Up to date as of March 2023

BETTER BELT INSIGHTS AND FASTER

REACTION TIMES

CONVEYOR
DIAGNOSTICS
& MONITORING
www.fennerdunlopamericas.com
Manage Your Conveyor Belt
Better with Fenner Dunlop
Monitoring Systems and Services
Instant System Response
Resolving Conveyor Issues
Better Than Anyone
Direct Access to Support
Staff in Minutes

Our systems analyze thousands of events.

However, it’s not about the number of data points, but prioritizing which events matter.
Not just one, but our full team of expert engineers evaluate and analyze the data so you
know when you should immediately react to better protect the longevity of your belt.

How we funnel
and prioritize events:

DATA

INFORMATION

KNOWLEDGE

INSIGHT

IMPACT

Immediate Reaction
Conveyor Diagnostics & Monitoring – 

Fenner Dunlop
Conveyor Diagnostics
Our mobile scanning & fixed monitoring and diagnostic solutions
are best-in-class not only for the data rich insights that help you
elongate the life of your belt, but also for their ease of use.

Fenner Dunlop Conveyor Diagnostics........................................... 3

Mobile Scanning Solutions............................................................... 4
Hidden Damage X-Rays..................................................................................................4
Ultrasonic Thickness Tester............................................................................................4
Steel Cord Scanning.........................................................................................................5
Magnetic Splice Analysis.................................................................................................5
Advanced Rip Detection Technology (Flexi–Loop™)..................................................8
Fixed Monitoring Solutions............................................................ 10
Rip Ranger™...................................................................................................................... 10
EagleEye®......................................................................................................................... 12
BIRDSi®.............................................................................................................................. 14
Training..............................................................................................15

3
To find your local distributor visit www.fennerdunlopamericas.com
 Conveyor Diagnostics & Monitoring – Mobile Scanning Solutions

MOBILE SCANNING
SOLUTIONS
No Hardware Permanently Mounted to Conveyor

Hidden Damage
X-Rays Fabric or Steel

Our technicians use a Vidisco Digital X-ray

Imaging machine to review and analyze
internal steel cable and/or fabric damage.
The digital X-ray “generates” its energy only
when it is needed. Any radi-
ation created by the digital
X-ray is less than your stan-
dard dental X-ray.

Ultrasonic Thickness Tester Fabric or Steel

We use an ultrasonic tester to perform two different tests, depending

on your operation needs:
1. Spot Check: Gathering enough data points to provide an average carry
and pulley cover thickness for your records.

2. Cover Wear Profile: Gathering 20 data points per

splice joint and then compiling into a fully
analyzed report with cover wear and belt
life projections.

20 data points per splice

joint compiled into a fully
analyzed report.

4
Conveyor Diagnostics & Monitoring – Mobile Scanning Solutions

Steel Cord Scanning Magnetized

Steel Cord
(Cord Breaks & Corrosion) Magnetic Flux
Leakage

We use a combination of devices to obtain a proper read on your

steel cord damage, including:
Break in
■ Steel Cord Monitoring Array ■ Data Collection Unit Steel Cord
(Converts to Digital)
■ Fixed Monitoring Earth
Magnet Array
■ Proprietary Software to help
you analyze each data point

Steel cord only

Magnetic Splice Analysis y

(Failures & Elongations) a

We evaluate your splice damage with MFL technology h

(Magnetic Flux Leakage occurs between 2 cords). The signals
are captured and analyzed to determine splice layout and/or N S x
damage. This is often done alongside steel cord scanning.

Steel cord only

To find your local distributor visit www.fennerdunlopamericas.com 5

 Conveyor Diagnostics & Monitoring – Mobile Scanning Solutions

Mobile scanning
Monitoring Case Study
A valued mining customer of Fenner Dunlop had their quarterly
steel cable manual scan with MFL and digital X-ray images.
We identified a massive increase in steel cable damage (largely due to
a cut running the length of the belt that allowed several cables to start
corroding) and a splice that had a vast amount of internal damage.
Our expert engineers organized the most pertinent analysis of the
data in the summary portion of the report to assist the customer in
understanding the problem. We did not just hand over 100+ pages of
data that was collected and leave it with the customer to interpret on
their own.
The X-ray found that the belt was on the verge of failure and the
customer intermediately brought in a belt crew to fix it.

X-ray of 7 damaged
cables pulled out of belt
approximately 2.5 feet from
right edge, near leading edge
of splice.
Fig. 1

X-ray of 12 damaged/
corroded cables
approximately 1 foot from
left edge in middle of splice.
edge of splice.
Fig. 2

6
Conveyor Diagnostics & Monitoring – Mobile Scanning Solutions

X-RAY To find your local distributor visit www.fennerdunlopamericas.com 7

 Conveyor Diagnostics & Monitoring – Advanced Rip Detection Technology (Flexi–Loop)

Fenner Dunlop

Advanced Rip Detection

Technology
Patent-pending High performance
fabric design product

Most loop technology brands have one main flaw that affects your uptime and revenue:
Material Fatigue — Several hours of down time as a result of numerous belt stoppages
and the time required to install new loops. Fenner Dunlop’s patent-pending Flexi-Loop™
Technology solves these common issues. Flexi-Loop™ is a robust product that offers
superior performance and up to 2.5x better life expectancy vs. typical loops.

How Flexi-Loop™ Works:

1. Belt rip detection systems use 2. Loops are embedded into 3. When a belt rip occurs, the
embedded inserts (loops or your conveyor belt and relay loop signal is disrupted and
sensors) that pass detailed your belt’s health back to the the control system stops
information from the sensors control system. your conveyor belt.
to the control system.

8
Conveyor Diagnostics & Monitoring – Advanced Rip Detection Technology (Flexi–Loop)

Competitive Test Results

Flexi-Loop™ outperforms in all categories
Fenner Dunlop is committed to offering a comprehensive line of safe, high performance conveyor belting
products suited for the industry’s toughest applications. Over 150 years of research and development have
gone into engineering and producing our conveyor belting products. In the laboratory, we test our products
to destruction to ensure that our conveyor belts perform exactly as they are designed to do.

Multiple, dynamic tests on competitor loops’ steel material

vs. Fenner Dunlop’s Flexi-Loop’s propriety material

Competitor
Test Types Flexi-Loop™ Advantages
Loop

Tensile Strength 2.2 kN 3.68 kN 67% Stronger

Pullout Test 1.21 kN 1.57 kN 30% Better Adhesion

1 Million Cycle
400k Cycles > 1 Million Cycles 150% Longer Life
Flex Test

Dynamic Conveyor Tested 5 Flexi-Loops with no failures

NA > 1 Million Cycles
Belt (with 45° Idlers) Did not test competitor loop

Comparison

Fenner Dunlop Distance From

Flexi–Loop™ Sensor (in) Competitor
Loop

2 100% 100%

3 100% 100%

4 99% 100%
Competitor
Loop 5 47% 100%

6 13% 87%

7 0% 71%

8 0% 49%
Flexi-Loop™ is North American made.
The construction of the loop begins at our 9 0% 23%
state-of-the-art weaving facility in Lavonia,
GA. Production is then passed on to
our Diagnostics Facility in Bluefield, VA.
10 0% 0%
Flexi‑Loop™ is then embedded into the
pulley cover next to the fabric carcass
during the curing step of the conveyor belt
manufacturing process.
To find your local distributor visit www.fennerdunlopamericas.com 9
 Conveyor Diagnostics & Monitoring – Fixed Monitoring Solutions

FIXED
MONITORING
SOLUTIONS
Conveyor System Equipped with Fixed
monitoring Sensors and Controllers

HOW IT WORKS
When a signal is not received by the receiver because it has been interrupted (caused
by a damaged detection loop for example) then the conveyor is immediately shut down
in order to keep damage to a minimum. Having multiple detection locations is especially
advisable on particularly long individual conveyor belts in order to provide the earliest
possible warning. The simple equation is that the faster the conveyor belt is stopped then
the shorter the length of longitudinal rip damage will be.

ALERT KEY TECHNICAL DATA

The Rip Ranger System specifications are designed
for conveyors operating above ground. Systems for
WARNING use with underground conveyors can be individually
built to meet specific local requirements.
OK Belt Speed: Upto 7m/sec
Belt Thickness: Minimum 6 mm cover thickness –
pulley cover preferred
Belt Type: Steelcord and Fabric


RECEIVED  RECEIVER  RECEIVED RECEIVER
RECEI VER  RECEIVED R E C E I VE R

!
INTERRUPTED INTERRUPTED
DISTORTED !

TR A NS M I TTER TRANS M I TTER TRANSMITTER

10
Conveyor Diagnostics & Monitoring – Rip Ranger™

Fenner Dunlop

RIP RANGER™
Protect your operation with rip detection technology
A conveyor breakdown can often involve huge costs, both in terms of repairs as well as lost productivity. When
belts have to be replaced because of accidental damage then the financial implications can be disastrous.
Although incorporating rip stop breaker plies will reduce the risk, Fenner Dunlop’s Rip Ranger ‘incident alert’
technology will significantly reduce the extent (and cost) of the damage by switching off the conveyor as soon
as a rip is detected.

Components: Applications:
Transmitter, Receiver, Proximity wheel and Any steel cord or fabric belting conveyor
Inductive Loops embedded at set distances with risk of longitudinal rips.
in the belting.

■ Reads up to 1,000 loops per belt

with real-time loop diagnostics.
RECEIVER
■ Helps keep belt repair and
replacement costs to a minimum.
■ Minimizes lost production with RIPPED BELT

automatic belt shut downs limiting

SIGNAL INTERRUPTED

the extent of potential damage.

■ Additional remote units are
available to create up to four
monitoring stations.
LOOP

TRANSMITTER

CONTROLLER
Real-time loop diagnostics

Rip Ranger™ NETWORK

diagram ACCESS (TCP/IP)

To find your local distributor visit www.fennerdunlopamericas.com 11

 Conveyor Diagnostics & Monitoring – Eagle Eye®

Most Complete Steel Cord

Monitoring System

The leading-edge of conveyor diagnostics with the latest breakthrough in the industry.
Eagle Eye Advanced is the most state-of-the-art combination steel cord condition monitoring and rip detection system
available in the market. While the system provides proven 24/7 protection through seamless integration with the conveyor
control, it also allows users on demand access to information about conveyor belt condition. Eagle Eye Advanced allows
for the extraction of historical data to provide users insight on conveyor trends so predictive analytics can be a realization.

Components:
Steel Cord Condition Monitoring Array with precise Encoder feedback,
Magnetic Array, RF Sensors to analyze Inductive Loops embedded at set
distances in the belting.

■ 24/7 protection with steel cord condition monitoring, ■ Proven Allen Bradley PLC processing for reliable
splice analysis, and rip detection. conveyor protection and ease of conveyor control
■ Advanced belt graphics to keep an eye on your integration.
investment in real time with the ability to select ■ Multiple rip detection locations can be added to create
multiple view points and zoom levels. up to four monitoring stations.
■ New multicore processing to couple technical belt ■ Custom engineered product to conveyor
data with an intuitive interface for simplified user specifications manufactured in the USA at a certified
interaction and experience. Rockwell/Fenner Dunlop Facility.
■ Historical data collection for cradle-to-grave analysis. ■ Mark events such as splices or damage events in
■ Automatic reporting, extensive smart log messages specific locations along the conveyor for inspection or
and information filters. maintenance on demand or by schedule.
■ Remote connectivity to other devices such as smart
phones, tablets and control room computers. Upgrade your
■ User defined email and text message available. existing Eagle Eye Systems
■ Superior internal diagnostics for ease of system
Retrofit Kits are available to integrate with your existing
maintenance.
Eagle Eye technology. Any existing Eagle Eye can be
upgraded to our next generation system.
EagleEye® is fully customizable, scans any brand of
belt and the ownership is for life.

1
HOW IT WORKS
The system collects data from multiple sensors 1 to
build a detailed map of events. Once the map of data
is complete it continuously monitors each splice and
steel cord damage 2 events for real-time changes and
2 trends the data so the user is able to forecast potential
issues through an intuitive interface. The system also
continuously monitors inductive loops 3 at up to four
points to ensure belting continuity and minimize risk.

12
 Conveyor Diagnostics & Monitoring – Eagle Eye®

INTELLIGENCE AT YOUR FINGERTIPS

Eagle Eye Advanced makes it extremely easy to identify unexpected or developing belting
problems quickly and pinpoint the failure area with precision. Also next generation internal
diagnostics continuously monitors system hardware health and generates interactive
troubleshooting steps to diagnose and resolve if a problem should occur.

Splice, damage and rip Splice anomalies are easily System Overview allows List of troubleshooting
detection events are quantified and located within a quick look at the health steps for each fault.
actively tracked as the the splice grid display. status of the system and
conveyor stops. each sensor.

New Interface
The new interface allows for additional processing power which enables Eagle Eye
Advanced to collect, store and analyze historical data, and then provide improved
performance trends as to how something might fail, helping you to have a more
comprehensive understanding of the belt life. In addition, our new system offers
increased connectivity, which can be accessed from any smart device including
emails and a new texting feature.

Supporting access from

mobile devices

Join Satisfied Users

More than 100 companies use Fenner Dunlop’s Belt
Monitoring Solutions. Join them!

One of the biggest wins for us purchasing the

Eagle Eye System is the technical support we
have received. The Fenner Dunlop group have
been excellent to deal with. Implement the
complete belt
I attended a two day training on the system that gave
me a very good understanding of the system and how diagnostics system
to use it. The Eagle Eye System is a great system that in your company
does what it advertises.
To find your local distributor visit www.fennerdunlopamericas.com 13
 Conveyor Diagnostics & Monitoring – BIRDSi®

Cloud + Analytics

INS
IG
H
A

TS
T
DA
Dashboard,
System Alerts,
+ Sensors Reports

E
NC
GE
AC
TI L

LI
ON TE
S IN

Facility Manager

YOUR YEARLY BIRDSi®

SUBSCRIPTION INCLUDES:
REAL–TIME, REMOTE ACCESS ■ Instant access to the condition of your conveyor belt
and the EagleEye® Advanced or Rip Ranger system
TO YOUR BELT PERFORMANCE from anywhere
■ Identification of critical belt damage areas and trends in
BIRDSi is a premium online application that identifies the system and belt health performance
potential issues before they create the need for ■ Ability to add notes and messages tied to each belt and
larger, more time-intensive and expensive action. system event

Increase your belt reliability PLUS:

■ Historical Information for each belt event, every day,
and up‑time from the beginning of your belt life to the very end.
Events include what is happening to your splice(s), any
View current and historical belt health events and
damage to your steel cable, and placement / operation
sensor status. of your inductive loops. With our service you can access
Automatically monitor the status of all your conveyors, these anytime through your personalized control panel.
from a single dashboard. ■ Instant Alerts sent via SMS and/or Email (to anyone in-
ternally in your organization) for system warnings, belt
Send and view messages, as well as print the trips, sensor faults, bypasses by the sensor or system,
resolution needed. and parameter or other changes that are necessary to
understand at a moment’s notice.

Ability to connect insights

Any Permanent Advanced PLC
instantaneously to wherever you
Fenner Dunlop Hardware connected to internet
and your team need to see them

Login anywhere via computer To order your system or for more information, please contact
14 or smart phone/tablet [email protected]
Conveyor Diagnostics & Monitoring – Training

TRAINING 2-3 Day

Training Seminar with our Expert Engineers

Fenner Dunlop Diagnostics is proud to offer

comprehensive training on our full range of solutions and 1 Day
in various formats to meet the needs of your bulk Hands On Field Training (During Install)
material handling operation.

Here’s what to expect:

■ General physics of how the different sensors work
■ How to determine where to place your sensors and
equipment to provide the best protection
■ Full wiring and connection details
■ How to fully commission your system once it has
been installed
■ A full overview of the monitoring software
■ In depth troubleshooting processes for hardware,
wiring, and software (full access to systems and test
conveyor)

Both training sets include a reference sheet document

that covers the common features of the systems, Contact [email protected]
how to change normal operation settings and how to for more information on our comprehensive
quickly reset and troubleshoot issues. training program.

To find your local distributor visit www.fennerdunlopamericas.com 15

 Better Manage Excessive
Belt Wear and Damage

Our goal is to extend the working life

of your conveyor systems by providing
safe, value-added and intelligent
solutions through advanced monitoring
systems, innovative inspection programs
and superior service.

[email protected]
Monitoring Solutions Sales

Fenner Dunlop
Belt Monitoring Production
654 Camp Joy Road, Building 2, Suite B
Bluefield, VA 24605
Phone: (276) 322-1426

fennerdunlopamericas.com

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Process Chlorine Free 10% Total Recycled Value

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