Rexnord Falk V-Class VR Instruction manual

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 1 of 12)
How to use the manual
This manual provides detailed instructions on the
installation, operation and maintenance of V-Class
right angle type VR gear drives equipped with an
inching drive, for bucket elevator applications. Use
the table of contents below to locate required
information.
CAREFULLY FOLLOW THE INSTRUCTIONS IN
THIS MANUAL FOR OPTIMUM PERFORMANCE
AND TROUBLE-FREE SERVICE OF YOUR FALK
GEAR DRIVE.
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INTRODUCTION ..................................................... 1!
INSTALLATION ...................................................... 1!
Speed Switch Installation .....................................1!
Oil Level, V-Class ................................................3!
Oil Level, Ultramite UB .......................................4!
OPERATION............................................................. 4!
MAINTENANCE......................................................8!
INCHING DRIVE DISASSEMBLY ........................ 9!
INCHING DRIVE ASSEMBLY...............................9!
Ultramite UB Assembly .......................................9!
Mounting Clutch Hub ......................................... 10!
Overrunning Clutch & Clutch Housing..............11!
Mounting Ultramite to Clutch Housing..............11!
Mounting Inching Motor .................................... 11!
Magnetic Pickup (Speed Sensor)........................11!
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The Bucket Elevator Inching Drive consists of a
right-angle V-Class drive with either a hollow or
solid low speed shaft with an Ultramite®drive
mounted as the inching drive. The connection of the
inching drive is with an overrunning clutch in an oil
bath. A typical bucket elevator inching drive is
shown in Figure 1.
Instructions in this manual apply to drive sizes M127
thru M187 with a mounted inching drive designed for
bucket elevator applications. See Owners manual
178-052 for additional V-Class installation and
maintenance information. Ultramite installation &
maintenance instructions can be found in manual
288-400.
Figure 1 – Bucket elevator inching drive
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Rexnord highly recommends the use of a speed
sensor as a safety device to protect against back
driving the inching drive. The installation steps in
this section apply to the speed switch that is available
from Rexnord.
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A speed switch is a safety device used to stop
operation in the event of a back driven event. If the
clutch locks, the inching drive will be back driven at
dangerous speeds. The switch will detect these
speeds and send a signal to the customer’s interface
for it to shut down the main motor, preventing
damage and injury.
WARNING: Switch off and lock out the main power
supply before installing, service or making
connections to the speed switch. Follow all local
electrical and safety codes, as well as the National
Electrical Code (NEC) and Occupational Safety and
Health Act (OSHA). Installation work and electrical
wiring must be done by qualified person(s) in
accordance with all applicable codes and standards.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 2 of 12)
Figure 2 – PRS1 Speed switch mounting dimensions
Rexnord’s over-speed protection system includes the
following components: speed switch (either model
PRS1 or IFMR), magnetic pick-up, and target. The
target is mounted to the clutch hub. A magnetic
pickup is used as the speed sensor and is mounted on
the clutch housing to sense the speed of the target as
it rotates. The speed switch should be mounted in the
motor starter cabinet. Mounting dimensions are
shown in Figure 2 & 3.A 12-pin socket will be
provided with the PRS1 speed switch. The IFMR
switch is equipped with a universal mounting foot for
attachment to standard DIN style mounting rails,
including top hat profile rail according to EN 50 022
– 35x7.5 and 35x15 and G profile rail according to
EN 50 035 – G32.
Figure 3 – IFMR Speed Switch
After all components are installed, the speed switch
can be wired per Figure 4 for PRS1 models or Figure
5 for IFMR models.
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Pushing the start button energizes and latches the relay and starts the
machine. The relay stays latched as long as machine operates below
set-point speed. If the machine exceeds the set-point speed, the relay
unlatches, sounding the alarm and stopping the machine.
Figure 4 – Wiring diagram – PRS1 speed switch
Model IFMR speed switches should have the primary
power connected to terminals 10 and 12 (labeled
AC). For best results, the AC power should be
relatively “clean” and within 85 to 250 VAC, 48 to
62 HZ and 5.5VA. Drawing power from heavily
loaded circuits or from circuits that also power loads
that cycle on and off, should be avoided. Terminals
1, 2 and 3 are used to connect to the relay output.
Terminal 3 is normally closed contact and terminal 2
is the output relay common.
Figure 5 – Wiring diagram – IFMR speed switch
SPEED SWITCH
(MODEL PRS1)
SOCKET

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 3 of 12)
The magnetic pickup should be wired and
programming switches set per Figure 6 for PRS1
switches and Figure 7 for IFMR switches.If the
magnetic pickup is ordered from the factory with the
inching drive, it will have the proper air gap already
set. If Rexnord’s magnetic pickup is mounted in the
field, refer to the Inching Drive Assembly section for
instructions on setting the proper air gap.
Figure 6 – Magnetic pickup, wiring to PRS1 switch
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Figure 7 – Magnetic pickup, wiring to IFMR switch
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Carefully follow lubrication instructions in this
procedure, on the main gear drive nameplate,
warning tags, and V-Class manual 178-052 furnished
with the gear drive. Failure to follow instructions
voids warranty.
WARNING: V-Class Drives are shipped without oil.
The V-Class reducer and clutch housing share the
same oil. To minimize the time it takes for the oil
level in the V-Class reducer and the clutch housing to
equalize, first add oil to the clutch housing per Table
1. See Figure 8 for oil fill locations.
Table 1 – Clutch housing oil volume
Fill V-Class gear drive with oil to high mark on oil
dipstick. Prime oil troughs and pans with at least two
gallons of oil when filling. Allow minimum of 1
hour for shared oil sumps of the V-Class reducer and
clutch housing to equalize. If necessary, add or drain
oil, then recheck level. This may require checking
dipstick several times when adding oil. Approximate
system oil capacities are given on the drive
nameplate.
The gear drive can be filled through dipstick tube, oil
fill plug, or inspection cover. The inspection cover
must be removed to prime oil troughs, located inside
housing. If the reducer is equipped with a shaft fan,
the top fan deflector will have to be removed to get to
the inspection cover. Clean area around fill location
before removing dipstick plug or inspection cover to
reduce risk of debris getting into gear drive.
Lubrication must be clean to maximize gear and
bearing life. It is recommended to filter new oil
when filling or adding oil to the gear drive.
Figure 8 –Oil fill locations
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Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 4 of 12)
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Ultramite UB drive sizes 03-07 are only furnished
from the factory with oil as determined by the drive
mounting position. Verify that the oil has been filled
to the correct level before operating the drive.
Ultramite UB drive sizes 08 and larger are NOT
furnished with oil. Add oil per manual 288-400. The
oil level and oil fill location are shown below. Install
air vent plug in place of a standard plug before
operating drive.
Figure 9 – Ultramite UB oil locations
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The clutch housing and the V-Class reducer are
shipped dry. Prior to operation, make sure the shared
sumps are filled with oil as outlined in the installation
section.
Nameplate — Operate Falk™ gear drives only at
horsepower, speed and ratio shown on nameplate.
Before changing any of these, submit complete
nameplate data and new application conditions to the
Factory for correct oil level, parts, and application
approval.
Bucket elevator inching drives are used for inspection
or maintenance purposes. The inching drive consists
of an Ultramite UB right angle bevel drive. These
drives are designed to be used for both loaded, non-
continuous inching operation, and unloaded
(maintenance) inching operation with the V-Class
output shaft rotating between 1.8 and 4.0 rpm.
An inching drive connected with an overrunning
clutch requires no physical effort to go from main
drive operation to inching operation. The clutch
automatically disengages the inching drive when the
main motor is operating. It is highly recommended
to use a speed sensor and speed switch as a safety
device to shut down the main motor in the event of a
back driven event. This will prevent back driving the
inching drive and motor at high speeds and the risk of
damage and injury.
The speed switch (PRS1 or IFMR) should be set to
cut out when the speed of the Ultramite output shaft
exceeds the normal inching speed of the Ultramite
output shaft, which is typically less than 60 rpm.
Instructions to set the two speed switches are outlined
below.
To set the proper overspeed cutout using a PRS1
speed switch, operate the inching drive. Turn the set
point adjustment screw on the PRS1 speed switch
(Figure 2) until the LED relay-on indicator goes off.
Then turn the adjustment screw the opposite direction
½turn. Reset the relay and make sure the inching
drive speed does not trip the switch.
The PRS1 speed switch supplied from Rexnord can
either detect speed ranges of 6-60 rpm or 60- 600
rpm. For Ultramite output shafts rotating at normal
inching speeds just slightly below 60 rpm, the 60-600
rpm speed switch should be selected to make sure
that the overspeed condition is detected. However,
the above procedure may not be able to be used to set
the overspeed cutout. Instead, the lowest speed
setting on the 60-600 rpm switch should be used.
The IFMR speed switch has an operating frequency
range from 0 Hz to 25 kHz. A summary of the IFMR
speed switch configuration is shown in Figure 10.
The steps outlined in figures 11 through 16 can be
used to set the proper overspeed cutout with an IFMR
speed switch.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 5 of 12)
Summary of IFMR speed switch configuration.
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Figure 10 - Configuring IFMR speed switch
Step 1: Set operating mode to “Overspeed latched
trip, release only after alarm reset pulled to common”
(setting no. 2).
Figure 11 – Operating Mode

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 6 of 12)
Step 2: Set trip frequency using actual input speed.
Figure 12 – Set trip frequency using actual input
Step 3: Set trip frequency using rotary switch
(required only if step 2 was not completed).
Figure 13 – Set trip frequency with rotary switch

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 7 of 12)
Step 4:Use standard factory setting of “0” (5 msec).
Figure 14 – Set minimum response time
Step 5:Use setting number 5 (5.0%) to account for
any variation in motor speed.
Figure 15 – Set relay trip point (offset)

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 8 of 12)
Step 6:Operating mode number 2 requires the relay
to be manually released.
Figure 16 – Set relay release point (Hysteresis)
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Periodically check oil level in V-Class drive when it
is stopped, at ambient temperature and has been shut
down for a minimum of 20 minutes. Add oil if
needed. If oil level is above the high oil level mark
on dipstick, lower the oil level to dipstick mark and
have the oil analyzed for water content and other
contaminants.
Follow maintenance instructions provided in manuals
178-052 & 288-400. When draining the V-Class
reducer, the oil in the clutch housing must also be
drained by removing the drain plug at the bottom of
the housing as shown below.
Figure 17 – Oil drain locations

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 9 of 12)
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The inching drive can be disassembled by following
the steps outlined below. Refer to Figure 18 for an
illustration of the components.
1. Drain oil from inching drive clutch housing
and V-Class reducer.
2. The inching motor may be removed to
facilitate disassembly of the Ultramite by
removing the mounting fasteners.
3. With Ultramite reducer properly supported,
remove the bolts that secure the Ultramite to
the clutch housing. To prevent damage to
the clutch do not allow the Ultramite
gearbox to hang at an angle while sliding the
Ultramite reducer off.
4. If necessary, remove the clutch outer
element by removing the mounting bolts.
5. If necessary, remove the clutch hub by first
removing the two (2) setscrews. The clutch
hub can then slide off.
6. Before removing the inner element of the
overrunning clutch, the snap ring must first
be removed from the V-Class shaft. The
inner element of the overrunning clutch may
require the use of a wheel puller to remove it
from the shaft. The tapped holes in the
clutch should be used for removal to prevent
damage to the sprag cage or sprags.
7. Only if necessary, remove the clutch
housing from the V-Class reducer by
removing the mounting bolts.
CAUTION: Since the clutch housing is
used to set the bearing float in the V-Class
reducer, removal is only recommended
when servicing the V-Class reducer. A
Rexnord factory service representative will
be required when reassembling the clutch
housing to verify the V-Class reducer has
the proper bearing float and bevel gear
contact.
8. Thoroughly clean all surfaces on the clutch
housing and the Ultramite flange to remove
any gasket eliminator before reassembling.
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The inching drive assembly consists of an Ultramite
UB drive with output flange, Ultramite output shaft,
inching drive motor, clutch hub, overrunning clutch
and clutch housing. These components are shown
below in Figure 18.
Figure 18 – Inching drive assembly
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The Ultramite UB is supplied from the factory with
flange sealant applied to the output flange when it is
mounted to the Ultramite. If the output flange is ever
removed from the Ultramite, flange sealant will need
to be applied to a clean surface before remounting it
to the Ultramite.
Insert the snap ring into the Ultramite hollow shaft on
the side opposite the output flange. Install the keys in
the keyways of the Ultramite output shaft. Apply a
continuous bead of flange sealant (Loctite 515 or
equivalent) to the Ultramite drive side of the flange
on the output shaft as shown in Figure 19. Slide the
output shaft into the Ultramite drive hollow shaft.
Apply Loctite 242 or equivalent to the cap screw and
using the keeper plate, secure the output shaft.
Tighten cap screw to torque value specified in Table
2. Apply Permatex sealant to the bore plug and
install into the Ultramite housing to cover the output
shaft.
Figure 19 – Ultramite UB components

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 10 of 12)
Table 2 – Inching drive fastener tightening torque
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Measurements must be taken to accurately position
the clutch hub on the Ultramite output shaft.
Measure distance “A” from the clutch housing face to
the face of the inner element of the clutch as shown
in Figure 18.
Add OFFSET from Table 3 to measurement “A”.
The resulting value is “B”, which represents the
distance from the face of the clutch hub to the
machined face of the Ultramite output flange.
Depending on the size of the V-Class & Ultramite
reducers, the clutch hub may have a noticeable
overhang.
Calculated hub position: B = A + OFFSET
Table 3 – Clutch constant
Apply Loctite 242 or equivalent to the two (2) hub
set screw threads. Tighten setscrews to secure hub in
proper location. Mount the clutch outer element to
the hub, apply Loctite 242 to fastener threads.
Tighten fasteners to specified torque values given in
Table 2.
Inching drives are supplied from the factory with a
target sensing cap screw already installed. If the
target sensing cap screw is removed or a new hub is
being installed, the following steps must be
completed to install the sensing cap screw:
Apply Loctite 242 or equivalent to target sensing cap
screw. Install cap screw with jam nut into clutch hub
such that the top of the cap screw is located at a
distance “C” from the clutch hub as shown in Figure
20.Refer to Table 4 for the required mounting
distance “C”. Lock in place with jam nut.
Figure 20 – Speed sensor target
Table 4 – Target mounting distance
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Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 11 of 12)
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If the clutch housing was removed from the main V-
Class housing, contact the factory for scheduling a
service representative to assist with its reinstallation,
since the clutch housing must be shimmed to obtain
the proper bearing float and bevel gear contact.
After correct float settings have been achieved, apply
a continuous bead of flange sealant (Loctite 515 or
equivalent) to the clutch housing. Encircle each
fastener hole and connect the holes with a bead of
sealant. Assemble the clutch housing to the V-Class
drive. Apply Loctite or equivalent to fastener
threads. Use Loctite 262 for bolt diameters up to
0.75 inches (19 mm) and Loctite 271 for bolt
diameters larger than 0.75 inches. Tighten bolts to
torque values listed in Table 2.
Assemble clutch key into intermediate V-Class shaft
keyway (metric keys are interference fit, freezing key
may aid in assembly). Install the inner element of the
overrunning clutch to the first intermediate shaft
extension. To aid in assembly, the clutch may be
heated up to 100°C (212°F). Verify the overrunning
rotation is correct by rotating the V-Class high speed
shaft by hand in the direction that the main motor
will drive it. Using the inspection plug in the clutch
housing, confirm that the clutch hub & Ultramite UB
LS shaft are not rotating.
Install the retaining ring for the clutch. Place an O-
ring or wire tie around the clutch inner element to
hold the clutch sprags down, which will facilitate
assembly of the outer element.
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To assist with setting the gap for the magnetic
pickup, orientate the clutch hub so that the target bolt
is located in the 12 o’clock as shown in Figure 21.
This can be accomplished by rotating the Ultramite
output shaft until the clutch hub is properly oriented.
Figure 21 – Mounting Ultramite to clutch housing
Before mounting the Ultramite assembly to the clutch
housing, apply a continuous bead of flange sealant
(Loctite 515 or equivalent) to the face of the output
flange, outside the register. Properly support the
Ultramite assembly and bring it into mounting
position. With the Ultramite output shaft (and outer
clutch) in a horizontal position, carefully, slide the
outer clutch onto the inner clutch. The clutch
position can be seen through the inspection opening
in the clutch housing by removing the inspection plug
shown in Figure 21.Once the outer element engages
the sprags, remove the O-ring or wire tie by cutting it
and pulling it out through either the top or bottom
inspection hole. Install output flange fasteners and
lock washers, apply Loctite 242 or equivalent to
threads. Tighten to torque values given in Table 2.
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With the inching drive motor properly supported,
bring it into mounting position. Install key into
motor shaft before mounting the motor. Install
mounting fasteners with Loctite 242 applied and
tighten to torque values given in Table 2.
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If the magnetic pickup is purchased from Rexnord,
the pipe plug will already be machined to
accommodate the magnetic pickup. The clutch
housing has a 1.25” NPT pipe plug in the top to be
used with a magnetic pickup. If the magnetic pickup
is not purchased from Rexnord, the pipe plug will
have to be machined to accommodate a customer’s
speed sensor.
The wiring information, specifications and
dimensions of the magnetic pickup available from
Rexnord are shown in Figure 22.

Rexnord
3001 W. Canal St., Milwaukee, WI 53208-4200
Telephone: [phone] Fax: [phone] www.rexnord.com
178-810
July 2015
Falk V-ClassTM • Bucket Elevator Inching Drive • Installation, Operation & Maintenance Manual
Type VR Series • Sizes M107 thru M227 (Page 12 of 12)
Figure 22 – Magnetic pickup wiring and dimensions
The magnetic pickup available from Rexnord or other
magnetic pickups can be installed by completing the
following steps.
1. If using customer’s magnetic pickup,
remove 1.25” NPT pipe plug and have it
machined to accommodate sensor. If the
magnetic pickup is supplied by Rexnord, the
1.25” NPT pipe plug has already been
modified.
2. Verify the target bolt is located in the 12
o’clock position by using the 1.25” NPT
hole in the clutch housing. If necessary,
rotate the clutch hub so that the target
sensing bolt is vertical and can be seen thru
the hole. The inching drive motor can be
jogged to accomplish this.
3. Move the locking nut of the magnetic
pickup to the top of the threads. Thread the
magnetic pickup into the machined hole in
the pipe plug until the bottom of the sensor
makes contact with the target sensing bolt.
4. Using a dial indicator (or other measuring
device), adjust the location of Rexnord’s
magnetic pickup so there is a 2-3 mm (0.08”
- .012”) air gap between the magnetic
pickup and the target (Figure 23). A 2-3
mm air gap will take approximately 2 turns
of Rexnord’s magnetic sensor. Tighten the
lock nuts. The air gap of other sensors can
be set in a similar manner.
Figure 23 – Air gap between magnetic pickup and
target
Before operating the equipment, complete the
Installation and Operation sections of this manual for
oil fill instructions and other important information.