarm or stop the ®
DynaFlight ST 4500 66 1676 54 1372 48 1219 48 1067
belt should significant ®
DynaFlight ST 5000 72 1829 60 1524 54 1372 48 1219
damage occur. EyeQ ®
DynaFlight ST 5400 78 1981 66 1676 54 1372 48 1219
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DYNAFLIGHT ® STEEL CORD BELT

Troughability, Sag
and 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 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 45-
degree idlers.

Minimum Belt Width for Troughing Empty

Idler Trough Angle
Belt Style 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
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DYNAFLIGHT ® STEEL CORD BELT

Splicing

DynaFlight® Steel Cord Belting is made Fenner Dunlop recommends DynaFlight®

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.
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.
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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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DYNAFLIGHT ® STEEL CORD BELT

Transition Distances angle and the level of the terminal pulley in

relation to the last full-troughing idler.

Transitions occur wherever a belt changes at When belt tension is low the "Full Trough"
a terminal pulley from a flat shape to a position, where the top surface of the pulley
troughed shape, or vice versa. Transitions is tangent to the top of the troughing idlers,
force a disproportionate share of the full is the most common arrangement.
width tension to the edges of the belt. If the
share is excessive at the head pulley, where
The "Half Trough" position is used where
full width tension is high, the belt edges will
belt tension is high. This position allows for
be damaged. At the tail pulley, where full
shorter transitions with less potential for
width tension is low, center buckling may
spillage, but large lump materials may hit the
cause damage to the splice or pinching at
pulley and cause damage.
the idler gaps.

The following transition distances are

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
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 % of Idler Trough Angle
Pulley Operating w = Belt Width
Position Tension 20° 35° 45°
91 - 100 3.3(w) 5.5(w) 6.7(w)
Full 81 - 90 3.0(w) 5.1(w) 6.2(w)
Trough 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)
Half 81 - 90 1.5(w) 2.6(w) 3.1(w)
Trough 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)
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 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

Recommended Take-up Travel

Conveyor Center
Distance Take-Up Travel
% of C-C
FT M
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
Minimum Take-up Travel 0.25% of C-C
 Index Page

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 Fenner Dunlop Americas does provide information, written
21 Laredo Drive and verbal, relative to its products which it considers to be
accurate and reliable. Such information is offered as a service
Scottdale, Georgia 30079-0865 only and is not an expression of warranty and Fenner Dunlop
Americas does not assume any liability whatsoever in regard
Telephone: (404) 294-5272 to its use. The buyer of Fenner Dunlop Americas’ products
should determine for itself the suitability of such products for
Fax: (404) 297-3174 the particular purpose of the buyer or the specific uses to
Internet: www.fennerdunlopamericas.com which the product will be applied.

09.13.04