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Fenner Dunlop design and manufacture a range of rollers to suit every application.
100% Safe Behaviour & Conditions, Today.
Rol
lers
The best engineered conveyor products for the material handling industry.
Fenner Dunlop stock an extensive and ever growing range of rollers for both surface and underground applications. Our rollers are generally interchangeable with many existing conveyors in the Australian market.
Fenner Dunlop design and quality assurance are of the highest standard to provide confi dence to the client that the product is exactly fi t for purpose. We stock steel rollers subject to specifi c requirements.
Fenner Dunlop Rollers have become the preferred roller of choice for major projects within the Australian and International markets.
Rollers to suit every application;
Steel trough carry rollers
Steel return rollers
Rubber impact rollers
Weigh rollers
Suspended rollers
Rubber disc return rollers
Rubber lagged rollers
Stock available and ready for useFenner Dunlop stock approximately 25,000 rollers in Brisbane with various satellite stores around Australia also stocking popular sizes. All our rollers are caged undercover and ready for immediate use.
CLASSIC HD
CLASSIC PLUS
CLASSIC
Optimising the component design Fenner Dunlop utilise custom developed idler design software to maximise the accuracy and speed of product design and manufacturing.
3D CAD software and Finite-Element Analysis (FEA) packages allow us to optimise the component design and selection process whilst maintaining fl exibility.
R&D & TestingFenner Dunlops’ in-house testing facilities allow for continual product development and peace-of-mind operation, ensuring that our rollers perform to meet client’s requirements and expectations.
Loading geometryIdler loading geometry is based on the Conveyor Equipment Manufacturers Association (CEMA) standard coupled with a numerical analysis of the burden geometry for the highest accuracy loading distribution.
DesignFenner Dunlop Rollers apply a comprehensive approach to the roller design life factoring in bearing fatigue life, grease life and shell wear where possible to help predict a roller’s life.
BearingsDefl ection criteria are monitored to ensure the design exceeds the minimum recommendations. Specifi c lubrication grease is selected to improve the life expectations and shielded bearings are always used to assist in the prevention of contaminant ingress.
ShaftBoth bearing defl ection criteria under running conditions and yield strength under fl ooded conditions are considered during the design phase, using stepped shafts where appropriate to control both values.
ShellFenner Dunlop Rollers specify tight tolerancing on the raw shell materials to provide superior standard TIR and balance properties. Shell thicknesses are varied depending on the site and running conditions to meet client requirements.
HousingSeveral bearing housing options are available depending on the roller series requested ranging from light-medium duty pressed housings through to extra heavy duty solid housings.
ROLLER SERIES GUIDE
BEARING SIZE CLASSIC CLASSIC PLUS CLASSIC HD
6204 • •
6304 • •
6205 • •
6305 • •
6306 • • •
6307 • • •
6308 • •
6309 • •
6310 • •
6311 • •
6312 • •
Quality rollers built to last
CLASSIC CLASSIC PLUS CLASSIC HD
ROLLER SHELL
MaterialGB/T 13793 - Q235B(Grade PD.C, PT.B, PS.C)
GB/T 13793 – Q345B(Grade PD.C, PT.B, PS.C)
GB/T 13793 – Q345B(Grade PD.C, PT.B, PS.C)
Shell Thickness 4mm 4mm + 6mm +
TIR Avg Trough Roller = 0.50mm Avg Trough Roller = 0.50mm Avg Trough Roller = 0.15mm
ROLLER SHAFT
Material GB/T 905 – Q235 GB/T 905 – Q235 GB/T 905 – Q345
Type Plain Stepped Stepped
Bearing Seat Tolerance h8 h6 h6
ROLLER BEARING HOUSING
Material SPCC SPHE Q345
Type Pressed Pressed Cast/Machined
Fit Interference + Weld Interference + Weld Interference + Weld
BEARING
Manufacturer LYC, NSK NSK NSK, FAG, SKF
Sealing 2Z 2Z, 2RS 2Z, 2RS
TypeDeep Groove Ball Bearing, C3 Clearance
Deep Groove Ball Bearing, C3 Clearance
Deep Groove Ball Bearing, C3/C4 Clearance
Lubrication Sealed for Life, ENS equivalent Sealed for Life, ENS Sealed for Life, ENS
SEALING
Material Fire Resistant Nylon Fire Resistant Nylon Fire Resistant Nylon
Type Seal Cleaning LabyrinthSeal Cleaning Labyrinth inc rear seal
Seal Cleaning Labyrinth inc rear seal
Grease HP-R Blue HP-R Blue HP-R Blue
SURFACE PROTECTION
Type 2 Coat Paint System 2 Coat Paint System 2 Coat Paint System
Coating Thickness 40µm 40µm 70µm
PERFORMANCE CHARACTERISTICS
Running Friction 2N* 2N* 2N*
Balance Quality G40 G40 G16
Warranty** 12 months 18 months 24 months
*Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Frictionmeasured at the face as per SANS1313-1. ** Subject to LECS Warranty Terms and Conditions
1 High accuracy Q235 ERW 4mm tube with internal seam burr removed to improve balance
2 SPCC deep drawn interference fi t housing, matched machine to tube recess for high accuracy concentricity
3 Double Shielded C3 sealed for life deep groove ball bearing
4 Tertiary Multi Labyrinth FRAS main seal HP-R grease fi lled
5 Secondary Self draining centrifugal chamber + rear containment cavity
6 Primary ingress prevention cap
7 Rear seal to retain grease and keep contamination out
8 Class 8 precision ground cold drawn bar
Classic All-purpose economy roller
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2
3
6
5
4
78
CLASSICMATERIAL SPECIFICATIONS DESCRIPTION
ROLLER SHELL
MaterialGB/T 13793 - Q235B
(Grade PD.C, PT.B, PS.C)
The Classic Roller shell consists of a 4mm shell compared to the 3.5mm industry standard shell thickness. Unlike the A.S steel specifi cations we’re able to specify a tolerance for each parameter so the roller quality is matched to the client’s requirements. This shell uses:
• High Accuracy (PD.C) Diameter tolerance for consistent TIR• Medium/high accuracy (PT.B) shell thickness tolerance• High accuracy (PS.C) shell straightness tolerance.
All these tolerances meet or exceed AS1450 requirements. We believe by specifying each individual tolerance we can supply a more consistent roller and have better control over our quality. (refer material specifi cations comparison sheet)
Shell Thickness 4mm
TIR Avg Trough Roller = 0.50mm
ROLLER SHAFT
Material GB/T 905 – Q235 The Shaft material is of Grade 8 Q235 precision ground cold drawn bar to GB/T905
Type Plain
Bearing Seat Tol. h8
ROLLER BEARING HOUSING
Material SPCC The bearing housing is SPCC pressed steel, 3.5mm in thickness. The housing has an interference fi t into the shell to provide accurate concentricity, It’s then robotically fi llet welded to completely seal and lock the housing in place. Welds are not in contact with the belt at any time, maximising belt life and roller fatigue life.
Type Pressed
Fit Interference + Weld
BEARING
Manufacturer LYC, NSK Have your choice of NSK or more economical LYC brand bearing in your roller. Both options consist of a double steel shield deep groove ball bearing with C3 clearance. Fenner Dunlop prefer ENS grease in our NSK bearings for the best performance under varying local temperatures especially in the hot Australian climate.
Sealing 2Z
Type Deep Groove Ball Bearing, C3 Clearance
Lubrication Sealed for Life, ENS equivalent
SEALING
Material Fire Resistant Nylon Our Rollers use fi re resistant self-cleaning labyrinth seals. Our seals consist of a 4 part design comprising of:
• A primary steel outer seal that utilizes centrifugal force to expel containments at the face of the roller, this is extremely effective once the roller is at speed and can self-drain water at a 0-45 degree angle.
• A secondary steel containment chamber• A tertiary grease fi lled multi labyrinth seal chosen to minimise running friction
whilst still preventing the ingress of contaminants.• Finally there is a back seal on the opposite side of the bearing to stop reverse
contamination of the bearing.
Both the front and rear sealing are fi lled with HP-R type grease which provides a high drop point of 250 degrees whilst providing optimal viscosity for best ingress protection, low running friction and low energy consumption.
Type Self Cleaning Labyrinth
Grease HP-R Blue
SURFACE PROTECTION
Type 2 Coat Paint System The standard roller comes with a 2 coat paint system which is applied to the face, bearing housing and shaft ends providing storage protection and anti-rust properties whilst in service.Coating Thickness 40µm
PERFORMANCE CHARACTERISTICS
Running Friction 2N*
Balance Quality G40
Warranty** 12 months
* Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction measured at the face as per SANS1313-1 ** Subject to Warranty Terms and Conditions
1 High accuracy Q345 ERW 4mm + tube with internal seam burr removed to improve balance
2 SPHE deep drawn interference fi t housing, matched machine to tube recess for high accuracy concentricity
3 Double Shielded (Steel or Rubber) NSK C3 sealed for life deep groove ball bearing
4 Tertiary Multi Labyrinth FRAS main seal HP-R grease fi lled
5 Secondary Self draining centrifugal chamber + rear containment cavity
6 Primary ingress prevention cap
7 Precision machined bearing seat & shoulder for optimal bearing alignment and extended life
8 Rear seal to retain grease and keep contamination out
9 Class 8 precision ground cold drawn bar
1
2
3
6
5
4
8 79
Classic Plus High quality roller - built to last
CLASSIC PLUSMATERIAL SPECIFICATIONS DESCRIPTION
ROLLER SHELL
MaterialGB/T 13793 - Q345B
(Grade PD.C, PT.B, PS.C)
The Classic Plus Roller shell consists of a 4mm shell compared to the 3.5mm industry standard shell thickness. Unlike the A.S steel specifi cations we’re able to specify a tolerance for each parameter so the roller quality is matched to the client’s requirements. This shell uses:
• High Accuracy (PD.C) Diameter tolerance for consistent TIR• Medium/high accuracy (PT.B) shell thickness tolerance• High accuracy (PS.C) shell straightness tolerance.
All these tolerances meet or exceed AS1450 requirements. We believe by specifying each individual tolerance we can supply a more consistent roller and have better control over our quality. (refer material specifi cations comparison sheet)
Shell Thickness 4mm+
TIR Avg Trough Roller = 0.50mm
ROLLER SHAFT
Material GB/T 905 – Q235 The Shaft material is of Grade 8 Q235 precision ground cold drawn bar to GB/T905. The shaft is precision machined to house the bearing with a stepped shoulder for increased bearing support.
Type Plain
Bearing Seat Tol. h8
ROLLER BEARING HOUSING
Material SPHE The bearing housing is SPHE pressed steel, 3.5mm in thickness. The housing has an interference fi t into the shell to provide accurate concentricity, It’s then robotically fi llet welded to completely seal and lock the housing in place.Welds are not in contact with the belt at any time, maximising belt life and roller fatigue life.
Type Pressed
Fit Interference + Weld
BEARING
Manufacturer NSK NSK deep groove ball bearing with C3 clearance are used in all Classic Plus Rollers and utilize 2zz or 2rs sealing depending on the application. Fenner Dunlop exclusively use ENS grease in our NSK bearings for the best performance under varying local temperatures especially in the hot Australian climate.
Sealing 2Z
Type Deep Groove Ball Bearing, C3 Clearance
Lubrication Sealed for Life, ENS equivalent
SEALING
Material Fire Resistant Nylon Our Rollers use fi re resistant self-cleaning labyrinth seals. Our seals consist of a 4 part design comprising of:• A primary steel outer seal that utilizes centrifugal force to expel containments at
the face of the roller, this is extremely effective once the roller is at speed and can self-drain water at a 0-45 degree angle.
• A secondary steel containment chamber• A tertiary grease fi lled multi labyrinth seal chosen to minimise running friction
whilst still preventing the ingress of contaminants.• Finally there is a back seal on the opposite side of the bearing to stop reversecontamination of the bearing caused by condensation.Both the front and rear sealing are fi lled with HP-R type grease which provides a high drop point of 250 degrees whilst providing optimal viscosity for best ingress protection, low running friction and low energy consumption.
Type Self Cleaning Labyrinth
Grease HP-R Blue
SURFACE PROTECTION
Type 2 Coat Paint System The standard roller comes with a 2 coat paint system which is applied to the face, bearing housing and shaft ends providing storage protection and anti-rust properties whilst in service.Coating Thickness 40µm
PERFORMANCE CHARACTERISTICS
Running Friction 2N*
Balance Quality G40
Warranty** 18 months
* Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction measured at the face as per SANS1313-1 ** Subject to Warranty Terms and Conditions
1 High accuracy Q345 ERW 6mm + tube with internal seam burr removed to improve balance
2 Precision machined Q345 billet housing withstands high loads and guarantees the tightest tolerances for optimal bearing clearances under extreme dynamic loading
3 Double Shielded (Steel or Rubber) NSK, FAG or SKF C3/C4 sealed for life deep groove ball bearing
4 Tertiary Multi Labyrinth FRAS main seal HP-R grease fi lled
5 Secondary Self draining centrifugal chamber + rear containment cavity
6 Primary ingress prevention cap
7 Precision machined bearing seat & shoulder for optimal bearing alignment and extended life
8 Rear seal to retain grease and keep contamination out
9 Class 8 precision ground cold drawn bar
1
2
3
6
5
4
8 79
Classic HDHigh quality roller - built to last
CLASSIC HDMATERIAL SPECIFICATIONS DESCRIPTION
ROLLER SHELL
MaterialGB/T 13793 – Q345B
(Grade PD.C, PT.B, PS.C)
The Heavy Duty Roller shell consists of a 6mm shell compared to the 3.5mm industry standard shell thickness. Unlike the A.S steel specifi cations we’re able to specify a tolerance for each parameter so the roller quality is matched to the client’s requirements. This shell uses:• High Accuracy (PD.C) Diameter tolerance for consistent TIR• Medium/high accuracy (PT.B) shell thickness tolerance• High accuracy (PS.C) shell straightness tolerance.All these tolerances meet or exceed AS1450 requirements. We believe by specifying each individual tolerance we can supply a more consistent roller and have better control over our quality. (refer material specifi cations comparison sheet)
Shell Thickness 6mm +
TIR Avg Trough Roller = 0.15mm
ROLLER SHAFT
Material GB/T 905 – Q345 The Shaft material is of Grade 8 Q345 precision ground cold drawn bar to GB/T905. The shaft is precision machined to house the bearing with a stepped shoulder for increased bearing support.
Type Stepped
Bearing Seat Tol. h6
ROLLER BEARING HOUSING
Material Q345 Bearing housings are made from cast Q345 and precision machined for best fi t. Housings are specifi cally designed for each application to maximise roller life and durability whilst minimizing bearing defl ection and fatigue. The housing has an interference fi t into the shell to provide accurate concentricity, It’s then robotically fi llet welded to completely seal and lock the housing in place. Welds are not in contact with the belt at any time, maximising belt life and roller fatigue life.
Type Cast/Machined
Fit Interference + Weld
BEARING
Manufacturer NSK, FAG, SKF NSK deep groove ball bearing with C3 or C4 clearance are used in all Classic HD rollers and utilize 2zz or 2rs sealing depending on the application. FAG & SKF bearings are also available upon request. Fenner Dunlop exclusively use ENS grease in our NSK bearings for the best performance under varying local temperatures especially in the hot Australian climate.
Sealing 2Z, 2RS
TypeDeep Groove Ball Bearing,
C3/C4 Clearance
Lubrication Sealed for Life ENS
SEALING
Material Fire Resistant Nylon Our Rollers use fi re resistant self-cleaning labyrinth seals. Our seals consist of a 4 part design comprising of:• A primary steel outer seal that utilizes centrifugal force to expel containments at
the face of the roller, this is extremely effective once the roller is at speed and can self-drain water at a 0-45 degree angle.
• A secondary steel containment chamber• A tertiary grease fi lled multi labyrinth seal chosen to minimise running friction
whilst still preventing the ingress of contaminants.• Finally there is a back seal on the opposite side of the bearing to stop reverse
contamination of the bearing caused by condensation.Both the front and rear sealing are fi lled with HP-R type grease which provides a high drop point of 250 degree’s whilst providing optimal viscosity for best ingress protection, low running friction and low energy consumption.
Type Self Cleaning Labyrinth
Grease HP-R Blue
SURFACE PROTECTION
Type 2 coat paint system The standard roller comes with a 2 coat paint system which is applied to the face, bearing housing and shaft ends providing storage protection and anti-rust properties whilst in service.Coating Thickness 70µm
PERFORMANCE CHARACTERISTICS
Running Friction 2N* All premium HD Rollers come dynamically balanced to reduce noise and vibration and are 100% quality checked at fi nal assembly to ensure reliable and optimal performance.Balance Quality G16
Warranty** 24 months
*Based on 152 Dia Roller, 6306 NSK Bearing with Self Cleaning Labyrinth Seal running at 750rpm. Running Friction measured at the face as per SANS1313-1** Subject to Warranty Terms and Conditions.
ROLLER TUBE MATERIAL COMPARISON:AS1450 vs GB/T 13793
AS1450Steel Tubes for
Mechanical Purposes
GB/T 13793Steel Tubes with a Longitudinal
Electric (Resistance) Weld(PD.C, PT.B, PS.C)
Document Scope Specifi cation for carbon and carbon-manganese steel tubes (incl. round), hot and cold forming for mechanical applications
Specifi cation for general-purposehigh frequency ERW tube withOD < 630mm
GEOMETRIC PROPERTIES
Straightness 1.67mm in 1000mm 0.5mm in 1000mm
Outer-Diameter Variation 100 to 125 OD : ± 0.5mm125 to 150 OD : ± 0.6mm150 to 175 OD: ± 0.7mm> 175 OD: ± 1%
80 to 114.3 OD : ± 0.4mm114.3 to 219.1 OD : ± 0.6mm
Wall Thickness ± 10% > 3.2 to 3.8mm : ± 0.2mm> 3.8 to 4.0mm : ± 0.22mm> 4.0 to 5.5mm : ± 7.5%> 5.5 : ± 10%
Roundness Not controlled/specifi ed < 50 % of OD variation tolerance
ERW burr Not controlled/specifi ed - 0.05 to + 0.20 mm
Mechanical Properties
Yield StrengthC250 or H250 : 250 MPaC350 or H350 : 350 MPa
Q235B : 235 MPaQ345B : 345 MPa
UTSC250 or H250 : 350 MPaC350 or H350 : 450 MPa
Q235B : 375 MPaQ345B : 470 MPa
Elongation before FractureC250 or H250 : 22 %C350 or H350 : 20 %
Q235B : 20 %Q345B : 18 %
ROLLER SHAFT MATERIAL COMPARISON:AS1443 vs GB/T 905
AS1443Carbon and carbon-manganese
steel – Cold fi nished bars
GB/T 905Dimension, shape, weight and
tolerance for cold-drawn round,square and hexagonal steels
Document Scope Specifi cation for cold-fi nished carbon and carbon-manganese steel bars (incl. round) for general engineering purposes
Specifi cation for the dimension,shape, weight and tolerance forcold-drawn round, square andhexagonal steels from 3 to 80mm
GEOMETRIC PROPERTIES
Straightness 2mm in 1000mm> 25 to 50mm : 0.75mm in 1000mm> 50 to 80mm : 0.5mm in 1000mm
Diameter Variation h8 h8
Roundness< 50 % of diametervariation tolerance
< 50 % of diametervariation tolerance
Mechanical Properties
Yield Strength M1020 : 340 MPaQ235B : 235 MPaQ345B : 345 MPa
UTS M1020 : 430 MPaQ235B : 375 MPaQ345B : 470 MPa
Elongation before Fracture M1020 : 13 %Q235B : 20 %Q345B : 18 %
Rollers life cycle Whilst the initial capital cost of a roller is often the only commercial consideration in a new product purchase, the total life-cycle cost is generally much more important.
Roller Life-Cycle
PurchaseCapital Cost
InstallationEase of installation, OH&S - manual feeding
OperationFriction, rim drag - Power Consumption
MaintenanceTime between maintenance, wash down etc.
ReplacementOperation life (L10, grease life, etc.), supply chain & leadtimes
RecyclingCost of disposal, recycling options
World-Class TechniciansUndoubtedly, our highly skilled engineers and technicians are what really set us apart. We take staff training seriously - so seriously in fact that Fenner Dunlop has its own registered training organisation to ensure all technicians reach the highest industry standards and qualifi cation levels. Our technicians bring this knowledge to your operation, to support your business.
AccountabilityService is not just a word to Fenner Dunlop. It is in our culture, our training and our attitude. We take full accountability for the projects that you entrust to us. We always take a collaborative approach to solutions and this has been the key to our growth and success. Importantly, this growth and success have not changed our focus on highly customised and personal service.
We know that we are the only company in Australia that can provide a complete engineered conveyor solution, regardless of which OEM conveyor system you have. We take this responsibility very seriously, always ensuring that your needs are our objectives.
Remember - whether you need advice, an urgent repair, or the complete after sales service platform, one phone call is all it takes.
Thinking Globally. Acting Locally.With 4,800 employees and over 30 factories worldwide, we are always at the forefront of international research and development into conveyor systems and productivity. What matters to you most, of course, is that our regional service branches are conveniently located throughout Australia, which means that help is never far away.
Single Source ProviderFenner Dunlop offer complete conveyor solutions and components as a single-source provider.
Quality Systems and Components
Dependable Conveyor Services
Value Adding Diagnostic Services
Precise Engineering
State of the Art Facilities
Talk with us about our complete range of engineered conveyor solutions.
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The expertise and support you need, fast.
Thinking Globally. Acting Locally.
Cairns
Townsville
Mackay
RockhamptonGladstone
Brisbane
SomersbySydney
Wollongong
Melbourne
Adelaide
Whyalla
Burnie
Emerald
Mt Isa
Darwin
Port Headland
Karratha
Perth
Thinking Globally. Acting Locally.
It doesn’t matter what challenge you are facing with your conveyor or how small or large the problem, we have Fenner Dunlop service centres nationwide with fully trained technicians ready to take your call and provide the required support.
Phone 1800 Fennerwww.fennerdunlop.com.au
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