S-Wall™ Sidewall Conveyor Belting: Technical Manual

S-Wall™ Sidewall Conveyor Belting
Technical Manual
The definitive technical guide
to steep angle conveying
utilising the S-Wall™ corrugated
Sidewall Conveyor Belt
Features
System Analysis
Extreme Conveyor Belt Solutions
Full Product Details
Conveyor Design Criteria
Installation Procedures
Splicing Details
Tracking Guide + Maintenance Guide
S-WALL™
Introduction
Since 1984 the S-Wall brand has been committed to the

development of the Sidewall Conveyor Belt System. The
launch of S-Wall™ represents the latest developments in
steep angle conveying using the Sidewall Conveyor Belt
System.
This new brochure contains our current technical data on

both components and conveyor design. The brochure is
produced in loose-leaf format so that we may keep you
up to date with the latest developments, if you need more
detailed information than that shown here please contact
our technical sales department.
S-Wall™ is the latest generation of Sidewall Conveyor

Belts, following a considerable investment programme We hope that you find this brochure of interest and can
we now produce the profiles at our new dedicated find the information you require, whether it’s for loose
factory in Germany. The design of the new profiles and profiles or design criteria for a new installation. If you have
the equipment used in the production is of the highest any doubts or would like more information please contact
technical standards. New revised polyester fabrics our sales or technical departments for assistance.
used in our range of cross-stabilised base belts mean
higher rigidity values with very low elongation and newly PHOENIX Conveyor Belt Systems GmbH
developed rubber compounds for our Sidewalls and Hannoversche Straße 100
Cleats ensure they can withstand the high stresses 21079 Hamburg
imposed in high capacity steep angle conveying. Germany
Ph: +49 (0)40 7667-03
The Sidewalls are produced from a high elasticity and Fax: +49 (0)40 7667-2413
high strength rubber compound and offer excellent info@phoenix-cbs.com
flexibility and therefore maximum flexing. The use of www.phoenix-conveyorbelts.com
diagonal fabric for the reinforcement within the Sidewalls
ensures maximum elongation of the fabric at the
flexing points as well as increasing tensile strength, again
increasing the life of the Sidewall The assembly lines
for complete belts has also received new investments
for maximum quality standards and higher productivity.
The recently installed computer controlled roughening
machine can precisely roughe the base belt automatically
and to an exact depth, important in ensuring maximum
bond strengths.
2 PHOENIX Conveyor Belts

S-WALL™
System Advantages
1. No Transfer Points
From the feed hopper to the discharge point, the belt
is capable of turning through any angle up to a vertical
line and back to the horizontal. This eliminates the need
for multi drives and prevents product degradation and
spillage at transfer points. In addition the method of
feeding the belt reduces further still dust and pollution.
Material is loaded onto the

horizontal feed point and
stays within the belt until it is
discharged at the head end
without transferring it from one
system to another.
2. No Spillage with Steep Angle Conveying

Once material is loaded onto the belt it is effectively
contained between the Sidewalls and is prevented by
the cross cleats from falling back. As the belt travels
along the conveying line it retains the load within its own
‘side skirts’, eliminating spillage, but more importantly, as
the Sidewalls actually form part of the belt there is none of
the wear normally associated with side skirts. The smooth
transition when changing angle also ensures the material
remains within the belt’s effective carrying area.
3. Maximum Utilisation of Space

In areas where land is at a premium, i.e. dockside,
or within existing plant where space is a problem, the
S-Wall™ Sidewall Conveyor Belt System provides the
ideal solution. With the ability to convey material at angles
up to 90° the required ground space is minimal.
Illustration of ground saving ability of the S-Wall™ system.
PHOENIX Conveyor Belts 3

S-WALL™
System Advantages
4. Minimum Maintenance, Long Belt Life

In comparison between mechanical elevators and
Sidewall Belt systems it has been proven that the
S-Wall™ Sidewall Belt has considerable advantages. The
belt itself requires no maintenance and the reduced
number of moving parts plus simple conveyor construction
virtually eliminates costly downtime. The actual
components used in the belt have been developed from
high strength abrasion and wear resistant material to extend
operational life. The design of the corrugated Sidewalls
is such that they have excellent resistance to idler
penetration on return side supports.
5. Wide Range of Materials can be Handled

With the extensive range of belt sizes available, the
PHOENIX S-Wall™ Sidewall Conveyor Belt System is

capable of handling almost all materials: large lumps, free
flowing, delicate or fragile substances, highly abrasive
material, light weight or heavy loads. Our application
engineers have the experience and a thorough working
knowledge to specify the systemto suit your needs.
6. Low Power Requirement, Quiet Smooth Running

A clear advantage of using an PHOENIX S-Wall™
Sidewall Conveyor Belt System is the low power required
to move the loaded belt. Because the system can elevate
at steep angles (up to 90°) centre distances tend to be
small and even in high lift applications power required to
elevate is considerably less than in other systems. As the
belt is running on rotating idlers, the low resistance results
in a quiet system, an advantage when operating in close
proximity to personnel. Where environmental factors need
to be considered, the system can be totally enclosed.

S-WALL™
Profiles
The next section gives details of the S-Wall™ range of profiles.
Sidewalls 6
Cleats 8
Cross-Stabilised Base Belts 11

S-WALL™
Sidewalls
S-Wall™ Sidewalls are available in 4 basic product

groups as shown below. If purchased as loose profiles the
Sidewalls are packed into non-returnable containers,
there is not normally any minimum order quantity, however
for special qualities please check before ordering. Please
refer to your price list for information on ordering and
quantity discounts.
PHOENIX S-Wall™ corrugated Sidewalls represent the

latest in design ideas and manufacturing techniques.
PHOENIX S-Wall™ Sidewalls are manufactured

The Sidewall design ensures maximum flexing without utilising the latest production techniques.
fatigue, the profile has excellent vertical stability for load Type S
retention and return side support. The design allows Standard Construction in heights from 40mm to 120mm.
for high compression to ensure smooth inner deflection Future developments will include the possibility to supply
around small radii. Another important design feature is with a Tacky Back.
that the Sidewalls can be pressed from both sides when
mounting, this offers much higher bond strengths and Type SR
security. Standard construction but with Diagonal Fabric
Reinforcement.
The fabric insertion is of the diagonal type which gives
excellent tear resistance and also allows the Sidewall to Type HDSR
flex more easily. Heavy duty construction including fabric reinforcement
as standard in heights from 120mm to 300mm. The
The rubber compounds used have been tested to ensure fabric reinforcement is of the diagonal type ensuring
maximum flexibility along with high abrasion resistant and maximum flexibility with high vertical stability. If required
high tensile strength. these can be supplied without fabric reinforcement to
special order, Ref: HDS.
The ‘in-house’ test conveyor designed and built
specifically to test the new range of S-Wall™ Sidewalls Type XHDSR
has proved the design and rubber compounds work Heavy duty Special design including fabric reinforcement
together in harmony increasing the life of the Sidewall and as standard in heights from 300mm to 630mm.
ensuring maximum durability.
Rubber Qualities
Black Standard High Abrasion Resistant
Black Oil and Fat Resistant
Heat Resistant to 100°C
High Heat Resistant to 130°C
Flame Retardant

S-WALL™
Sidewalls
Type H Sw Tw P Min Pulley Dia. Weight

mm kg/m
40 35 30 30 125 0.60
60 50 45 40 160 1.80
S*
80 50 45 40 200 1.80
120 50 45 40 250 2.23
120 75 70 60 315 2.67
160 75 70 60 400 4.77
200 75 70 60 500 6.48
HDS*
250 75 70 60 630 7.55
280 75 70 60 800 8.60
300 75 70 60 800 9.30
300 100 90 75 800 12.50
XHDS**
400 100 90 75 1000 18.75
* Denotes available with or without Fabric Reinforcement.
** Available only with Fabric Reinforcement.

S-WALL™
Cleats
All S-Wall™ Cleats have been specifically design to give optimum performance. The shape of the ‘C’ and ‘TC’
types has been created to offer best conveying capacities along with excellent self-cleaning properties. S-Wall™
cleats are either of the extruded type for the smaller profiles, all larger cleats are moulded to give the best shape re-
tention even when conveying high-density materials. Cleats are available in either 2.5 m for moulded and 3 m/5 m
lengths for extruded profiles. Cleat profiles are shipped in non-returnable packing cartons, please refer to the price list
for ordering details.
1. Type ‘Tk’ 2. Type ‘T’

Used as a drag-out cleats.
3. Type ‘MBT’ 4. Type ‘T-XS’

Separate moulded base, cleat blade The cleat base is a moulded section
can be of rubber or PU and can be of and the blade is bolted into position.
any height.
5. Type ‘C’ 6. Type ‘TC’
7. Type ‘MBTC’ 8. Type ‘TC-XS’

Separate moulded base, cleat blade The cleat base is a moulded section
can be of rubber or PU and can be of and the blade is bolted into position.
any height.
Side Blinkers.
Side Blinkers can be fitted in-between the ross cleats
profile and the Sidewall to make a seal. Side Blinkers are
used when the material is particularly free flowing.

S-WALL™
Cleats
Cleat Types Height Base Width Weight Min Pulley Dia. Production Length
mm mm kg/m mm m
Type C 35 55 0.50 100 3/5

55 75 1.50 125 3/5
75 80 2.00 150 3/5
90 110 2.30 250 3/5
110 110 2.50 315 3/5
Type TC 75 80 1.80 150 3/5

90 110 2.50 250 3/5
110 110 2.80 315 3/5
140 160 6.60 400 2.5
180 160 8.30 500 2.5
230 175 10.46 630 2.5
Type MBTC 110 160 7.90 315 3

140 160 9.25 400 3
180 160 11.50 500 3
230 160 13.50 630 3
250 160 14.60 630 3
280 160 17.65 800 3
360 160 19.25 1000 3
Type TC-XS 230 225 17.95 630 2.5

250 225 18.90 630 2.5
280 225 22.50 800 2.5
360 230 26.00 1000 2.5
The above are standard heights, non-standard are available, please enquire.
Ancillary Equipment for S-Wall™ Cleat Profiles

Screw Reinforcement sets are available in a selection of sizes to suit specific Cleat designs as follows:
• Type 1 Cleat height 75 mm
• Type 2 Cleat heights 90 mm to 110 mm

S-WALL™
Cleats
Cleat Types Height Base Width Weight Min Pulley Dia. Production Length
mm mm kg/m mm m
Type Tk 35 110 1.65 100 3/5

40 110 1.80 100 3/5
20 40 0.28 75 3/5
25 40 0.3 75 3/5
35 55 0.55 100 3/5
40 70 0.60 125 3/5
Type T 55 80 1.45 125 3/5
75 80 1.80 150 3/5
90 110 2.50 250 3/5
110 110 2.80 315 3/5
140 160 6.60 400 2.5
180 160 8.30 500 2.5
230 175 10.46 630 2.5
Type MBT 110 160 7.90 315 3
140 160 9.25 400 3
180 160 11.50 500 3
230 160 13.50 630 3
250 160 14.60 630 3
280 160 17.65 800 3
360 160 19.25 1000 3
Type T-XS 230 210 17.85 630 2.5

250 220 18.60 630 2.5
280 230 19.50 800 2.5
360 230 22.50 1000 2.5
Ancillary Equipment for S-Wall™ Cleat Profiles

Screw Reinforcement sets are available in a selection of sizes to suit specific cleat designs as follows:

S-WALL™
Base Belts
The PHOENIX S-Wall™ range of cross-stabilised base

belts has been developed in conjunction with Europe’s
leading conveyor belt manufacturers. Please enquire as
to the suitability of any given belt for the application for
which you intend to use the belt, alternatively allow us to
calculate the belt for you, please see the enquiry section
for details.
Type ‘XE’
This belt incorporates the cross-stabilising ply in the
tensioning ply, mainly used for medium duty applications.
Type ‘XE+2’
The cross-stabilising ply and tensioning plies are
separate, in this case the belt has 2 crossstabiling plies,
application areas are medium to heavy.
Type ‘XE-SC+2’
This belt incorporates textile tensioning plies with
Steelcord cross-stabilising members. The high ateral
stiffness means the belt can be used in application areas
where rigidity is an important factor, i.e., high lift heights
and wide belts.
Type ‘XST-SC’
This belt incorporates Steelcord tensioning with Steelcord
cross-stabilising members. High tensile strengths can
be achieved making the belt ideal for high vertical lift
applications.

S-WALL™
Base Belts
Base Belt Type Strength Cover Thickness Weight Min Pulley Dia.
N/mm mm kg/m mm
Type XE 250/2 2:2 9.40 200
400/3 4:2 13.50 315
500/3 4:2 13.75 400
630/4 4:2 15.20 500
800/5 4:2 16.85 630
Type XE+2 400/3+2 4:2 12.10 315
500/3+2 4:2 12.60 400
630/4+2 4:2 14.40 500
800/5+2 4:2 16.10 630
1000/5+2 4:2 17.80 800
1250/5+2 4:2 18.25 1000
Type XE-SC+2 315/2+2 4:2 13.70 315
400/3+2 4:2 14.50 315
500/3+2 4:2 15.20 400
630/4+2 4:2 16.70 500
800/5+2 4:2 18.00 630
1000/5+2 4:2 19.50 800
1250/5+2 4:2 21.40 1000
Type XST-SC* 1600 8:8 1250
2000 8:8 1250
2500 8:8 Please Enquire 1400
3150 8:8 1400
3500 8:8 1600
4500 8:8 1600
*Belt weight will be decided by the final belt design which is dependant on the application.
Belt Composition Cover Thickness

X = Cross-Stabilised construction Above are standard constructions, belts can be supplied
E = Polyester Tension Plies with non-standard covers to special order.
+2 = Number of Separate Cross-Stabilising Plies
SC = Steel Cord Cross-Stabilised Belt Strength
XST-SC = Steel Cord Above are standard items, others available to special
order.
Note
Pulley diameters shown are for normal quality,
and standard cover thickness. Please enquire for
recommended diameters on belts with special quality
covers or different tensile ratings as these may require
larger diameters.

S-WALL™
Design Information
The next section gives details on the basics of correct conveyor design for S-Wall™ steep inclineconveyors.
Customers are strongly recommended to check with our technical department if unsureabout any aspect of belt
selection or conveyor design.
Carrying Side Support 14
Return Side Support 15
Belt Feeding and Feed Hopper Design 16
Upturn Deflection 17
Top Inner Deflection 19
Drive and Tail Pulley 20
Pulley Crowning 21
Snubbing 22
Downturn Deflection 23
Bottom Inner Deflection 24
Belt Cleaning 25
Guiding Wheels 27
Belt Tracking 29
Ancilliary Equipment 30

S-WALL™
Carrying Side Support
Generally idlers are pitched at a maximum of 1000mm along the carrying side. Additional idlers are required underneath
the feed hopper to give sufficient support to the belt; it is recommended that they be rubber covered in case of
high impact.
Idler Diameter D2 Dimension L

Sidewall Type D2 mm Bw mm Lmin mm
S 89 ↔ 108 400 ↔ 700 50
HDS 108 ↔ 133 700 ↔ 1400 75
XHDS Please enquire 1400 ↔ 2000 100
Note
The above are an indication only, the actual idler diameter needs calculating for the necessary load support, for the
idlers at the deflection points please refer to the appropriate page for guidance on selecting the correct idlers.

S-WALL™
Return Side Support
Method of determining return side idler pitch.

Generally on the horizontal sections the idler pitch is max
1000mm, however on the return side decline section the
idlers can be spaced out according to the sketch shown
opposite.
Stub Idlers
Method of determining idler pitch on return side.
Stub idlers are used mainly for heavy belts, or where
return side space is limited, and where build-up on con- α = 3° Steel Cord belts fg = 20% fs
5° textile belts
ventional idlers could occur. By setting the idlers at 3° or 5°
(depending on belt construction) belt tracking is assisted.
It is important that only stub idlers with rounded dome
Rounded
end caps are used and are slot mounted for adjustment. Dome Cap
The pitch of the stub idlers on the return side is max

1000mm on the horizontal and for the decline section the
pitch is determined as per the sketch. An allowance of
1% of the axle distance needs to be allowed for belt sag.
Bw. Please check for max. recommended widths.
Full Width Idlers

Idler diameter depends on belt weight and Sidewall type.
For larger belts stub idler support is recommended. If
insufficient sized idlers are used premature wear to the
Sidewalls can occur. In certain cases the method of
Bw is dependant on base belt type.
calculating return side pitch results insufficient support,
Please check for max. recommended widths.
i.e. low tension applications, to avoid excessive sag For Lmin see page 14.
please contact the PHOENIX technical department for

advice.
Sidewalls can also be inset.
Belts Without Cross Cleats

The recommended method is by inner lying disc wheels
or idlers. The number and positioning of these is
dependent on belt width and base belt type.
Particular care should be taken in ensuring sufficient
Max. pitch 1000 mm.
support adjacent to the Sidewalls and in calculating
clearance between Sidewalls andsupporting shafts.

S-WALL™
Belt Feeding and Feed Hopper
Feed Hopper
The design of the feed hopper is important in that it
optimises the system’s efficiency. Material can be fed
into the belt from any direction (although in-line is the
preferred direction), providing the belt pockets have Y
an even fill. The capacity calculation for S-Wall™ belts α
*Please check for the
assumes that material will be spread and distributed
Maximum recommended
evenly across the pockets. angle for inclines feeding.
Sec AA
If possible the hopper should be adjustable in the vertical α*
plane to optimise its position in relation to the top of the
Sidewalls.
Belt support under the feed hopper should be increased Incline Feeding
to prevent belt sag and absorb impact. Rubber covered

idlers are normally used although impact bars are an
acceptable means of support.
Dimension Y
Y
When loading onto the horizontal the length of the back
plate is min 1.5 x Cleat pitch. If loading directly onto the Sec AA α
incline section dimension Y needs to be increased to min

2.5 x Cleat pitch. It should be noted that normally the
maximum angle for loading onto the incline section is 40°
where after a horizontal feed station is required. If it is Horizontal Feeding
necessary to load at angles greater than 40° please

contact our technical department.
Angle α
A 0,5 x sw 0,5 x sw
The angles of the hopper sides are normally determined sw sw
by the material flow characteristics. Generally the hopper Depends on material

angle should be no less than 65°. Adjustable response angle
α
3-5mm
Note
The shaded idler detail shows how you can use a split
idler under the feed hopper to support the belt, this
system is very good where heavy material impact is
expected to occur, please consult our technical dept. for
more information.
sw

S-WALL™
Upturn Deflection
Stub Idler Upturn Deflection

The minimum recommended idler diameters for the
corresponding sidewall heights are as follows:
Type D
mm
S40 63.5
S60 63.5
S80 89
1.5 x D
S100 89
S120 89 Type ‘S’ = 15°
Others = 10°
HDS120 108
HDS160 108
HDS200 108
HDS250 133 α
HDS280 133
HDS300 133
XHDS300 Enquire
XHDS400 Enquire
The diameter of the radius is determined by the belt

speed, angle of inclination and the profile type / height,
material lump size may also have some influence. At the
deflection points it is essential that the stub idlers are
set horizontally and the brackets are adjustable. For the
downturn deflection point it is recommended to use the
deflection wheel system.
Fg
FS
Fg = 20% FS
Note that at deflection points the stub idlers are set horizontally to the belt.

S-WALL™
Upturn Deflection
Round off
inner face
D
FW FW
FS FW = 0.8 x FS FS
The general formula for determining the deflection wheel Deflection Wheel Diameters
diameter is 4 x H where H = Sidewall Height. Consideration
should be given to material lump size and cleat pitch Sidewall Type Sidewall Height D mm
to ensure a big enough radius to prevent pinching the
40 200
60 250
material in the curve.
S 80 350
100 400
Dimension Fw shown above is normally the minimum 120 500
value and can vary according to the required belt support. 120 500
Allowances must be made for clearance between the 160 630
200 800
deflection system and the Sidewalls. Normally this would HDS
250 1000
be 20% of the free space Fs.
280 1200
300 1200
300 1200
XHDS
400 1600

S-WALL™
Top Deflection Curve
The change in angle can be achieved either by a series

of idlers positioned as per the sketch opposite or by a
single pulley.
The minimum recommended idler diameters for the

corresponding sidewall heights are as follows: 1.5 x D
Type D
mm The amount of defection for
S40 63.5 each idler depends on the
S60 63.5 Sidewall type as follows: Type ‘S’ = 15°
S80 89 Others = 10°
S100 89 α
Type S: Max 15°
S120 89 Idler Deflection Curve
Type HDS: Max 10°
HDS120 108
Type XHDS: Max 10° It is beneficial to have these idlers mounted on a single
HDS160 108 plate to enable easier adjustment for belt tracking.
HDS200 108
HDS250 133 In addition the maximum
HDS280 133 pitch of the idlers is set at
HDS300 133 1.5 x D where D = Idler
XHDS300 Enquire
Diameter.
XHDS400 Enquire
The radius is determined by the belt speed and by the

method of deflection, angle of inclination, friction value of
the material and the profile type/height. The idler shaft
diameter must also take into account radial loadings
and may therefore need to be increased accordingly.
On installations with high lifts it may be necessary to
install small pulleys with external bearings.
Single Drum Deflection

Special care must be taken when selecting this method of
deflecting the belt, in particular the relationship between
belt speed and the material type. We have a computer
programme to determine the maximum belt speed for
the chosen pulley diameter for this point. Please enquire
regarding crowning of this pulley.
Single drum deflection.
The drum should be adjustable
Note in the direction of belt travel.
Both systems need to be adjustable to allow for belt

tracking, please see the section on belt tracking on page 29.

S-WALL™
Drive and Tail Pulley
Values for dimension L

Belt Width Bw L
mm mm
400 ↔ 700 50
700 ↔ 1400 75
1400 ↔ 2000 100
2000 ↔ 2400 125
Drive Pulley Tail Pulley

In the majority of cases the discharge drum is also the The design and construction of the pulley can be of
drive drum. The pulley is normally fixed after installation various types. Normally it is preferred that the pulley face
and requires no adjustment. For most applications the is crowned and can be rubber lagged. (In larger belts as
pulley face is crowned and rubber lagged. However, per the drive pulley this may not be the case, if in doubt
on some large belts, due to the type of tensile and please check.) The tail pulley is also the tensioning drum,
cross-stabilising members, it is not advisable to crown tension normally being applied via screw adjusters. As a
the pulley as damage may result to the base belt, please guide the maximum stretch of a belt will be 1.5%. When
contact the PHOENIX technical department if in doubt. calculating the amount of take up this should be taken
into account, plus an amount for safety.
Pulley Diameters
Sidewall Type Sidewall Height H Pulley Diameter D Pulley Diameter D

Black Normal Special Qualities
40 160 200
60 200 250
S 80 200 250
100 250 315
120 315 400
120 315 400
160 400 500
200 500 630
HDS
250 630 800
280 800 1000
300 800 1000
300 800 1000
XHDS
400 1000 1250
Notes
The above pulley diameters are based on 6 million bend changes Larger pulley diameters may be required dependant
on the tensile strength of the base belt, please check.

S-WALL™
Pulley Crowning
Formulae for the Determining the Degree of Crowning for Pulley’s
PW
Dm
Da
0.4L 0.2L 0.4L
Formulae
Da = Dm – (1 x 0.006)
Example:
Pulley, 500 mm diameter x 750 mm face width (Pw)
Da = 500 – (750 x 0.006)
Da = 500 – 4.5
Da = 495.5 mm
IMPORTANT!
Note
Please check with us to ensure that crowning of the pulleys is applicable to the base belt type intended for use. In the
case of belts with Textile Tension plies and Steel Cable cross stabilising plies and with Steel Cord Tension and Steel
Cord cross-stabilised belts crowning the pulleys may cause damage to the belt.

S-WALL™
Belt Snubbing
Snubbing of the Sidewalls

If full width return idlers are used to support the belt on
the return side then an allowance must be made for belt
sag in positioning these idlers. Due to the weight of the
25% of Sidewall height
belt if the idlers are positioned incorrectly compression of
Actual Belt line.
the Sidewalls will take place causing excessive wear. As
a guide idlers should be dropped by an amount equal to
25% of the Sidewall height.
Please not that if stub idlers are used to support the
Note belt on the belt free spaces then belt sag need not
Whilst the sketch shows the top section of a conveyor, be a point to consider as the base belt takes the
weight of the belt and not the sidewalls.
sag must also be considered along all horizontal sections.
Increasing the Angle of Wrap

Whilst it is general practice with most conventional belt
conveying systems to snub the belt to increase the angle
of wrap around the drive drum and thus increase the drive
factor, with Sidewall belts this must not happen.
Under no circumstances must snubbing on the S

idewalls
DO NOT SNUB THE BELT !
take place. The Sidewall profiles dynamic qualities are
Please not that if stub idlers are used to support the
great, including lateral rigidity; however, they are not belt on the belt free spaces then belt sag need not
designed to withstand forces imposed by snubbing. be a point to consider as the base belt takes the
weight of the belt and not the sidewalls.
In principal the angle of wrap on the drive pulley is not
greater than 180°.

S-WALL™
Downturn Deflection
Deflection Wheel Diameter Sidewall Type Sidewall Height D

At the downturn deflection point the deflection wheel mm
system is the preferred method of changing belt direction. 40 200
60 250
S 80 350
The general formula for determining the deflection wheel
100 400
diameter is 4 x H where H = Sidewall Height. 120 500
120 500
Dimension Fw shown above is normally the minimum 160 630
value and can vary according to the required belt support. 250 1000
HDS
280 1200
Allowances must be made for clearance between the
300 1200
deflection system and the Sidewalls. Normally this would 300 1200
be 20% of the free space Fs. 300 1200
XHDS
400 1600

S-WALL™
Bottom Deflection Curve
The change in angle can be achieved either by a series

of idlers positioned as the sketch opposite or by a single
pulley as per the top deflection curve.
Type S = 15°
The minimum recommended idler diameters for the Other = 10°
It is beneficial to have these
corresponding Sidewall heights are as follows: idlers mounted on a single plate
to enable easier adjustment for
belt tracking.
Type D
As the loadings are normally
mm 1.5 x D
S40 63.5 much lower at this point

S60 63.5 conventional idlers will suffice.
S80 89 The amount of deflection for
S100 89
each idler depends on the
S120 89
Idler deflection curve
HDS120 108 Sidewall type as follows:
HDS160 108
HDS200 108
Type S: Max 15°
HDS250 133
HDS280 133 Type HDS: Max 10°
HDS300 133 Type XHDS: Max 10°
XHDS300 Enquire
XHDS400 Enquire
In addition the maximum pitch of the idlers is set at

1.5 x D where D = Idler Diameter.
Single Drum deflection.

The single drum system is the preferred means of
deflecting the belt at the bottom bend point. The drum
may be rubber lagged for better frictional contact with
the base belt aiding belt alignment at this point. For textile
belts the drum can be crowned, for steel cord belts the
drum must be flat without any crown.
The diameter of the drum is the same as the recommended

minimum pulley diameters for the drive and tail pulleys.
Note
Both systems need to be adjustable to allow for belt
Single drum deflection.
tracking, please see the section on belt tracking on page 29. Drum is adjustable in the direction of belt travel.
Please see page 19 for details.

S-WALL™
Belt Cleaning
Note
The actual position of the discharge hopper will depend
on the length of the horizontal section, it may also be
necessary to install additional support. Please consult our
technical department for advice on the hopper design.
Belt Beater position at discharge point

The design of all PHOENIX S-Wall™ Sidewall Conveyor Belts assist in their self cleaning properties, but in the case of
very sticky materials, assistance will be required from a cleaning device.
Note
With prior consultation many cleaning problems can be avoided by installing highly efficient clean-up systems, please
refer to page 25 for more information.
Bd d2 d
mm mm
250 6 x 60° 20
315 6 x 60° 20
Note
Drums are positioned so that the outer face is directly above the Sidewall 400 6 x 60° 25
outer edge. 500 6 x 60° 25
630 8 x 45° 30
The dimension Bd is one size below the installed drum diameter. 800 8 x 45° 30
The steel rods (d2) must be off hardened steel, when installing it is very
important that the rods (d) are off-set. The system works best with belt speed
over 1 m/sec. For particularly sticky material we recommend that the units are
used as a pair (Tandem).

S-WALL™
Belt Cleaning
Self-Cleaning, discharge section

The dribble conveyor positioned directly under the
discharge section will effectively move any tailings bought
back with the belt or those knocked out by the cleaning
device. The device can be either a small driven belt
conveyor or alternatively it may be a mechanical chain
and scraper as per the bottom clean up system. The clean up system can also be a
mechanical Chain & Scraper.
There needs to be sufficient clearance between the clean up

system and the return run of belt allowing for any belt sag.
The actual positioning of the hopper should take into

account such items as the belts speed and material
repose angle and lump size. Please consult us for more
details.
Bottom Self-Cleaning system

It is recommended to fit a mechanical system such as a
chain and scraper type unit to return any material which
has been carried back by the belt.
Details on the design of the clean-up system are available

from our technical department.

S-WALL™
Guiding Wheels
PHOENIX S-Wall™ Guiding Wheels type GW300/80 can be used with all cross-rigid belt constructions. The hollow
sections inside the wheels allow for compression of the guiding wheel thus protecting the edges of the belt. The wheels
are made from a high precision rubber moulding ensuring consistent quality. The wheels are available as standard with
a 30 mm diameter shaft, if required they an be supplied without a shaft. The wheels are normally sold in sets of 4 but
can be supplied as individual pieces. These wheels are highly recommended and ensure a high degree of security in
both normal and difficult applications.
GW300/80
Guiding Wheels
Typical cross-section of a belt showing the correct positioning of the Guiding Wheels.

S-WALL™
Guiding Wheels
The positioning of the Guiding wheels is important. By placing the guiding system in the recommended places potential
damage to the belt edges and Sidewalls is eliminated. It is recommended that the fixing of the Guiding Wheel shafts
be adjustable by +/– 50 mm. The dimension of 2.5 x Bw is an approximation and can be varied between 2 and 3 times
belt width. If you are in doubt regarding the correct positioning of the Guiding Wheels please contact us for advice.
Note
The belt should always track correctly,
the Guiding Wheels are used to prevent
damage, for maximum life the belt needs to
be checked for straight running regularly.

S-WALL™
Belt Tracking
Belt Tracking
The positioning of the guiding wheels is important. By placing the guiding system in the recommended places potential
damage to the belt edges and sidewalls is eliminated. It is recommended that the fixing of the Guiding Wheel shafts
be adjustable by +/– 50 mm. The dimension of 2.5 x Bw is an approximation and can be varied between 2 and 3 times
belt width. If you are in doubt regarding the correct positioning of the Guiding Wheels please contact us for advice.
Adjustable as one piece
Direction of adjustment
Guiding Wheel
Note on guiding wheels

The belt should always track correctly, the
Guiding Wheels are used to prevent damage,
for maximum life the belt needs to be checked
for straight running regularly.
Guiding Wheel

S-WALL™
Ancillary Equipment
Stub Idlers
Diameter RL Al Shaft
mm mm mm
63.5 80 140 M20 x 55
63.5 150 210 M20 x 55
89 80 140 M24 x 55
89 150 210 M24 x 55
108 80 140 M24 x 55
108 150 210 M24 x 55
133 100 160 M30 x 55
133 150 210 M30 x 55
PHOENIX S-Wall™ Stub idlers are made with a special

dome end cap to protect the Sidewalls in case of miss
tracking.
Note
The above is the standard production range, different
diameters and shaft details are available to special order
as are Stainless Steel constructions,please enquire.
Rubber Return Disc
Type d1 d2 Idler Diameter W Sidewall Height

mm mm mm mm mm
RD63/80 250 61 63 35 80
RD89/90 275 86 89 35 80
RD63/120 330 61 63 40 120
Rd89/160 355 86 89 40 120

S-WALL™
Installation, Tracking and Maintenance
Installation and Jointing Procedure 32
Sidewall Head Joining 34
Belt Splicing Diagrams 36
Belt Handling 39
Tracking Instructions 40
Guiding Wheels 41
Maintenance and Enquiry Forms 43
Note
This manual is intended to give outline information only, due to the nature of site installation of conveyor belts it is
not possible to cover for all eventualities. You are strongly recommended to check with our Service or Technical
Departments if you are unsure about any aspect of the information given within this manual.

S-WALL™
Jointing Instructions
The S-Wall™ conveyor belt incorporated with your platten and stripped from the top.
conveyor system will provide long term service if correctly 5. Remove all remaining pieces of cured rubber from
installed and maintained. Our experience shows that belt the exposed fabric without causing damage.
failures only occur where the installation is incorrect and 6. Apply vulcanizing solution to both ends (skin-gum to
where there is insufficient maintenance. In most cases, trailing end which has been stripped from the top),
the belt specification selected has been the result of close and bottom filler strip.
co-operation with the designers and/or the manufacturers 7. Place both ends of belt together, ensuring they are in
of the complete system. To ensure the success of the line with the belt, and insert top filler strip.
S-Wall™ Conveyor, the following instructions should be 8. Position a sheet of cellophane paper over the joint;
adhered to: lay a rubber mat over this and place in position on
the top half of the vulcanising press and secure (as
A. Initial Installation is common practice with all belt splicing, steelbars
1. Unpack the belt according to our information sheet approximately 1mm thinner than the thickness of the
on belt handling. belt itself must be positioned along the edges of the
2. Ensure tail take-up pulley is at its’ minimum position. joint and secured).
3. Thread belt round head and tail pulleys. (Where ‘C’ 9. Apply correct pressure, and follow vulcanising
or ‘TC’ type inclined cleats are used, ensure these procedure in accordance with the quality of the belt.
point in the direction of belt travel.) 10. Split and remove the vulcanising press at the required
4. Select the best position on the conveyor where the temperature; remove all excess rubber along the
ends are to be spliced. edges and the filler strip area.
5. Clamp to the conveyor structure the trailing end of 11. Remove clamps and tensioning device.
the belt. The clamp should be positioned 1.5/2.0 m 12. Re-roughen thoroughly those areas where Sidewalls
from the end of the belt. and cleats are to be fitted, using a rectangular hard
6. On the leading end of the belt, attach a tensioning board section under the belt to form a working base.
device 2.0 m from the end. Tensioning the belt to
remove as much sag as possible. C. Joining Procedure (by fasteners)
1. Ensure ends are cut perfectly square and ‘butt up’
B. Jointing Procedure. (by splicing) against each other.
1. Place in position the bottom half of the vulcanising 2. Install fasteners to suit thickness and tensions,
press. ensuring that the pulley diameters are sufficiently
2. Place both ends of belt over vulcanising platten large.
ensuring the leading end is on top. 3. Remove clamps and tensioning device.
3. Remove excess belting and leave the overlap in 4. Re-roughen where necessary those areas where
accordance with the relevant splicing diagram. Sidewalls and cleats are to be fitted.
4. Step-down the ends of the belt, accordingly to the
measurements in the attached diagram, ensuring D. Finishing of Sidewalls and Cleats over Joint Area
the leading end is folded back and stripped from the 1. Place loose ends of the S-Wall™ Sidewalls across
bottom and the trailing end is left on the vulcanising the joint area, matching the two ends and cutting

S-WALL™
Jointing Instructions
in accordance with the diagram attached, i.e., so VI. The outer lip of the Sidewall base is rolled with
that the profile is one continuous curved line and not a small steel roller to form a seal along the edge
interrupted. of the Side wall and base belt.
2. With a rotating wire brush, taper the two surfaces to VII. The two joined end faces of the S-Wall™
be joined, so that when joined together, they form Sidewalls are then compressed together using
the same shape and thickness as the other parts of pliers or similar hand tools.
the Sidewalls. VIII. For additional security 2 steel plates with bolts
3. All roughened areas of Sidewalls, base belt, and are supplied with the belt to join the Sidewall
cleats, which are to have the cold cure adhesive heads.
applied must be cleaned by “Secondary Buffing”. 6. The second coat of adhesive is then applied to the
This process of using say a motor with flexible shaft cleats and the areas of the base belt where cleats
and wire brush freshens the rubber by removing dust are to be fitted. Again, when this second coat is
and oxidization. almost dry, but still feeling slightly tacky, the parts to
DO NOT USE ANY SOLVENTS TO CLEAN THE be joined are placed together in the following way:
RUBBER, THESE MAY EFFECT THE BOND I. The cleats are placed in their correct position.
STRENGTH. II. The upstand of the cleat is hammered securely
4. All these surfaces should be painted with two coats with a rubber mallet.
of adhesive. After the first coat has been applied, it III. The base of the cleat is rolled with a steel hand
should be left to dry for approx. 60 minutes before roller, starting against the upstand, and gradually
applying the second coat. working across to the outer edges of the base.
5. When the second coat is almost dry, but feeling IV. Using a shaped piece of wood with a base
slightly tacky, the parts to be joined are placed of approx. 35 mm square, the cleat base is
together in the following way: hammered firmly until the whole base area of
I. A clean 10
cm wide strip of cellophane is the cleat has been covered.
placed a long that part of base belt where the
Sidewalls are to be bonded. This enables the REMEMBER
two matching end faces of the Sidewalls to be 1. Once areas to be bonded are placed together, they
joined together as closely and accurately as must not be moved.
possible. 2. The belt should not be moved or tensioned for 12 hours,
II. When these faces are joined, they are pressed the time necessary for the bond to cure completely,
together using shaped pieces of wood. giving full strength, in the case of Heat Resistant belts
III. The strip of cellophane paper is then removed this may need to be extended, please enquire.
and the base of the Sidewall is bonded to the 3. The majority of S-Wall™ belt failures are due to
base belt. incorrect joining of Sidewalls and cleats, therefore it is
IV. Next the top of the Sidewall is then hammered essential these instructions are carried out explicitly.
with a rubber mallet to expel any trapped air. 4. In more difficult locations the use of a ‘Bonding
V. Following this the base of the Sidewall is then Layer’ will increase bond strength, please enquier
hammered with a shaped piece of wood. with our service dept for details.

S-WALL™
Sidewall Head Joining Method
Plan View of head preparation.

S-WALL™
Splicing Diagram
Splicing diagram for XE250/2 type belts. Direction of Belt Travel

S-WALL™
Splicing Diagram
Splicing diagram for XE400/3 type belts. Direction of Belt Travel

S-WALL™
Splicing Diagram
Splicing diagram for XE500/3+2 and XE-SC500/3+2 belts. Direction of Belt Travel

S-WALL™
Splicing Diagram
Splicing diagram for XE630/4+2 and XE-SC630/4+2 belts Direction of Belt Travel
Note
For belts with more tensioning plies follow the diagram and add the required number of steps depending on
the number of plies.

S-WALL™
Belt Handling
All PHOENIX S-Wall™ Conveyor Belts leave the production line packed in such a way as to ensure safe transportation.
It is essential that when off loading and unpacking the belt that the utmost care be taken not to damage the belt. The
belt should be unpacked as the following sketches, it is most important that under NO CIRCUMSTANCES should a
steel cable or rope be used to lift the belt either out of a crate or onto the conveyor.
CORRECT METHOD NO!
Correct method of removing an

endless belt from a steel crate
Handling of steel crates.
When handling the steel crates it is important to always lift the crate from
underneath by straps or by chains, do not lift the crates at any other point
as damage may result.

S-WALL™
Tracking
To ensure accurate belt tracking, the following points are belt wander be evident, correction is made initially by the
essential. positioning of the idlers (or drums) at the bottom inner
bend, this is the main point of tracking.
1. The conveyor structure must be square.
2. The terminal pulleys must be set square with the If belt wander still persists, correction is made by similar
conveyor structure. adjustments to the drum or idlers at the top deflection
3. In general the head and tail pulleys must be crowned curve, if the belt still miss tracks the deflection wheels
and lagged, the exception to this is with high should also be adjusted. It should be remembered that it
tensile belts where the pulleys must not be crowned, is the deflection point before the area where belt wander
please check with us first. is occurring that is adjusted. Following this the carrying
4. The correct number of idlers (or the required size of the and return side idlers should be checked and adjusted
drum) must be used at the deflection points. as necessary. As previously stated our recommended
5. The correct size of carrying and support idlers are used. design of feed hopper assists in belt tracking, particu-
6. The vulcanized joint must be perfectly square. larly when feeding from the side, and the use of PHOENIX
S-Wall™ Guiding Wheels type GS300/80 is recommend-
Sufficient tension should be applied to the belt to enable ed to protect the belt from damage caused by miss-
it to be driven by “letting out” the screw adjustment at the tracking.
tail pulley, ensuring that equal amounts of screw take-up
are made on each side. When the belt is run, should any Belt Tracking
All components should be made adjustable. At the top
inner deflection curve and the bottom inner bend drum it
is important that the deflecting system is made adjustable
Adjustable as one piece

as a complete unit. As the bottom inner bend drum is the
main tracking point it is easier if a single drum is installed
as per the drawing and not a series of idlers. Generally,
providing that the installation and supporting members
Guiding Wheel are square and that the belt joint is square, because
the belt is cross stabilised in most cases this in its self
will assist straight running. For the correct procedure in
adjusting the relevant points please contact our service
department if unsure as to what adjustments are required.
Note
The foregoing is only a summary, for detailed advice
please contact our technical department.
Guiding Wheel

S-WALL™
Guiding Wheels
PHOENIX S-Wall™ Guiding Wheels type GW300/80 can

be used with all cross-rigid belt constructions. The hollow
sections inside the wheels allow for compression of the
guiding wheel thus protecting the edges of the belt. The
wheels are made from a high precision rubber moulding
ensuring consistent quality. The wheels are available as
standard with a 30mm diameter shaft, if required they
can be supplied without a shaft. The wheels are normally
sold in sets of 4 but can be supplied as individual pieces.
These wheels are highly recommended and ensure a high
degree of security in both normal and difficult applications.
Typical cross-section of a belt showing the correct positioning of the Guiding Wheels.

S-WALL™
Guiding Wheels
The positioning of the Guiding wheels

is important. By placing the guiding
system in the recommended places
potential damage to the belt edges
and Sidewalls is eliminated. It is
recommended that the fixing of the
Guiding Wheel shafts be adjustable by
+/– 50mm. The dimension of 2.5 x Bw
is an approximation and can be varied
between 2 and 3 times belt width. If
you are in doubt regarding the correct
positioning of the Guiding Wheels
please contact us for advice.
Note
The belt should always track correctly,

the Guiding Wheels are used to prevent
damage, for maximum life the belt needs to
be checked for straight running regularly.

S-WALL™
Maintenance and Enquiry Form

Maintenance costs on conveyors are less than on ordinary troughed belt conveyors and bucket elevators, but it should
be remembered that anything between 25% and 50% of the initial cost of the conveyor can be attributed to the cost of
the belt, whereas troughed conveyors may only amount to 10% to 15%. Therefore it can be seen that the replacement
of a S-Wall™ belt is an expensive operation, and it is in your interests to ensure that all S-Wall™ belts are regularly
inspected for signs of wear caused by mechanical damage and spillage.
REMEMBER, most belts are torn out rather than worn out. In particular, the following points should be noted:
Idlers: These must rotate freely, and be free from any Tracking: The belt should run without touching any side
material build-up. Lubrication of all moving parts on a members or deflection gear, please refer to the section
planned basis is essential for dependable operation and on belt tracking if the belt is running out of alignment.
minimum maintenance. Component life will be extended
by following the manufacturer lubrication instructions. Good housekeeping: This is necessary for continuous
operation and low maintenance. Spillage and build up of
Pulleys: These should be free from any material build-up. material can eventually cause the idlers to stop rotating
The lagging on the drive pulley should be inspected on and an accumulation of lumpy material can cause belt
a regular basis. If the lagging is in poor condition it may damage.
be necessary to apply more tension than is normally
necessary to drive the belt resulting in premature wear. Check: The belt edges, Sidewalls, Cleats and the belt
splice need to be checked on a periodic basis for wear
Deflection Gear: Again, these must be free to rotate or separation. Any minor areas of damage should be
freely. repaired as soon as is possible.
Feed Hopper: It is important that this is just free from Contract: A maintenance contract may be available for
the top of the S-Wall™ Sidewalls, any rubber seals your S-Wall™ belt either on a direct basis from PHOENIX
around the hopper need checking for wear to prevent Conveyor Belt Systems or from your local PHOENIX
excessive dust or spillage. Conveyor Belt Systems approved service company,
please ask for details.
The storing of S-Wall™ belts is also an important factor. They must be kept on the steel or wooden crates in which they
are delivered, ensuring that the loops are not compressed by the weight of the belt. Ideally, the belts should be stored
in normal factory conditions, away from the direct sunlight and heat. Please see DIN 7716 which is available on request
for details on the recommended storage practice for rubber goods.
Enquiry Form
A careful study of simple and most difficult applications is all time guaranteed
through the support of the Application Technology from PHOENIX Conveyor Belts.
Please contact us for an individual offer.

Please use our online forms: www.phoenix-conveyor-belts.com/belt-enquiry

PHOENIX Conveyor Belt Systems GmbH has

established a respected global market presence
based upon innovative product design and
cutting edge technology.
Our line of conveyor belt products is developed

from engineered product designs that have been
tested and proven to provide the highest level of
performance in conveying applications worldwide.
Dedication to all aspects of the manufacturing
process and the highest level of quality control
standards ensure that our products provide the
best value to our customers. With over 100 years
of experience and a multitude of world records,
PHOENIX Conveyor Belt Systems GmbH continues
to demonstrate its position as the global leader
in conveyor belt technology.
PHOENIX Conveyor Belt Systems GmbH The content of this publication is provided for information only and without responsibility. PHOENIX Conveyor Belt Systems
GmbH’s obligations and responsibilities regarding its products are governed solely by the agreements under which the products
Hannoversche Straße 100 are sold. Unless otherwise agreed in writing, the information contained herein does not become part of these agreements. This
21079 Hamburg publication does not contain any guarantee or agreed quality of PHOENIX Conveyor Belt Systems GmbH’s products or any
warranty of merchantability, fitness for a particular purpose and noninfringement. PHOENIX Conveyor Belt Systems GmbH
Germany
may make changes in the products or services described at any time without notice. This publication is provided on an “as
Ph: +49 (0)40 7667-03 is” basis. To the extent permitted by law, PHOENIX Conveyor Belt Systems GmbH makes no warranty, express or implied,
Fax: +49 (0)40 7667-2413 and assumes no liability in connection with the use of the information contained in this publication. PHOENIX Conveyor
Belt Systems GmbH is not liable for any direct, indirect, incidental, consequential or punitive damages arising out of the
info@phoenix-cbs.com use of this publication. Information contained herein is not intended to announce product availability anywhere in the world.
www.phoenix-conveyorbelts.com © 2018 PHOENIX Conveyor Belt Systems GmbH. All rights reserved.

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What are the main advantages of the S-Wall conveyor belt system?

What are the main advantages of the S-Wall conveyor belt system?

What materials are used to construct the different components of the S-Wall conveyor belt?

What materials are used to construct the different components of the S-Wall conveyor belt?

S-Wall™ Sidewall Conveyor Belting

Since 1984 the S-Wall brand has been committed to the

This new brochure contains our current technical data on

S-Wall™ is the latest generation of Sidewall Conveyor

2 PHOENIX Conveyor Belts

Material is loaded onto the

2. No Spillage with Steep Angle Conveying

3. Maximum Utilisation of Space

Illustration of ground saving ability of the S-Wall™ system.

PHOENIX Conveyor Belts 3

4. Minimum Maintenance, Long Belt Life

5. Wide Range of Materials can be Handled

6. Low Power Requirement, Quiet Smooth Running

4 PHOENIX Conveyor Belts

The next section gives details of the S-Wall™ range of profiles.

Cross-Stabilised Base Belts 11

PHOENIX Conveyor Belts 5

S-Wall™ Sidewalls are available in 4 basic product

PHOENIX S-Wall™ corrugated Sidewalls represent the

PHOENIX S-Wall™ Sidewalls are manufactured

6 PHOENIX Conveyor Belts

Type H Sw Tw P Min Pulley Dia. Weight

PHOENIX Conveyor Belts 7

1. Type ‘Tk’ 2. Type ‘T’

3. Type ‘MBT’ 4. Type ‘T-XS’

5. Type ‘C’ 6. Type ‘TC’

7. Type ‘MBTC’ 8. Type ‘TC-XS’

8 PHOENIX Conveyor Belts

Type C 35 55 0.50 100 3/5

Type TC 75 80 1.80 150 3/5

Type MBTC 110 160 7.90 315 3

Type TC-XS 230 225 17.95 630 2.5

Ancillary Equipment for S-Wall™ Cleat Profiles

PHOENIX Conveyor Belts 9

Type Tk 35 110 1.65 100 3/5

Type T-XS 230 210 17.85 630 2.5

Ancillary Equipment for S-Wall™ Cleat Profiles

10 PHOENIX Conveyor Belts

The PHOENIX S-Wall™ range of cross-stabilised base

PHOENIX Conveyor Belts 11

Belt Composition Cover Thickness

12 PHOENIX Conveyor Belts

Carrying Side Support 14

Return Side Support 15

Belt Feeding and Feed Hopper Design 16

Top Inner Deflection 19

Drive and Tail Pulley 20

Bottom Inner Deflection 24

PHOENIX Conveyor Belts 13

Carrying Side Support

Idler Diameter D2 Dimension L

14 PHOENIX Conveyor Belts

Return Side Support

Method of determining return side idler pitch.

The pitch of the stub idlers on the return side is max