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1 INDUSTRIAL IAL PRODUCTS C O N S T A N T L Y M O V I N G F O R W A R D

2 SALES SINCE 1932 SERVICE Epperson & Company Conveyor Equipment & Services TM INDUSTRIES SALES SINCE 1932 SERVICE SALES Epperson & Company Conveyor Equipment & Services SINCE 1932 SERVICE Epperson & Company Conveyor Equipment & Services Corporate Office Pittsburgh, PA USA Manufacturing Plant Lavonia, GA USA Manufacturing Plant Port Clinton, OH USA Manufacturing Plant Toledo, OH Canada Manufacturing Plant Bracebridge, ON Fenner Dunlop Engineered Conveyor Solutions manufactures a full range of conveyor belts that consistently outperform the competition in rigorous above-ground industrial applications. With over 150 years of manufacturing experience, four ISO 9001 certified manufacturing facilities, and top-of-the-line service capabilities, Fenner Dunlop ECS delivers measurable, sustainable results in the field, day in and day out. Fenner Dunlop ECS produces the highest quality fabric and steel cord conveyor belts for industrial applications. At Fenner Dunlop, we hold quality control in the highest regard. We ensure the integrity of our conveyor belt manufacturing by Fenner Dunlop s premier distribution network. For instructions on contacting your local distributor, see the back cover. LEGEND carefully monitoring each step of the production process. This starts with our unique state-of-the-art fabric weaving facility in Lavonia, GA. Production is then passed on to our conveyor belt manufacturing plants in Toledo, OH, Port Clinton, OH, and Bracebridge, Ontario. Focused attention is given to each belting order to ensure that the materials and processes used to produce a belt will assist the end-user in reducing costs, maximizing uptime, and improving revenue. Fenner Dunlop ECS and its nationwide distribution network offer belting solutions for all of your industrial needs. By conducting extensive research and development based on local markets, Fenner Dunlop and its distributor network provide a comprehensive product line well suited for conveying aggregates, cement, heavy ores, forest products, scrap metal, grain, oil sands, and precious metals. No matter how rigorous the application, Fenner Dunlop will design, produce, and install a customized total engineered conveyor solution. 2 T CSD N ETWORK

3 Table of Contents C A R C A S S C O N S T R U C T I O N 4-19 UsFlex and Super UsFlex 4 KordFlex 6 NovaCore 8 PSR 10 RockMaster 14 DynaFlight 16 Patriot 18 C O M P O U N D S P R O D U C T S B Y M A R K E T Aggregates 24 Precious Metals 26 Cement Plants, Steel Mills, Foundries, Potash 28 Oil Sands 32 Wood, Pulp, & Paper Products 34 Log Handling 35 Power Generation 36 Grain 37 Specialty 38 E C S P R O D U C T S Diagnostic 40 Cleaners 46 Idlers 48 Vulcanized Splicing 49 Mechanical Splicing 50 Belt Wizard 51 3

4 C A R C A S S C O N S T R U C T I O N UsFlex and Super UsFlex - Premium Carcass Our premium, longest-lasting fabric belts UsFlex is a revolutionary concept in straightwarp conveyor belts. Choose either the Single Unit S Series or Double Unit D Series for Outstanding carcass style and tension rating. Our high performance manufacturing specs meet the needs of your toughest applications. Fill Binder Warp Basic Straight Warp Features and Benefits UsFlex is different from the competition. We use heavyweight straight yarns in parallel planes lengthwise and crosswise locked together with a unique binder to concentrate belt strength. No traditional crimp-weave in plain or crows-feet patterns here. Our parallel planes reinforce like the multiple plies of old-fashioned belts but without the crimping that weakens and stretches the yarn. And our binder is a built-in breaker to resist impacts and punctures. Choose UsFlex for best value Get longer belt life in tough service Greater cost savings per ton conveyed Greater rip, tear and impact resistance High strength Excellent load support, troughability, and tracking Increased insurance against belt damage Impact resistance up to three times greater than traditional plied belt construction Longitudinal rip resistance more than five times equivalent-rated multi-ply belts Straight-warp Construction Super UsFlex is the toughest version of the UsFlex line. The series is a safer, more reliable and lower cost alternative for steel cord. UsFlex Tension Ratings Series S2 = 245 PIW Series S3 = 330 PIW Series S4 =Binder 440 PIW Warp Fill Series S5 = 550 PIW Series D6 = 660 PIW Series D8 = 800 PIW Series D10 = 1000 PIW Series Basic D12Straight = 1250Warp PIW Series D15 = 1500 PIW Key Features 4 Greater rip, tear and impact resistance Highest strength Excellent load support, troughability and tracking Longer rolls than steel cord for fewer splices Super UsFlex Tension Ratings Series D 18 = 1800 PIW Series D 20 = 2000 PIW

5 UsFlex SPECIFICATION TABLE - IMPERIAL GENERAL DATA GENERAL DATA Carcass Style Number of Plies Carcass Gauge3 (in) Carcass Weight4 (lb/in/v) ElasWc Modulus (lbs/in) UsFlex S2 UsFlex S UsFlex S Super UsFlex S5 UsFlex D5 UsFlex D6 UsFlex D8 UsFlex D10 UsFlex D12 UsFlex D15 UsFlex D ,000 CONVEYOR BELT SPECIFICS Max Tension RaWng2 (PIW) Troughing/Empty1 - Min Belt Width (in) 20 degree idlers 35 degree idlers 45 degree idlers Load Support1 Max Belt Width (in) 20 deg idlers 0 40 lbs/v3 20 deg idlers lbs/v3 20 deg idlers lbs/v3 20 deg idlers over 120 lbs/v deg idlers 0 40 lbs/v3 35 deg idlers lbs/v3 35 deg idlers lbs/v3 35 deg idlers over 120 lbs/v deg idlers 0 40 lbs/v3 45 deg idlers lbs/v3 45 deg idlers lbs/v3 45 deg idlers over 120 lbs/v Minimum Pulley Diameters (in) % belt rated tension 61 80% belt rated tension Up to 60% belt rated tension Maximum Tension RaWng (PIW) Grain, Wood Chip Service (50 lb/v3) 195 Industrial Service (100 lbs/v3) Minimum Pulley Diameters (in) % belt rated tension 61 80% belt rated tension Up to 60% belt rated tension Maximum Bucket ProjecWon (in) Centrifugal Elevators ConWnuous Elevators ELEVATOR BELT SPECIFICS 1 Troughibility and Load Support values can be influenced by certain cover gauge and compound combinations used. When in doubt, please contact your FDA representative for selection guidance. 2 UsFlex tension ratings reflect a minimum 10:1 safety factor through the 660 piw offering and an 8:1 minimum safety factor for the remaining higher tension offerings. With the appropriate fastener selection and installation, 4:1 minimum mechanical fastener safety factors can be achieved. 3 Add the appropriate cover gauge to the carcass gauge to obtain the approximate overall belt thickness. 4 Add the appropriate cover weight to the carcass weight to obtain the appropriate overall belt weight. 5

6 C A R C A S S C O N S T R U C T I O N KordFlex - Premium Carcass Our premium Aramid reinforced conveyor belt Revolutionary high-strength Aramid fibers Aramid Aramid a high-strength fiber used in many demanding industrial applications has been called the most important man-made fiber since nylon. Our innovative straight-warp carcass, the KordFlex K series, optimizes tension rating and tear resistance. Our Aramid fibers are engineered to give high strength, light weight and durability in rubber products. Its unique balance of properties makes it ideal for conveyor belts. KordFlex meets your needs in the toughest applications with a 10:1 safety factor. Straight-warp construction Our lengthwise and crosswise belt strength lies in parallel planes of heavyweight, high tenacity straight yarns locked together by a unique binder. Each plane provides the reinforcing effect of multiple plies of conventional fabric without the crimping that weakens yarns and causes stretch. The carcass binder is a built-in breaker that resists impact and puncture. The KordFlex straight warp shown here is Aramid fiber. Fill Binder Warp Basic Straight Warp Tensile Properties of Different Materials Tenacity (mn/tex) TENACITY / ELONGATION 2500 amid eel Polye e Polyamide (Nylon) Elongation (%) 30 Aramid has the highest specific modulus of any conventional non-steel reinforcement. Like steel, Aramid fibers offer high tenacity, low elongation and good thermal stability. But unlike steel, Aramid retains low density, chemical and fatigue resistance, and the positive handling qualities of a synthetic fiber. Aramid has the highest strength-to-weight ratio of all conveyor belt reinforcements more than twice our synthetic fibers (polyester and nylon), and five times that of steel. Aramid fibers have a fatigue resistance under pressure equal to nylon and superior to steel. DynaBreaker l and ll with UsFlex DynaBreaker I and II breaker fabrics are engineered with the properties and characteristics of our premium UsFlex carcass construction. DynaBreaker with UsFlex allows KordFlex belts to be built up to 102 widths. See the UsFlex product page in the Carcass Section for more information.

7 GENERAL DATA Carcass Style KordFlex KordFlex KordFlex KordFlex KordFlex Number of Plies K8 K10 K12 K16 K Carcass Gauge (in) Carcass Weight (lb/in/ft) Elastic Modulus (lbs/in) 21, ,000 CONVEYOR BELT SPECIFICS Max Tension Rating (PIW) Troughing/Empty Min Belt Width (in) 20 degree idlers degree idlers degree idlers Load Support Max Belt Width (in) 20 deg idlers 0 40 lbs/ft deg idlers lbs/ft deg idlers lbs/ft deg idlers over 120 lbs/ft deg idlers 0 40 lbs/ft deg idlers lbs/ft deg idlers lbs/ft deg idlers over 120 lbs/ft deg idlers 0 40 lbs/ft deg idlers lbs/ft deg idlers lbs/ft deg idlers over 120 lbs/ft Minimum Pulley Diameters (in) % belt rated tension % belt rated tension Up to 60% belt rated tension Key Features Longer belt life in tough service Low stretch belt with near steel cord specs for take-up travel Lighter weight for more energy savings/ton Less downtime, faster splicing than steel cord Greater rip, tear and impact resistance Excellent load support, troughability and tracking Longitudinal rip resistance more than five times equivalent multi-ply or steel cord belts KordFlex Tension Ratings Series K8 = 800 PIW 1400 N/mm Series K10 = 1000 PIW 1750 N/mm Series K12 = 1250 PIW 2000 N/mm Series K16 = 1600 PIW 2800 N/mm Series K20 = 2000 PIW 3500 N/mm 7

8 C A R C A S S C O N S T R U C T I O N NovaCore - Select Carcass Convey bulk materials more reliably with this advanced flexible belt core. Crimped-warp polyester yarns provide high strength and low stretch Key Features Excellent resistance to rip, tears, impacts and punctures using a technologically advanced and patented belt fabric design. Binder yarns lock the carcass together Fill yarns strong, stable under load for excellent rip, tear and impact resistance Applications: Mines: Copper, Gold, Limestone, Potash, Salt Power Plants: Coal handling Preparation Plants Rock and Aggregate Mining The unique fabric weave allows for improved mechanical fastener retention and splice life. The smaller gauge of the NovaCore carcass compared to similar tension rated multi-plied fabric belting allows for smaller diameter pulleys throughout the conveyor system as well as superior troughability, tracking and load support. The fabric construction and treatment process result in enhanced resistance to edge ravel, moisture, mildew and acid mine water. Can be used with all Fenner Dunlop cover compounds. Now available with Giant XE, a premium Grade 1 ARPM cover compound with high durability, low extraction, and excellent abrasion resistance. See our Cover Compound section for more details. Available in 300, 400 and 600 PIW constructions 868

9 NovaCore Specification Table - Imperial GENERAL DATA GENERAL DATA Carcass Style NovaCore NovaCore NovaCore F3 F4 F6 Belt Style Number of Plies Carcass Gauge 3 (in) Carcass Weight 4 (lb/in/ft) Elastic Modulus (lbs/in) 0, ,000 40,000 Carcass Safety Factor 10:1 10:1 10:1 CONVEYOR BELT SPECIFICS CONVEYOR BELT SPECIFICS Max Tension Rating 2 (PIW) Troughing/Empty 1 - Min Belt Width (in) 20 degree idlers degree idlers degree idlers Load Support 1 Max Belt Width (in) 20 deg idlers 0 40 lbs/ft deg idlers lbs/ft deg idlers lbs/ft deg idlers over 120 lbs/ft deg idlers 0 40 lbs/ft deg idlers lbs/ft deg idlers lbs/ft deg idlers over 120 lbs/ft deg idlers 0 40 lbs/ft deg idlers lbs/ft deg idlers lbs/ft deg idlers over 120 lbs/ft Minimum Pulley Diameters (in) % belt rated tension 61 80% belt rated tension 41 60% belt rated tension ELEVATOR BELT SPECIFICS ELEVATOR BELT SPECIFICS Maximum Tension Rating (PIW) Grain, Wood Chip Service (50 lb/ft 3 ) Industrial Service (100 lbs/ft 3 ) Minimum Pulley Diameters (in) % belt rated tension 61 80% belt rated tension 40 60% belt rated tension Maximum Bucket Projection (in) Centrifugal Elevators Continuous Elevators Troughability and Load Support values can be influenced by certain cover gauge and compound combinations used. When in doubt, please contact your FDA representative for selection guidance. 2 NovaCore tension ratings reach a minimum 10:1 safety factor through the 600 PIW offerings. With the appropriate fastener selection and installation, 4:1 minimum mechanical fastener safety factors can be achieved. 3 Add the appropriate cover gauge to this carcass gauge to obtain the approximate overall belt thickness. 4 Add the appropriate cover weight to this carcass weight to obtain the appropriate overall belt weigh 9

10 C A R C A S S C O N S T R U C T I O N PSR - Select Carcass Longer belt life and greater cost savings! Measurable, sustainable results day in and day out PSR, Fenner Dunlop s premium plied belting, is what you want for heavy duty applications where you expect many years of service. The true workhorse in the belting industry, PSR is custom engineered for each application to ensure minimum downtime and maximum haulage. Applications: Aggregates Wood/paper products Sand & gravel Precious metals Steel/foundries Power generation Cement plants Coal/prep plants Ports & terminals Features and Benefits Economical product Unsurpassed resistance to cutting, gouging and tearing Outstanding wear characteristics Excellent cover adhesion to carcass plies Low stretch Excellent load support and troughability Resistant to moisture and mildew 10

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12 C A R C A S S C O N S T R U C T I O N PSR - Select Carcass Specification Table - Imperial GENERAL DATA GENERAL DATA Fabric Ply PSR 80 PSR 110 PSR 125 Carcass Style Number of Plies Carcass Gauge 3 (in) Carcass Weight 4 (lb/in/ft) Elastic Modulus (lbs/in) CONVEYOR BELT SPECIFICS CONVEYOR BELT SPECIFICS Max Tension Rating 2 (PIW) Troughing/Empty 1 Min Belt Width (in) 20 degree idlers degree idlers degree idlers NR Load Support 1 Max Belt Width (in) 20 deg idlers 0-40 lbs/ft deg idlers lbs/ft deg idlers lbs/ft deg idlers 3 over 120 lbs/ft NR deg idlers 0-40 lbs/ft deg idlers lbs/ft deg idlers lbs/ft deg idlers 3 over 120 lbs/ft NR deg idlers 0-40 lbs/ft deg idlers lbs/ft deg idlers lbs/ft 3 NR deg idlers over 120 lbs/ft 3 NR NR Minimum Pulley Diameters (in) % belt rated tension % belt rated tension Up to 60% belt rated tension ELEVATOR ELEVATOR BELT BELT SPECIFICS SPECIFICS Maximum Tension Rating (PIW) Grain, Wood Chip Service (50 lbs/ft 3 ) Industrial Service (100 lbs/ft 3 ) Minimum Pulley Diameters (in) % belt rated tension % belt rated tension Up to 60% belt rated tension Maximum Bucket Projection (in) Centrifugal Elevators Continuous Elevators NR Troughability and Load Support values can be influenced by certain cover gauge and compound combinations used. When in doubt, please contact your FDA representative for selection guidance. 2 PSR tension ratings reflect a minimum 10:1 safety factor through the 750 PIW offerings, and an 8:1 minimum safety factor for the remaining higher tension offerings. With the appropriate fastener selection and installation, 4:1 minimum mechanical fastener safety factors can be achieved. 3 Add the appropriate cover gauge to this carcass gauge to obtain the approximate overall belt thickness. 4 Add the appropriate cover weight to this carcass weight to obtain the appropriate overall belt weight. 12

13 PSR 150 PSR 200 PSR 250 PSR 300 PSR

14 C A R C A S S C O N S T R U C T I O N RockMaster - Standard Carcass Durable and Economical Durable and Economical? We ve got your belt! RockMaster the reliable, economically priced belt for less demanding applications like sand and gravel. With full between-ply rubber gauges, RockMaster won t stretch more than two percent at full operating tension. We make RockMaster using the same stringent ISO 9001:2008 quality standards that we use for the entire Fenner Dunlop product line. Reasons to Count on RockMaster Less than 2% stretch at full working tension reduces downtime 4:1 mechanical splice fastener retention safety factor Full gauge rubber between plies for excellent beam stiffness and overall flexibility Outstanding wear characteristics with our Platinum and Abrader cover compounds Available in 2-220, or constructions Superior wet and dry adhesion to carcass 9:1 Safety Factor Markets & Applications: Crushed stone Sand & gravel Ready mix Cement Fertilizers 14

15 SPECIFICATION TABLE - Imperial (in Black) & Metric (in Red) Fabric Ply RockMaster 110 Carcass Style Number of Plies Imperial Metric Imperial Metric Imperial Metric Carcass Gauge 3 (in / mm) Carcass Weight 4 (lb/in/ft / kg/m 2 ) Elastic Modulus (lbs/in / N/mm) Max Tension Rating 2 (PIW / N/mm) Troughing/Empty 1 - Min Belt Width (in / mm) 20 0 idlers idlers Load Support 1 Max Belt Width (in / mm) 20 0 idlers (0 40 lbs/ft 3 / kg/m 3 ) idlers (41 80 lbs/ft 3 / kg/m 3 ) idlers ( lbs/ft 3 / kg/m 3 ) idlers (0 40 lbs/ft 3 / kg/m 3 ) idlers (41 80 lbs/ft 3 / kg/m 3 ) idlers ( lbs/ft 3 / kg/m 3 ) Minimum Pulley Diameters (in / mm) % belt rated tension % belt rated tension Up to 60% belt rated tension Standard Constructions Available 1/8 X 1/16 Platinum & Abrader covers Yes - - 3/16 x 1/16 Platinum & Abrader covers Yes Yes - 1/4 x 1/16 Platinum & Abrader covers - Yes Yes Note: RockMaster is designed for general purpose applications (ie, material size is 4 or less, the material drop is 4 or less, the idler troughing angle is 35 0 or less, and the material weight is no more than 120 lbs/ft 3.) 15

16 C A R C A S S C O N S T R U C T I O N DynaFlight - Standard Carcass When the Going Gets Tough No matter how demanding, DynaFlight delivers! Markets & Applications: DynaFlight belts are designed to withstand the most demanding applications. Using a single plane of carefully constructed, pre-tensioned steel cords, DynaFlight conveys the toughest loads over the longest distances and at the highest tensions. A century of belt design and manufacturing experience, enhanced by today s computer technology, goes into every Fenner Dunlop DynaFlight belt. No wonder customers worldwide have such confidence in our DynaFlight steel cord belting. Power generation Mining operations Conveying coal, copper, limestone Slope belts in deep mines, open-pit mines Stacker/reclaimer & bulk terminal conveyors Ship unloaders, high capacity feeders, unit train loadouts SPECIFICATION TABLE Standard Carcass Styles 1 Max Tension Rating 2 Elastic Modulus Cord Pitch Carcass Max. Cord Weight 5 Diameter 4 Troughing/Empty 3 Minimum Belt Width Minimum Pulley Diameter 6 % Rated Belt Tension Splice Step Pattern 20 0 idlers 35 0 idlers 45 0 idlers up to 60 PIW lbs/in in lbs/in/ft in in in in in in in ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step ST Step 1 For additional DynaFlight constructions, including those of higher tension, please contact your FDA representative. 2 DynaFlight tension ratings reflect a minimum 6.7:1 safety factor. 3 Troughability values can be influenced by belt construction. When using Dynacord breaker, another 6 (150 mm) of belt width is required. 4 Add the appropriate cover gauge to the cord diameter value to obtain the approximate overall belt thickness. 5 Add the appropriate cover weight to this carcass weight to obtain the appropriate overall belt weight. 6 Pulleys must be straight-faced, engineered class (no crowns) and for several reasons, preferably lagged. 16

17 Reasons to Count on DynaFlight Tension capabilities Highly efficient, precision-engineered steel cords with belt operating ratings up to 6000 PIW (ST7000) Product quality Superior results come from the finest materials, meticulous testing, and the best quality control. Product design Thanks to individually pre-tensioned cords with alternating twists, we position cables uniformly in-plane for optimum belt tracking Adhesion & corrosion protection With zinc plated open-weave steel cords, high pressure curing and quality compounding maximum belt adhesion and cable corrosion protection is assured. This leads to unrivaled splice life Available with DynaBreaker I and II with UsFlex Engineered with the properties and characteristics of our premium UsFlex carcass construction. Please see the UsFlex product page in the Carcass Section for more information Minimal elongation Take-up travel less than 0.25% of conveyor centers Energy efficient Low rolling-resistant rubbers available EagleEye, rescan, and Rip Ranger Highly sophisticated electronic monitoring, rip protection & X-ray options available Unsurpassed performance The finest materials, design, manufacturing and quality control make a problem-free belt 17

18 C A R C A S S C O N S T R U C T I O N Patriot - Economic Carcass Patriot is best suited for Light Duty Applications in the following markets Sand Cement (non-heat applications) Gravel Pulp and Paper (where oil resistance is not required) Agricultural Products (where oil resistance is not required) Other general light and medium duty bulk materials handling applications Patriot conveyor belt is an economical, North American-made cover and carcass combination. The carcass fabric is woven in our unique state-of-the-art weaving facility in Lavonia, GA. Production is then passed on to our conveyor belt manufacturing plants in Toledo, OH, Port Clinton, OH, and Bracebridge, Ontario, where our customized products are assembled. Features and Benefits ARPM Grade 2 cover compound Heat Resistance Class 1(212º Fahrenheit) Superior carcass adhesions in both wet and dry applications Available in and PIW constructions 18

19 Specification Table SPECIFICATION TABLE Fabric Ply Patriot Carcass Style Number of Plie s 2 3 Imperial Metric Imperial Metric Carcass Gaug e (in / mm) Carcass Weigh t (lb/in/ft / kg/m ) Elastic Modulus (lbs/in / N/mm) Max Tension Rating (PIW / N/mm) Troughing/Empt y Min Belt Width (in / mm) 20 0 idlers idlers Load Support Max Belt Width (in / mm) 20 0 idlers (0 40 lbs/f t / kg/m ) idlers (41 80 lbs/ft / kg/m) idlers ( lbs/f t / kg/m) idlers (0 40 lbs/f t / kg/m) idlers (41 80 lbs/f t / kg/m) idlers ( lbs/f t/ kg/m) Minimum Pulley Diameters (in / mm) % belt rated tensio n % belt rated tensio n Up to 60% belt rated tensio n

20 C O M P O U N D S General Service Covers The right cover compound for any conditions Conveyor belts are made of rubber compounds designed to protect the carcass. The belt must stay intact while flexing and bending under the harsh conditions of your operation. We build our compounds on a primary polymer that defines the grade or function of that compound. Our recipes also include supporting ingredients, such as carbon black, plasticizers, curing agents, and clays/fillers. At Fenner Dunlop, extensive research and development, rigid quality control, and years of experience give you the most innovative and appropriate compounds for your steadily increasing demands to move more material. You need conveyor belts that truly provide the lowest cost per ton of material conveyed. You need both the cover compound and carcass working together to create the optimal product for your specific needs. You need Fenner Dunlop on your team. General Service Covers Matchless (ARPM Grade I) Superior endurance against combined cutting, gouging and heavy impact Great for conveying heavy lump ores, heavy rocks, granite trap rock and quartz Unequaled for moving heavy logs from the debarker Superb handling of glass cullet and other sharp, abrasive materials Matchless Plus (ARPM Grade I) Adds enhanced features to Matchless for better cut and gouge endurance Designed for the most severe cut, gouge and impact applications Good abrasion resistance Complies with European DIN Standard X Giant XE (ARPM Grade I) High durability recipe offering resistance to dedusting agents or hygroscopic materials Specially designed for dry and dusty applications Ideal for heavy and abrasive materials -40ºF to 200ºF operating temperature Platinum (ARPM Grade I) Excellent endurance against heavy, continuous abrasion Excellent resistance to cuts and gouges Cost-effective upgrade from Grade II products Great for very abrasive applications, such as aggregates, crushed ores/rock, slag, run-of-the-mine materials, coal mine refuse and coke/sinter Titanium (ARPM Grade I) Best for resistance to abrasion and wear Get more life with less cover thickness Performs well in high-impact applications 20

21 Granite (ARPM Grade II) Excellent for heavy, continuous abrasion Good resistance to cutting and gouging Best for most abrasive materials - aggregates, limestone, sand/gravel, potash, trona, and salt. Abrader (ARPM Grade II) Meets new ARPM 175 mm3 abrasion limit Great for most abrasive materials aggregates, sand and gravel Black Diamond Get more belt life with less cover thickness Excellent resistance to abrasion and wear Performs best in high-impact applications Meets European DIN standard Y ZR2 (ARPM Grade I) Best resistance to heavy, continuous abrasion Best resistance to cutting and gouging ZR3 Same formidable characteristics as ZR2 Improved DIN Abrasion of 20mm3 Energy Lite Optimal for above-ground flat or low-incline conveyor systems with distance-to-center >1,500 feet Lower rolling resistance means that less force is required for a belt to roll over the idlers. This reduces the energy that is required for a conveyor to run. Less power use means lower operating costs Bottom cover only ZR1 (ARPM Grade II) High resistance to heavy, continuous abrasion Good resistance to cutting and gouging COMPOUND SPECIFICATIONS Recommended MINIMUM Cover Thickness Class of Material Top Cover Bottom Cover inches mm inches mm NON-ABRASIVE MATERIALS: Wood Chips, Pulp, Grain, Loose Cement, Potash Ore or very fine Coal. 1/16 to 1/8 1.5 to 3.0 1/ MILDLY ABRASIVE MATERIALS: Sharp Sand,Clinker, Earth, Bituminous Coal and Rock under 3 size. 1/8 to 3/ to 4.5 1/ ABRASIVE MATERIALS: Sinter, Gravel, or Crushed Stone. Iron and Copper ores or Limestone under 6 size. 3/16 to 1/4 4.5 to 6.0 3/ HEAVY ABRASIVE MATERIALS: Iron, Copper, Rock Ores, Zinc, Lead Ores, Limestone or Slag under 9 size. 1/4 to 3/8 6.0 to 9.5 1/8 3.0 HEAVY, SHARP ABRASIVE MATERIALS: Trap rock, quartz, Hard Ores, Slag, glass cullet. Any hard heavy sharp ore over 9 size. 3/8 to 3/4 9.5 to /

22 C O M P O U N D S Specialty Compounds The right cover compound for any condition Fire-Retardant and Oil-Resistant Covers Guardian Resists leaching agents and dust suppressants Fire-retardant, abrasion resistance compound that meets ARPM-FR Class 2 Increased resistance to abrasion and cover wear Good for power generation and coal prep plants Guardian AR (ARPM Grade II) High quality grade II fire-retardant compound that resists leaching agents and dust suppressants Meets ARPM-FR Class 2 Excellent resistance to abrasion and cover wear Great for power generation and coal prep plants Guardian CA (ARPM Grade II) High quality grade II fire-retardant compound Great for power generation and coal prep plants Halogen (chlorine) free Guardian SAR Best abrasion and cover wear properties Meets ARPM Grade 1 physical properties Meets ARPM- FR Class 2 fire resistance UGH (Ultra Grain Handler) 2.0 Maximum resistance to grain oils and oil-based dust suppressant additives. Temperature range: -30 to 200 F (-34 C to 93 C) Surpasses U.S. OSHA specs for static conductivity Fire-retardant, meets ARPM-FR Class 2 Designed for oil-treated grain, crushed soybeans and materials where mineral, animal, or vegetable fats can degrade the belt CGH (Classic Grain Handler) 2.0 Moderate oil-resistant covers for grain handling Compounded for colder climates. Temperature range -40 to 200 F (-40 C to 93 C) Surpasses U.S. OSHA specs for static conductivity Fire-retardant, meets ARPM-FR Class 2 Electrical resistance to 300 megohms maximum Designed for whole oily grains wheat, corn, soybeans, cotton seed, flax seed, and sunflower seed Guardian OR Great for power generation and coal prep plants that need moderate oil resistance Surpasses U.S. OSHA specs for static conductivity Fire-retardant, meets ARPM-FR Class 2 Static conductive cover Fire Boss Fire retardant abrasion resistant MSHA compound that meets requirements per MSHA CFR Title 30, Part 14 Meets ARPM-FR Class 1 Ideal when an increased fire retardant level is desirable Fire Boss AR Fire retardant abrasion resistant MSHA compound that meets U.S. Mine Safety and Health Administration requirements per MSHA title 30, part 14 Increased resistance to abrasion and cover wear Meets ARPM-FR Class 1 Ideal when an increased fire retardant level is desirable UV and ozone protection for above ground applications Fire Boss CSAR Designed for steel cable belting Combines superior abrasion resistance with the durability of Neoprene Compliant with Canadian standards level A2 for underground applications where resistance to ignition, propagation, and frictional heating is required Antistatic Fire Boss CAR Designed for UsFlex and plied belting Combines good abrasion resistance with the durability of Neoprene Compliant with Canadian standards level A2 for underground applications where resistance to ignition, propagation, and frictional heating is required Antistatic Heat-Resistant Covers DeltaHeat 2.0 Premium compound for hot materials superb for prolonged exposure to hot payloads and abrasives Temperature resistant to 400 F (205 C) for abrasive coarse lumps (>2 i/50mm) and 350 F (175 C) for abrasive fines Resists the cover cracking, hardening, abrasion, tearing and flexing of high-temperature environments Optimal for hot cement clinker, iron ore pellets, casting sand and more White DeltaHeat Off-white-color compound that resists the cover cracking, hardening, tearing and flexing of high temperature environments Premium compound for hot materials that protects against hot payloads and abrasive materials Temperature resistant to 350 F (175 C) for abrasive coarse lumps (>2inches/50mm) and 300 F (150 C) for abrasive fines Sahara SAR Good abrasion resistance in hot environments Temperature resistant to 300 F (150 C) for abrasive coarse lumps (>2 in/50mm) and 250 F (120 C) for abrasive fines Ideal for hot dusty products and environments 22

23 Sahara Alumina A special compound designed to offer resistant to heat, abrasion, and the impact of Alumina on the long term rubber compound properties Heat resistant to 250 F for fine material Sahara FR Designed for Steel making applications including hot clinker and lime applications. Offers a combination of abrasion, heat, and fire retardance to ISO 340 Heat & Oil Resistant Covers Sahara OR (formerly OHR) Resists oil and heat up to 349 F (176 C) for coarse lumps (>2in/50mm) and 302 F (150 C) for abrasive fines Great for moving hot mixtures containing diesel oil, kerosene, petroleum coke, hot asphalt, paving mixes and carbon pitch Ideal for oil extractors and handling oily grains and seeds withstands hot vegetable oils and moisture Oil Resistant ZR2 ORB Resists combined effects of cold, abrasion and petroleum products Cold weather resistance to -50 F (-46 C) Great for conveying oil sands, bitumen, oil-sprayed coal and similar materials MOR (Moderate Oil Resistance) Great for specialized service wood chips, waste disposal, sewage, sludge and lightly oil-treated materials Resists moderately oily materials and terpenes ORP (Oil Resistance Plus) Superior Resistance to materials containing high concentrations of fats and oils. Recommended for use involving heavy exposure to aromatic hydrocarbons such as petroleum based oily coke, benzol, and toluene. Specialty Cover Compounds Duroslide Special low-friction slider bed compound for the wood products Industry.30 coefficient of friction Best for non-reverting, non-marking, dark brown compound coal and similar materials 23

24 P R O D U C T S B Y M A R K E T AGGREGATES Aggregates You crush em, we ll carry em From crusher to kiln Fenner Dunlop ECS supplies conveyor belts for the most brutal aggregate crushing applications. Our products are great for primary and secondary crushers, transfers, loadouts, stackers, and overland conveyors. Our belts are built for tough quarry applications and are engineered to resist rips, tears, and impacts. We have a full range of compounds and textiles designed for the most critical conveyors in a cement plant. Crusher loadouts? Clinker conveyors? Kiln to storage? Silo or dome discharges? No problem. From polyester to fiberglass, and ARPM Grade II to DeltaHeat 2.0, we make belts that hold up to high heat and difficult abrasion. Standard Aggregates Applications Granite (ARPM Grade II) Excellent for heavy, continuous abrasion Good resistance to cutting and gouging Great for most abrasive material handling aggregates, limestone, sand and gravel, potash, trona, run-of-the-mine and sized coal, salt, and coal mine refuse 24

25 PSR Measurable, sustainable results day in and day out The proper carcass material in many applications will determine total belt life. Whether conveying coal, aggregate, sand, grain, wood products or mineral ore, PSR can be manufactured to suit a specific application by utilizing our standard carcass or our custom carcass constructions. Standard Carcass Polyester Warp with Nylon Filling This design offers the advantages of low overall stretch and excellent impact resistance. Nylon weft yarns with lower modulus and higher stretch withstand sharp object impacts and impingement from trapped materials without fracturing. That makes nylon a logical choice for a crosswise or weft member in the PSR belt fabric. Polyester warp yarns give superior troughability and fastener retention. Custom Carcass Nylon Warp with Nylon Filling We make a custom nylon/nylon carcass for low modulus and high stretch conveyor belts needed for specific applications. PSR belts can be installed and vulcanized in one trip to reduce downtime and costs by eliminating extra splices due to stretch. Heavy Aggregates Applications Our UsFlex and NovaCore carcasses can handle the toughest aggregates applications from sand and gravel to primary crushers where premium products are required. UsFlex and NovaCore offer unsurpassed impact and puncture resistance, excellent load support, and longer service life than other premium belts. Check out our NovaCore and UsFlex product pages in the carcass section for more information. Our many years as a textile manufacturer give Fenner Dunlop the ability to match the carcass design and materials to your application. Our engineered approach gives you performance you can measure. Belt Elongation PSR belts will elongate from 1.5% to 2.0% of total belt length depending on the carcass fabric: 110, 125, 200, 250 or 300 lb/ply. These percentages are at full rated tension for the belt, elastic and permanent according to ISO This elongation is the total for the life of the belt under normal operating conditions. 25

26 P R O D U C T S B Y M A R K E T PRECIOUS METALS ZR2 Aggregate and Hard Rock Belt Compound A Durable, 120% Longer Lasting Solution ZR2 Belt Compound We tested our ZR2 belting compound at Glencore Xstrata s Lomas Bayas copper mine in northern Chile. The harsh conditions and high performance expectations provided a perfect environment for us to test the ZR2 product. The Tripper #1 belt is 48 (1,219mm) wide, 36.1 feet (11 meters), made of three plies with a 450 PIW rating. It carries 2,800 TPH from the crusher at a belt speed of 8.3 mph (3.7m/sec). ZR2 lasted significantly longer than the previous five competitor belts used on the same conveyor under identical conditions. ZR2 Top Cover Thickness after 87 Days Our ZR2 compound has a DIN of 25 and meets ARPM Grade 1 specifications, producing an extremely durable belt that resists rips, tears, and abrasion. The numbers are impressive, but the true value was demonstrated in field tests. The chart on the left illustrates the top cover thickness after 87 days of continuous use. The operator intended to replace the belt at.14 inches (3.5mm), projected to be at 98 days, which is 2.2 times the average life (45 days) of five competitor belts. The cycle count diagram in the bottom left is a good indicator of belt life in other lower cycle applications. At Glencore Xstrata s site, Fenner Dunlop s ZR2 belt averaged 12,206 cycles/day at percent utilization - more than double the average of our top competitors in similar conditions. ZR2 Top Cover Originally 12mm Competitor 1 Competitor 2 Competitor 3 Competitor 4 Competitor 5 Fenner Dunlop s ZR2 26

27 Key Features Long Life ZR2 compound was designed for the harshest hard rock-mining conditions minimizing abrasion, rips, and tears. ZR2 meets ARPM Grade 1 specs with a DIN of 25mm3 High Value Fewer belt replacements reduce labor and material costs Higher Production Increased up-time with less maintenance yields higher production Competitor 1 Competitor 2 Competitor 3 Competitor 4 Competitor 5 Fenner Dunlop s ZR2 Multiple Carcass Options ZR2 can be used with the following Fenner Dunlop carcasses: PSR, UsFlex, NovaCore and DynaFlight 27

28 P R O D U C T S B Y M A R K E T CEMENT PLANTS, STEEL MILLS, FOUNDRIES, POTASH HotShot It can take the heat! HotShot is a conveyor belt carcass specially designed for the hottest applications. It has a fiberglass carcass built into a solid-woven design, maximizing the heat resistance of the belt carcass. It is protected by Delta Heat 2.0, the industry s best high-heat cover compound. HotShot will help protect your conveyor system against: Belt burn through Carcass meltdown Burned-away splices and carcasses Even in contact with isolated pockets of extremely hot materials, your belt integrity is assured with HotShot. HotShot SPECIFICATION TABLE SPECIFICATIONS Carcass Style HotShot 300 Number of Plies 1 Imperial Metric Carcass Gauge 3 (in / mm) Carcass Weight 4 (lb/in/ft / kg/m 2 ) Elastic Modulus (lbs/in / N/mm) Max Tension Rating 2 (PIW / N/mm) Troughing/Empty 1 Min Belt Width (in / mm) 20 0 idlers idlers Load Support 1 Max Belt Width (in / mm) 20 0 idlers (0 40 lbs/ft 3 / kg/m 3 ) idlers (41 80 lbs/ft 3 / kg/m 3 ) idlers ( lbs/ft 3 / kg/m 3 ) idlers (0 40 lbs/ft 3 / kg/m 3 ) idlers (41 80 lbs/ft 3 / kg/m 3 ) idlers ( lbs/ft 3 / kg/m 3 ) Minimum Pulley Diameters (in / mm) % belt rated tension % belt rated tension Up to 60% belt rated tension Applications: Cement clinker Ore pelletizing Sintering and coking Calcined lime Smelting and refining Hot foundry / casting Any yellow/cherry red material where burn-through is a problem Key Features Unique fiberglass carcass, resists burn-through to F No ply separation due to solid weave Premium cover compound DeltaHeat 2.0 gives optimal heat resistance Minimal belt elongation 1 Troughability and Load Support values can be influenced by certain cover gauge and compound combinations used. When in doubt, please contact FDA for selection guidance. 2 HotShot tension ratings reflect a minimum 10:1 safety factor. With the appropriate fastener selection and installation, a minimum 4:1 mechanical fastener safety factor can be achieved. (With extreme product temperatures, mechanical fasteners are the preferred splice method.) 3 Add the appropriate cover gauge to this carcass gauge to obtain the approximate overall belt gauge. 4 Add the appropriate cover weight to this carcass weight to obtain the approximate overall carcass weight. 28

29 Sahara For hot materials In our revised, expanded conveyor belt product line for hot materials, Sahara has the right belt for you five heat-resistant belts for a variety of hot-material applications! Key Features Long lasting conveyor belts Premium quality Wide variety of products to meet specific customer demands Markets: Hot Material - cement plants, steel mills, foundries, iron ore and taconite Applications: Hot cement clinker Iron ore pelletizing Hot foundry / casting Sintering and refining Taconite pellets Hot slag Calcined lime Furnace-hot materials Belt Compound Brand Temperature Resistant to Abrasion Resistance (DIN) Delta Heat 2.0 Sahara SAR (Superior Abrasion Resistant) Sahara FR (Fire REtardant) Sahara OR (Oil Resistant) 400ºF to 205ºC (coarse lumps) 350ºF or 177ºC (fines) 300ºF or 150ºC (coarse lumps) 250ºF or 120ºC (fines) 349ºF or 176ºC (coarse lumps) 302ºF or 150ºC (fines) Very Good (170 mm 3 ) Excellent (60 mm 3 ) Good (240 mm 3 ) Excellent (100 mm 3 ) Applications Hot cement clinker, iron ore pellets, calcined lime, and casting sand & clay Similar applications as Sahara SAR where fire retardant properties are mandatory or desired Hot mixtures containing diesel, kerosene, petroleum coke, asphalt, paving components and carbon pitch. Sahara Alumina 250ºF or 120ºC (coarse lumps) 200ºF or 93ºC (fines) Excellent (100 mm 3 ) Conveying Bauzite / Alumina Ore Sahara SAR Sahara OR Sahara FR Sahara Alumina Super Abrasion & Heat Resistant Oil, Abrasion & Heat Resistant Fire Retardant & Heat Resistant Tailor Made to Handle Hot Alumina! 29

30 P R O D U C T S B Y M A R K E T CEMENT PLANTS, STEEL MILLS, FOUNDRIES, POTASH DeltaHeat 2.0 Premium Hot Material Belt DeltaHeat 2.0 is our best hot material compound for fighting the cover cracking, hardening, flexing, tearing and abrasion of high temperature environments. Pair it with PSR, UsFlex, or HotShot 2.0 product lines to protect your investment in operations from cement plants to steel mills, and from foundries to iron ore or taconite handling. Markets: Hot Material Cement plants Steel mills Foundries Iron ore Taconite Applications: Hot cement clinker Iron ore pelletizing Hot foundry / casting Sintering and refining Taconite pellets Hot slag Calcined lime Furnace hot material 30

31 Heat Age Flex Test at 350 F Myths Competitor belt at 0 hours Sasquatch DeltaHeat 2.0 belt at 0 hours Competitive Comparisons We tested DeltaHeat Ply PSR for service life in a heat/age flex test at 302 º F and 350 º F against our competitors comparable compounds. The results were impressive: 20% greater service life 20% greater heat resistance Their cover cracked at 0 hours. Ours showed no signs of cracking. DeltaHeat 2.0 had significantly better adhesion Better abrasion resistance than either the competition or original DeltaHeat Loch Ness Monster 750º F Manufacturers who claim 750º F protection! Fact is, nylon belts melt at 550º F 31

32 P R O D U C T S B Y M A R K E T OIL SANDS Oil Sands Innovative Belts for Bitumen Sands Super UsFlex construction and DynaFlight steel cord belt combined with the ZR2 ORB cover compound and DynaBreaker with UsFlex protection ensures less downtime and maximum operating efficiencies for lower costs. Key Features Significantly improved abrasion resistance Great for oil sand Cold resistance to -76 F (-60 C) High tear resistance High cut and gouge resistance ZR2 ORB Belt Cover ZR2 ORB Belt Cover We designed ZR2 ORB compound specifically for bitumen sands applications. It s ideal for crusher feed belts, train belts, slurry prep feed belts, surge bin feed belts, spill belts and reject belt systems. ZR2 ORB is an outstanding choice for resistance to the combined effects of cold temperatures, abrasion and petroleum products. 32

33 DynaFlight DynaFlight steel cord conveyor belt conveys the toughest loads over the longest distances and at the highest tensions. When your bulk haulage requirements exceed the tension capabilities of textile construction, DynaFlight provides the following benefits: Tension ratings up to ST7000 Extremely low elongation Excellent tracking, troughability and load support Available in DynaBreaker I and II with UsFlex for maximum rip, tear and impact resistance DynaBreaker l and ll with UsFlex The new standard in breaker fabrics for protection beyond detection DynaBreaker I and II breaker fabrics are engineered with the properties and characteristics of our premium UsFlex carcass construction. Please see the UsFlex product page in the Carcass Section for more information. DynaBreaker is excellent for bitumen sands applications with enhanced rip, tear and impact resistance. Super UsFlex Super UsFlex is part of our high performance series that meets the needs of bitumen sands applications with longer life in tough service environments and tension ratings up to 2000 PIW Use it in place of ST belting. For decades, the unique construction of UsFlex has provided unsurpassed puncture, rip and damage resistance for mining customers most demanding applications. LBS LBS DynaBreaker Rip Rip && Tear Comparison Dynacord 250NN Breaker DynaBreaker l DynaBreaker ll Rip Strength Tear Strength Super UsFlex Rip & Tear Comparison Super UsFlex D15 Super UsFlex D18 Rip Strength Tear Strength With all these added features, our oil sands product is the ultimate belt to fight the challenges of tough environments. 33

34 P R O D U C T S B Y M A R K E T WOOD, PULP, & PAPER PRODUCTS WoodMaster and WoodMaster Supreme Longer life is built-in WoodMaster Good rip resistance High tear resistance Superb abrasion resistance Optimal adhesion values Uses Fenner Dunlop s RockMaster carcass WoodMaster Supreme Significantly greater rip resistance than the competition Best tear resistance Maximum abrasion resistance Superior adhesion values Highest safety factor in the market Uses Fenner Dunlop s PSR carcass Key Features Exceeds APRM standards for Grade 2 & MOR Strongest oil resistant products available Strong adhesion Excellent fastener holding High abuse resistance High performance at maximum operating tensions Maximized belt life leads to less unscheduled downtime Serviced & supported by our vast, experienced distribution network Applications: Paper mills Saw mills Board plants Wood chips Bark Broke belt Chipper end feed Planer belt Pulp belt Sander belt Tray belt and anywhere you need moderate oil resistance 34

35 LOG HANDLING LogMaster Your Best Defense Conveying logs? You need LogMaster! LogMaster Fenner Dunlop s PSR conveyor belt carcass handles the impacts, cutting and gouging of wood products day in and day out. LogMaster III (3-ply) and LogMaster IV (4-ply) wood handling conveyor belts are your solution to the most severe challenges. Our specially formulated cover compounds maximize belt life and lower your cost per ton. Applications: Slasher decks Log drops Debarkers - in and out feeds Chipper in feeds Drum discharge Standard Offerings: Available Top Cover Compounds Platinum (RMA Grade 1) Matchless (RMA Grade 1) MOR (Moderate Oil Resistance) ZR2 ORB Key Features Exceeds ARPM standards for Grade 2 & MOR Maximum belt life low cost per log Superior impact and abuse resistance Increased skim gauges enhance energy absorption and belt resistance Carcass construction made for optimal crosswise rigidity High performance at maximum tension Strong adhesion values Excellent fastener holding The perfect combination for slider beds Fenner Dunlop has the perfect combination for slider beds and pan conveyors. UsFlex D6 conveyor belt carcass handles the impact. Grade 1 conveyor covers protect against cut and gouge. Duroslide bottom cover provides the optimal coefficient of friction for the largest and heaviest logs in the world. Top Cover Gauges 3/8 1/4 3/16 5/32 Bottom Covers Duroslide (.30 coefficient of friction) Bareback (.18 coefficient of friction) 35

36 P R O D U C T S B Y M A R K E T POWER GENERATION - coal fired power plants PowerGuard Conserving energy, safely and efficiently Reduce your downtime and keep energy flowing. PowerGuard is built for coal-handling in power generation and coal prep plants where leaching agents and dust suppressants can wear out your belts. We have compounds formulated to fight these conditions: Guardian, Guardian AR and Guardian CA and Guardian SAR. Markets Coal preparation plants Power generation facilities Above ground coal handling Reasons to Count on PowerGuard Resists dust suppressants and leaching agents Our compounds reduce durometer creep and plasticizer extraction Balanced carcass construction minimizes cupping and curling Excellent resistance to abrasion, tearing and cover wear Low stretch to reduce break-in and downtime Outstanding load support and tracking Compounds that Outperform the Competition Guardian Fire retardant Meets ARPM Class 2 fire retardance Increased resistance to abrasion and cover wear Guardian AR High quality ARPM Grade 2 compound Excellent abrasion and cover wear properties Meets ARPM Class 2 fire retardance Guardian SAR Best abrasion and cover wear properties Meets ARPM - FR Class 2 fire resistance Guardian CA Halogen (chlorine) free High quality Grade II fire retardant compound Giant XE High durability recipe offering resistance to dedusting agents or hygroscopic materials Designed for applications that do not require fire retardancy 36

37 Grain Master and Grain Master Supreme Best product for grain elevators GRAIN Grain Master Supreme boasts a carcass with maximum rip and tear resistance plus superior bolt retention. Uses Fenner Dunlop s premium UsFlex carcass. Grain Master Supreme is available in the following UsFlex specs: S3, S4, S5, D5, D6, D8, D10, D12, D15. Grain Master s carcass delivers high strength along with low elongation and excellent fastener holding properties. Uses Fenner Dunlop s PSR carcass. Grain Master is available in the following PSR specs: 2-160, 2-220, 2-250, 2-300, 3-330, 3-375, 2-400, 4-440, 3-450, 4-600, RT, 3-600, 3-750, 4-800, 3-900, , , Applications: Grain handling Elevators Feed silos Milling and other applications requiring durability, oil and cold temperature resistance Key Features Strong rip and tear resistance Unsurpassed bolt retention Outstanding troughability and load support Unequaled ply and cover adhesion Meets or exceeds OSHA requirements for conductivity and flame resistance Various cover compounds guard against oil and cold temperatures Excellent tracking characteristics UGH Ultra Grain Handler 2.0 CGH Classic Grain Handler 2.0 Cover compounds resist oil and low temperature. 37

38 P R O D U C T S B Y M A R K E T SPECIALTY CleatLine Locks in your materials Free flowing materials...no problem! Made for aggressive transfer and elevation of free flowing materials, our CleatLine gives you efficient, smooth operation over return idlers and quick pick-up at loading points. Cleat patterns are molded into the belt no separation problems or vulcanizing of cleats to the belt. Markets and Applications: Grain Wood chips Bark Cement Light aggregates Materials handled on road machines Key Features Molded cleats for years of trouble-free service Recessed-edge cleats available for skirtboarding Available constructions: UsFlex, PSR, RockMaster or NovaCore Available compounds: MOR, Granite, UGH 2.0, CGH 2.0 and Platinum Available widths: 48, 60 & 72 or custom Available lengths: 600 & 1,200 or custom Choose from nine proven patterns: V-Top Y-Top C-Top Bucket-Top 38

39 SPECIFICATIONS CLEATMASTER PSR CLEATLINE Carcass Style Number of Plies Carcass Gauge 2 (in mm) Carcass Weight 3 (lb/in/ft kg/m 2 ) Max Tension Rating 1 (PIW N/mm) Troughing/Empty 1 - Min Belt Width (in mm) 20 0 idlers idlers Load Support 1 Max Belt Width (in mm) 20 0 idlers (0 40 lbs/ft kg/m 3 ) idlers (41 80 lbs/ft kg/m 3 ) idlers ( lbs/ft kg/m 3 ) idlers (0 40 lbs/ft kg/m 3 ) idlers (41 80 lbs/ft kg/m 3 ) idlers ( lbs/ft kg/m 3 ) Minimum Pulley Diameters (in mm) % belt rated tension % belt rated tension Up to 60% belt rated tension PSR CleatLine tension ratings reflect a minimum 10:1 safety factor. CleatMaster tension ratings reflect a minimum 8:1 safety factor. With the appropriate fastener selection and installation, a minimum 4:1 mechanical fastener safety factor can be achieved. 2 Add the appropriate cover gauge to this carcass gauge to obtain the approximate overall belt thickness. 3 Add the appropriate cover weight to this carcass weight to obtain the appropriate overall belt weight. 4 Imperial/English values above are in BLACK, while Metric values are in RED. Standard Offerings: Cover gauges - 1/8 min top cover and 3/32 min bottom cover Roll size - 72 inch max width and inch max roll diameter 24 and 42 Chevron Mini-Bucket F-18 and F-36 B-Top Unicleat 39

40 E C S P R O D U C T S Diagnostic Protecting your investment Fenner Dunlop can help you reduce belt damage, premature wear, cumbersome and costly repairs, blown schedules, and unexpected lost production time. Fixing a broken conveyor system is expensive. Now there s a better way. Manage your conveyor systems proactively with a powerful set of monitoring, diagnostic and troubleshooting tools from the conveyor experts at Fenner Dunlop. Conveyor systems are significant capital investments. They need to run to recoup their costs. A conveyor failure can take your whole business down with it. A small, smart investment can yield big returns reduce repairs, improve safety, and sustain productivity. World-class conveyor solutions and diagnostic services from Fenner Dunlop give you the tools to monitor, manage and maintain your systems. Our advanced, intelligent diagnostic tools and services will flag trouble spots, predict replacement cycles, and prevent surprise work stoppages in any operation. 40

41 Rip Ranger Plus is a microprocessor monitoring unit designed with durable, field-proven components. Our advanced diagnostics will continuously monitor your system to help minimize faults and malfunctions. Antennae embedded intermittently in your rubber-plied fabric or steel cord conveyor belt provide critical data to receivers located near conveyor loading and discharge sections, where most belt rips occur, helping to keep your operation running smoothly. Key Features Reads >1,000 loops per belt Real-time loop diagnostics: loop numbers, loop signal strength, and loop spacing Modbus interface for external control unit Remote monitoring/control from any computer Connect two rip detectors with one main control unit, or up to four monitoring stations with a slave unit Provides log of last 10,000 status changes 41

42 E C S P R O D U C T S Diagnostic Protecting your investment rescan 24/7 Scanning continuously on fixed or variable speed belts, rescan 24/7 alerts you by phone or LAN instantly when it detects any significant cord or splice damage. Our PLC interface lets you stop the system at any belt length location. rescan 24/7 offers a Splice Monitoring System (SMS) for fabric belting. By remotely measuring splice elongation, SMS can predict and prevent splice failure. It reads the position of small targets embedded around each splice for constant monitoring. Key Features Continuous monitoring of belt integrity Options: alarm, notification or auto stop Pre-set maintenance window for quick repairs Reports detailed belt map, splice condition, anomalies/damage, cycles, and setting changes Works with many rip-detection systems EagleEye The world s most advanced intelligent belt monitoring system for steel cord belting. It lightly magnetizes the belt, establishes a profile, then reads magnetic variations to continuously monitor splices, cord damage, corrosion, wear and rips. The user-friendly interface allows belt positioning and auto-stops at any position. Key Features Continuous monitoring of belt integrity Options: alarm, notification or auto stop Pre-set maintenance window for quick repairs Reports detailed belt map, splice condition, anomalies/damage, cycles, and setting changes Works with many rip-detection systems 42

43 Mobile Manual Scan Mobile Manual Scan Our trained technicians will travel to your site and perform a full longitudinal scan, an overall condition inspection, and make a life expectancy prediction for the conveyor belt. Our detailed report will include a map of your belt, an analysis of splice conditions, a table of notable anomalies within the belt and recommendations for maintenance or replacement. If some anomalies need closer examination, Fenner Dunlop s portable x-ray system can generate highly detailed digital images of those issues. Cover Profiling/ Ultrasound Surveys Our onsite survey will measure the rate of wear on each conveyor to help you more intelligently predict and manage belt life expectancy. By analyzing historical data, reports show trending belt wear and forecast replacement cycles. The data will also warn you if excessive wear is taking place due to a correctible mechanical problem or a change in loading. X-Ray Proprietary software creates safe 3-D x-ray images that accurately show the exact nature of any cord or fabric ply damage. With an unparalleled level of accuracy, this service quickly quantifies issues like ply adhesion, cord displacement and cord damage. These detailed images reveal otherwise hidden problems with steel cord spacing, cord damage, cord fraying, cuts in fabric belting and metal fatigue. 43

44 E C S P R O D U C T S Thermal Datalogger Records and displays exact temperature conditions during the splice-curing process Key Features: Produces temperature graph vital for end user s Quality Assurance records Helps identify faulty vulcanizer heating elements, preventing downtime from a splice failure Custom log intervals with enough memory to last 18 months* Free online supporting software Easy to use and install *assuming 2 minute log intervals 44

45 D C A B How this tool helps improve splice quality: Documents that proper heating procedures were used Helps splice technicians review cure time B and correct cure temperature C with an easy to read graph Tracks vulcanizer heating elements performance by verifying temperature uniformity D A 45

46 E C S P R O D U C T S Cleaners Protecting your investment The Fenner Blue Tech Line Series is an Engineered Cleaning Solution customized for your coal mining application. In underground mines the variables that impact effective cleaning are numerous: constantly changing material properties, water content, conveying speed, belt rubber compound, etc. The Tech Line Series was designed with these challenges in mind. Our superior urethane mix provides extended wear life that will keep your conveyor running as efficiently as possible. TM Tech Line Series Primary Cleaner Pre-Cleaner Size Blade Coverage Overall Length HD Assembly MD Assembly (inches) (inches) MD & HD (inches) Part No. Part No FDHSHD-36-XX-YYY Y FDHSMD-36-XX-YYY FDHSHD-42-XX-YYY FDHSMD-42-XX-YYY FDHSHD-48-XX-YYY FDHSMD-48-XX-YYY FDHSHD-54-XX-YYY FDHSMD-54-XX-YYY -XX-YYY-YYY FDHSHD-60-XX-YYY FDHSMD-60-XX-YYY FDHSHD-72-XX-YYY FDHSMD-72-XX-YYY X-YYY FDHSHD--XX-YYY FDHSMD--XX-YYY -YYY Key Features Uniquely designed for use with MSHA belt compounds Superior urethane mix that provides extended wear life Innovative TriZone cleaning has the most resilient part of the cleaner located in the center. This is where the most material on a conveyor belt accumulates and where the cleaner suffers the most wear Offset arm yields less s belt-to-blade contact (premier r cleaning ng edge) 46

47 Tech Line Series Secondary Cleaner Key Features Uniquely designed for use with MSHA belt compounds Superior urethane mix that provides extended wear life and less maintenance Innovative TriZone cleaning Long life bi-metal blade cleaning inserts do not degrade over time in the most corrosive applications Thinner contact surface creates a true squeegee effect across the length of the blade, keeping a better edge as it wears Blades and segments are available in: AR500 Steel- Urethane back blades used for most applications. Works best with Tech-24 combination Mild Steel- Gentler than AR and better for lighter, slower belt Tech-24 Urethane- Urethane backed blades that work best in wet material conditions Standard Urethane - used for lighter applications. Easiest on the belt covers. Pre-Cleaner Siz e Blade Coverage Overall Length MD Assembly (inches) (inches) MD & HD (inches) Part No 47

48 E C S P R O D U C T S Idlers Idlers Since 2001, Fenner Dunlop Engineered Conveyor Solutions has supplied high quality idlers and components to the bulk material handling industry, consistently manufacturing a complete range of CEMA class idlers from CEMA D to CEMA F. We have supplied impact idler rollers and steel idlers for installations in underground mining, pipe conveyors, long/high capacity overland conveyors, ship-loading terminals and in-plant conveyors. We have successfully supplied idlers for large conveyor systems throughout North America. Our idlers use a centrifugally sealed roller, which has been used world-wide since the 10 s. We use the latest design and manufacturing technology together with on-going programs that ensure the highest quality components, including AUTOCAD and 3D Inventor design facilities, laser alignment and measuring equipment. Research and development includes monitoring selected underground and surface installations over a number of years, while in-house test rigs and specialized monitoring equipment also help improve the quality of our products. We continually monitor manufacturing tolerances and consistently implement new manufacturing techniques with the latest technology. Precision E.R.W Conveyor tube Rotating metal seal expels dirt centrifugally and drains water away Full M.I.G. weld protected from belt wear Quality sealed deep groove ball bearings greased and sealed by bearing manufacturers. No relubrication necessary because contamination stays outside and the grease inside. High accuracy and strength bearing housing ensures long bearing life Durable, high-impact resistance outer seal Solid steel shaft with bearing seat preparation by a proprietary technique 48

49 Vulcanized Splicing Vulcanized Splicing As a leader in conveyor belt splicing technology, Fenner Dunlop s belt technicians have been extensively trained on numerous splicing procedures and techniques to ensure a superior approach to vulcanizing our customers conveyor belting. Our technicians offer a wide array of splicing services for belts up to wide, up to 2000 piw for fabric carcasses, and up to ST7000 for steel cable. Our technicians can install overlap, filler strip, finger (high integrity), single stage, and multi-stage splices to meet your conveyor belt requirements. Each splice is assembled and performed by certified technicians using the highest quality raw materials. It is then heated at a controlled temperature and consistent pressure in order to create the highest quality finished product with a long service life. 49

50 E C S P R O D U C T S Mechanical Splicing Mechanical Splicing Fenner Dunlop and its distributors are trained to install mechanical fasteners of all types. When vulcanized splicing does not fit your situation and there is need for a quick repair, mechanical fasteners are most likely the proper solution. If your fabric conveyor belt develops a rip or tear, our highly capable technicians can install a specially designed mechanical fastenings to seal shut the damaged area and keep the conveyor belt moving. Fenner Dunlop and our distributor team will help you select the proper fastener type and rivet size, maximizing the life of the splice and your conveyor belt. See the back cover for information on finding your local distributor. 50