Engineered Conveyor Systems and Equipment

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Fenner Dunlop ACE Conveyor Belt Systems 3

ACE Drive Systems 3

ACE Discharge/Transfer Systems 3

ACE Mainline Conveyor Systems 4-7

ACE Dual Drives 5

ACE Quad Drives 5

ACE Inline Discharge 5

ACE 90 Degree Discharge 6

ACE Take-up Units 6

ACE Stationary Tail Piece 6

ACE Winches 7

Spatial Imaging Technology 7

ACE Panel DevelopmentConveyor Systems 9-11

ACE 90 Degree Discharge Frame 9

ACE Alignment Free Boom & Booster Drives 9

ACE Angular Discharge/Transfer 9

ACE Booster Drive 10

ACE Belt Storage Unit 10

ACE Winches 11

ACE Moveable Tail Piece 11

ACE Belt Support Equipment 12-15

ACE De-Watering System 13

ACE Head-To-Tail Drive Systems 13

ACE Belt Winders 14

ACE Pinch Rollers 14

ACE Structure 15

ACE Pulleys 15

Table of Contents

Fenner Dunlop ACE Conveyor Belt SystemsFenner Dunlop ACE offers complete and tailored engineered conveyor solutions.

ACE Drive SystemsNot all drive systems are the same. Fenner Dunlop’s focus on safety, perfromance and operational maintenance at the design stage yields benefits throughout the equipment life cycle and saves money by generating more uptime for our customers.

Fenner Dunlop ACE drive systems feature: • soft-start technology including VFD, CST, Fixed and Variable Fluid Couplers • integrated overhead crane system • modular design with sub-bases matched and marked for ease of assembly • machined power modules • full shop assembly with power testing • customer specified manufactured belt widths

ACE Discharge/Transfer SystemsFenner Dunlop’s ACE discharge/transfer systems are custom engineered to create a variety of solutions for material handling. Available in inline, angular and 90 degree configurations. Belt widths are manufactured to customer specifications.

Fenner Dunlop’s ACE robust underground transfers typically include: • custom chute design • integrated belt cleaners • impact and roller type slider beds • complete custom component integration

Fenner Dunlop ACE® Conveyor Belt Systems and SolutionsReferenced in this brochure are the types of equipment and systems that Fenner Dunlop ACE is equipped to design, manufacture, repair and refurbish. However, our capabilities are not limited. No job is too large, small or customized.

Give us a call. We have the solutions.

• Turnkey Conveyor Systems

• Component Repairs

• System Refurbishments

ACE SolutionsACE designs and manufactures customized systems and support equipment and is fully equipped to repair and refurbish your existing equipment. Based on performance specifications, time-frame, and equipment preferences, ACE can engineer many variations of equipment to suit any customers’ needs while maintaining safety, quality and production as core values.

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ACE Inline DischargeFenner Dunlop’s ACE inline discharge operates with minimal belt wear and zero spillage. Variables such as production rate, belt speed, minimal height, material size and consistency are used to model trajectory, creating a uniquely engineered bulk-material transfer model. Inline rockboxes, cleaners, skirting and impact bed placement are determined once a model is de-signed for the application.

Just like the 90 degree transfers, the goal of zero wear from using bulk material as an impact media creates a trouble-free system. Assemblies are specially designed with maintenance in mind to change out wearable impact pieces, even after the system has been commissioned and in operation.

Key Features and Benefits: • rock box design for reduced wear from coal transferring • fully enclosed skirting assemblies • hardened wear plates on key impact areas • impact zone frames designed for easy maintenance

ACE Mainline Conveyor Systems Fenner Dunlop ACE Mainline Conveyor Systems typically include inline and angular transfers, drives at any HP and configuration, take-ups with maximum amount of belt storage.

ACE Dual DrivesAvailable in both alignment-free and parallel configurations, Fenner Dunlop’s ACE dual drives are designed to use gearboxes, motors and couplings from various manufacturers. Drives are adapted to match production targets of each mine. All drives are fabricated in our state-of-the-art manufacturing facility. With ease of installation in mind, all pieces are marked to the corresponding joining assemblies. To ensure years of continued operation, fully machined surfaces on gear boxes and motor mounts help avoid premature failure of any drive component. Options such as overhead cranes and full guarding packages satisfy safety and downtime concerns.

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ACE Quad DrivesDesigned for maximum bulk material production in the range of 10,000 tons/hour, Fenner Dunlop’s ACE quad drives offer maximum production output from a compact and logical package. ACE manufacturing technologies produce a drive system you can count on for the entire life of the mine.

ACE quad drives typically use two engineered drive pulleys driven from each end. Customized fitting for each mine is tailored to space availability in each cut area underground. Fully integrated crane systems are unique to ACE drives and allow the change-out of any pulley, coupler, gearbox, fluid coupler, or motor in real time, without tying up extensive mine resources.

Key Features and Benefits: • available up to 4000 HP • overhead crane designed into the unit for safe, efficient installation and removal of gear box, fluid coupler, motor and pulleys to reduce downtime • 3D imaging customizes the fit to each customer’s space requirements in the designated mine area • Comprehensive installation from detailed prints and piece-match marking

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ACE Subbases

ACE Stationary Tail PieceACE stationary tail pieces are available in belt widths manufactured to customer specifications. Stationary tails are typically used on mainline applications back multiple blocks from coal transfer points. Spiral-lagged tail pulleys are typically used to extend belt life.

Key Features and Benefits: • compact A-frame design • incline self-cleaning spiral pulley • static or live shaft pulleys

ACE WinchesACE heavy duty winches for mainline conveyor systems are customized solutions that provide precise tension control of a conveyor belt. ACE winches are high perfor-mance, fully reversible and include smooth or grooved rope drums available from 50 to 250 horsepower.

Typical winch designs use alignment-free motor combi-nations with brake assemblies. Fully integrated electrical controls are available to communicate with drives and load cells to provide optimal tension on panel and main-line belt systems at all times. Key Features and Benefits: • zone lubrication for bearing assemblies • Fenner Drives keyless locking devices • machined bearing assemblies • grooved winch drums to control fleet angle between moveable carriage and winch

ACE Take-up UnitsDouble-lap mainline belt take-ups offer a reliable means of tensioning mainline belts for the entire lifeof the mine. ACE mainline take-ups are constructed with a rigid, stationary pulley “A” frame and one moveable carriage. This take-up can be built in customized lengths and the carriage wheel blocks detach very easily for maintenance.

Key Features and Benefits: • zone lubrication • available with electric winch or hydraulic units • custom length designs • easy detachment of carriage wheel blocks for maintenance

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ACE 90 Degree DischargeFenner Dunlop’s ACE 90 degree discharge uses the ability of bulk material to create an impact area against the inner structure of the transfer for bulk solids to reduce wear and streamline flow without spillage and blockages.

Bulk material drop height onto the out-by belt is minimized to protect against premature wear on topcovers. Heavy subbases, beam construction, and engineered chute panels ensure that discharge installation is a long-term investment that will ensure years of service even through mine growth. Like all underground equipment, piece markings for installation and comprehensive operation manuals are standard.

Key Features and Benefits: • compact design with a drip pan that opens for easy access to cleaners • rock box for reducing wear and impact • heavy duty support structure • integrated cleaner mounting assemblies • skirting assemblies to eliminate spillage • adjustable head pulley mounting • optional integrated snub pulley

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Mine Fitment

Spatial Imaging TechnologySpatial Imaging Technology allows the production of CAD accessible dimensions in a complete 3-D rendering of the installation site. This eliminates 95% of the need for reference measurements and allows us to place ACE equipment in any installation site showing interference and clearances in 3D imaging and renderings.

3D Software Assembly Scans

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ACE Panel Development Conveyor Systems

Fenner Dunlop ACE conveyor systems have tail-loading or intermediate-loading sections and typically include 90 degree or angular discharge units, boom drives, booster drives, storage units, winches (electric or hydraulic), pinch rollers and moveable tail pieces.

ACE 90 Degree Discharge Frame The flow of bulk material through the ACE 90 Degree Discharge creates a natural impact area against the inner structure to reduce wear and streamline flow without spillage and blockages.

Bulk material drop height onto the out-by belt is minimized to protect against premature wear on top covers. Heavy subbases, beam construction, and engineered chute panels ensure that discharge installation is a long-term investment maximizingyears of service even through mine growth. Like all underground equipment, piece markings for installation and comprehensive manuals are standard.

Key Features and Benefits: • compact design with a drip pan that opens for easy access to scrapers • rock box for reducing wear and impact • heavy duty support structure • integrated scraper mounting assemblies • skirting assemblies to eliminate spillage

ACE Angular Discharge/TransferIn the event that section development does not allow use of standard 90 degree or inline transfers, special angular transfer sections are available to fit the mine’s needs. These transfer sections have special provisions built in to allow offset loading and transfer of bulk material to achieve even distribution on to the out by belt.

Key Features and Benefits: • custom design for specific angle • rock box for reducing wear and impact • streamlined material flow to reduce spillage and blockage

ACE Alignment Free Boom & Booster DrivesDesigned to operate in areas such as longwall and development sections, ACE boom/head drives offer the diversity and flexibility to mine coal in any situation. With clean, effective coal transfer onto out-by conveyor assemblies in mind, extendable boom discharges have become a popular option for ACE customers. Adjustable boom height, modular installation, easy maintenance, and compact design make operating in any under-ground area possible.

Key Features and Benefits: • discharge pulley height can be adjusted for proper material flow with the chute height • drive and discharge are in one unit • heavy duty manufacturing allows continued use and decommissioning

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ACE Belt Storage UnitBelt storage units use the key points of take-up units with additional pulleys to increase the amount of storable belt for advancing the active underground mining section. With storage capacities as high as 1,200 feet and beyond, ACE provides diverse offerings to many satisfied customers.

Key Features and Benefits: • zone lubrication on all assemblies • fully machined carriage wheel assemblies • piece-marked assemblies • available with winch or hydraulic units

ACE WinchesACE heavy duty winches for sectional terminals are customized solutions that provide precise conveyor belt tension control. ACE winches are high performance with smooth or grooved drums available from 50 HP to 250 HP.

Typical winch designs use alignment-free motor combinations with brake assemblies. Fully integrated electrical controls are available that communicate with drives and load cells to provide optimal tension on panel and mainline belt systems at all times.

Key Features and Benefits: • four-piece design – power assembly, sub-base, upper frame, and rope drum • zone lubrication for bearing assemblies • Fenner Drives keyless locking devise assemblies on drum/shaft attachment • grooved winch drums to control fleet angle between moveable carriage and winch

ACE Moveable Tail Piece ACE moveable tail pieces are manufactured in belt widths to meet customer specifications and provides the ability to extend the tail pulley toward the mine’s working section as it advances further into the coal seam. ACE moveable tail pieces provide clean underground operation and lower costs by preventing belt damage.

Anchoring options such as stab jacks and hold-down lugs give flexibility to each mining operation. Optional construction in a two-piece design allows larger tail pieces to be taken underground and re-assembled to provide a larger loading surface.

Key Features and Benefits: • compact design for efficient relocation • low-profile models available • equipped with loading chutes and impact beds

ACE Booster DriveACE designs and fabricates booster drives in many configurations. Available in two and four-pulley designs, self-tripping drives greatly improve the reach of under-ground drive systems. Soft-start motors or VFD systems can be integrated into any ACE booster drive assembly. ACE booster drives are designed with the properelectrical controls to power any motor configuration.

Key Features and Benefits: • alignment-free installation of driving components • optional load-cell tripping function • integrated cleaner assemblies • heavy duty components designed for initial drive installation

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ACE De-Watering SystemACE de-watering systems remove water from underground belts to eliminate wash-backs, maintain drier raw coal piles, and reduce wear on out-by conveyor components due to water damage. De-watering systems are typically installed at the discharge/transfer point and are an available option for all ACE discharge systems.

Key Features and Benefits • available for optional installation in 90 degree and in-line transfers • uses common assemblies already used in coal-prep facilities to reduce needed spares - shakers, cyclone separators, augers • minimal running components to reduce downtime • fully integrated electrics that can be incorporated into aboveground monitoring stations

ACE Head-To-Tail Drive SystemsACE head-to-tail drive systems are an innovative solution for longwall mines to optimize mine advancement and development. They enable the mine to apply power to a new conveyor flight eliminating the need for additional drive and power stations.

Key Features and Benefits • head pulley driven by tail of out-by conveyor tail pulley • ability to install additional conveying capacity without downtime pressure • no electrical required • visible disconnect between conveyors • eliminates all rotating shaft hazards • modular compact design for efficient assembly and relocation

ACE Belt Support Equipment

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ACE Pinch RollersPinch rollers pull belt without actually winding it onto a roll and are typically used to recover and lap belt onto an adjacent rail car in underground mining environ-ments. The ACE pinch roller is designed and developed with mine personnel to optimize time for recovering conveyor belt from long panels or mainline drives.

Key Features and Benefits • 80% of construction is wide-flange beams • hydraulic operation with valve placement on either side • staple block fittings on hose connections • zone lubrication and fully protected hose assemblies • two-speed models with shiftable hydraulic motors available • reversible thru sectional valve bank • standard model features a 55,000 pound pulling tension • subbase included that has mine specified hold down assemblies • machined pilot assemblies for gearbox alignment to ensure long life

ACE PulleysACE pulleys are designed using sophisticated computer modeling based on the steady state and transient loads for the conveyor. Each engineered-class pulley is designed and manufactured to individual requirements, ensuring optimum performance on site. ACE engineered pulleys use Fenner Drives® B-LOC keyless locking assemblies. ACE also provides pulleys for smaller and less-critical belt systems manufactured to common industry practices for economical options.

ACE StructureFenner Dunlop ECS has a full range of engineered conveyor structures to meet the most demanding applications for underground mining. Fenner Dunlop’s CEMA E&F structure is tailored for underground mining operations. State-of-the-art engineering and manufacturing processes are used in producing Fenner Dunlop ECS structure. Fenner Dunlop offers both rigid bolt-together and rigid quick-connect structure typically furnished with 5”, 6” and 8”channel rails for long term, demanding underground work environments.

Standard Offering: • rigid bolt-together CEMA E&F structure - 54” to 84” belt widths • slide lock CEMA E-structure - 54” & 60” belt widths • quick lock CEMA E&F structure - 54” – 84” belt widths • 5”, 6” and 8” channel • manufactured in 8’, 10’ and 12’ sections • structure and components can be engineered to retrofit existing system channel rails

ACE Belt WindersACE belt winders quickly reel belt during belt retraction or installation. The winding units are designed with an oversized base for strength and stability and they have high-torque hydraulic motors and planetary gear boxes. The lifting arms are synchronized and the hydraulic line routing is fully protected. An optional turntable feature is available to wind belt and direct the rollout and adjacent entry. ACE belt winders are constructed with durability and versatility in mind.

Key Features and Benefits • customer-defined belt widths • roll diameters up to 100” • oversized base frame • fully protected hydraulic line routing • high-torque motors and planetary gearboxes • optional turntable with 180 degree deck rotation • synchronized hydraulic lifting arms • low profile construction

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©2015 Fenner Dunlop Engineered Conveyor Solutions FDECSACE0215TG

a service to our customers. As operating conditions, performance requirements and conveyor designs vary system to system, no representation or warranty is made by

information provided herein about our products and services are applicable to or will in any way guarantee performance in any individual conveyor system.

any liability whatsoever in regard to the use of the information provided herein by a current or potential purchaser of Fenner Dunlop products or services. A purchaser of Fenner Dunlop products should determine for itself the suitability of such products or

which the products or services will be applied. Please contact Fenner Dunlop Americas,

120 Mine Street

Allison, PA 15413

724-785-6115

scott.croftcheck@fennerdunlop.com

www.fennerdunlopamericas.com