REXNORD

About Rexnord

Profile

Rexnord, headquartered in Milwaukee, Wisconsin, is a world-leading manufacturer of industrial mechanical power transmission solutions. Falk leverages its legacy in power transmission solutions - from standard and custom gear drives, to shaft couplings and backstops, to unmatched service and support - to provide the best customer experience and the lowest total cost of ownership through its reliability, leadership, and speed in everything it does. Rexnord's 900+ distributor locations and production facilities in the U.S., Canada, Mexico, Brazil, and Australia provide both local and global availability in industries such as aggregate, cement, coal, metal, mining, paper, water treatment installations and power generation.

Rexnord is one of America's leading producers of industrial gear drives and shaft couplings. Apart from providing the essential equipment to various industries, Rexnord also has a Renew Inventory that Renew Surplus Equipment.

Service: Unmatched responsiveness

Falk support helps balance capital investment against spares inventories, operating and maintenance costs... to keep you producing... and to show why Falk is your lowest total cost supplier.

Speed Parts online spare parts information and pricing helps you more efficiently manage spares inventories and maintenance programs.
Online service data includes information on lube intervals, tightening torques, and alignment procedures.
Field service from factory-trained experts is available worldwide.
Falk School presents the latest field-practical gear drive and coupling service techniques.
RENEW restores like new or upgraded performance for significantly less than the price of new.

Falk support also includes:

• Project planning & consulting
• Plant Surveys
• Diagnostics & troubleshooting
• Breakdown service
• Surplus equipment listings
• Spares networking
• Drive exchange program

Falk RAM Drives

Falk power transmission solutions for water treatment installations

The Falk Corporation manufactures industrial mechanical power transmission solutions. Falk products include Vertical mixing drives for aerators, Flocculators and flash mixers, RAM mixers, Gear motors for material handling, including skimmers, rakes, conveyors and compactors, Vertical drives for clarifiers, Parallel shaft, shaft-mounted, and concentric drives for conveying and solids processing and couplings and fluid couplings.

Falk RAM Drives for Water Treatment Installations

Falk has been producing mixing drives for over 40 years. Falk RAM drives use rugged steel housings, high capacity output shafts, and premium gears, bearings, and seals that contribute to high durability and long life. Falk is used for new water treatment installations as well as for replacement.

AirMax™ Breather

Unique Moisture & Particulate Protection for Enclosed Gear Drives (Optional Accessory)

Reduce premature gear drive failure. During the "inhalation" cycle the AirMax media blocks moisture from entering. During the "exhalation" cycle the media allows moisture to exit.

Gear Drives, Couplings and Steel Castings

Falk Corporation, US, delivers superior power transmission solutions and products like Gear Drives, Couplings, Backstops, Open Gearing and Steel Castings. Other products include Vertical mixing drives for aerators, Flocculators and flash mixers, RAM mixers, Gear motors for material handling, including skimmers, rakes, conveyors and compactors, Vertical drives for clarifiers, Parallel shaft, shaft-mounted, and concentric drives for conveying and solids processing and couplings and fluid couplings.
 
Falk Gear Drives 
Falk Corporation delivers the total power transmission solutions package. Falk gear drives feature super-rugged designs to meet every operating challenge.
 
Falk Corporation provides application-engineered to minimize stress and wear, and to extend service life, these drives deliver steady, trouble free operation, day-after-day. They're also specially designed and constructed to offer maximum application flexibility.

• Parallel & Right Angle Shaft
• Conveyor Drives
• High Thermal Capacity
• Concentric Drives
• Gearmotor Drives
• Shaft Mounted Drives
• Worm Gear Drives
• Ram Mixer Drives
• Drive One
• Marine Drives
• Custom Drives
• Airmax

Falk Shaft and Fluid Couplings

Falk Corporation has designed and manufactured a variety of state-of-the-art couplings to meet virtually any requirement. Falk Speed Quote software or a team of qualified power transmission specialists can analyze application, and determine how special characteristics - including bore fit options, stiffness, balance, shaft gaps, operating speed, and environmental conditions - can affect coupling selection.

• Wrapflex Elastomer Couplings
• Steelflex Grid Couplings
• Freedom Disc Couplings
• Lifelign Gear Couplings
• Fluid Couplings
• Rubber Element Couplings
• Long Term Grease

True Hold ® Low Speed Backstops
Falk True Hold Backstops prevents power quit or a motor fail and provides instant-response, no-slip mechanism to help put a stop to trouble before it can start.

True Hold Backstops provides more system holding power than any other backstop. Long-life designs and ability to engineer and manufacture complete integrated drive packages, assure that customers get ideal systems whether it's a single, tandem, or multiple backstop configuration.

Open Gearing
Complete drive assemblies for rotary mills, kilns, mine hoists, dryers, digesters and other large rotating equipment, including ring and pinion gear sets, main and inching drives from 150 kW to 15,000 kW (200 to 20,000 hp) and beyond.
 
Falk High Integrity Steel Castings
Falk foundries have the capacity to pour 43 359 kg (100,000 pounds) steel castings. It controls all stages of the production process - from computer aided casting design to pattern- making, from metallurgy to melting, from pouring to cleaning, to non-destructive testing and heat treatment, from rough machining to finish machining.

AirMax

Moisture and Particulate Protection for Enclosed Gear Drives

Gear Drive Breathers are a common source of moisture and particulate contamination. These two factors cause:

• Premature Gear Drive Failure due to Corrosion
• Reduced Lubricant Performance/Life, and Ultimately
• Increased Equipment Wear

AIRMAX BREATHER PERFORMS AS A GATE TO PREVENT MOISTURE FROM ENTERING THE GEAR DRIVE

During the “inhalation” cycle, the AirMax media blocks moisture from entering the gear drive. During the “exhalation” cycle, the media allows the moisture in the gear drive to exit. The moisture is carried off the media by the exiting air, therefore permanently removing it from the gear drive.

In typical operating systems the lubricant is warmer than the ambient air, but after the drive is shut down the temperature inside the drive begins to equalize with the ambient air. During this process the humid air enters the gear drive through the breather. The moisture that enters can condense on the cooler inner walls of the gear drive, which contaminates the lubricant. That’s where the AirMax breather is most effective - it prevents this moisture from entering. Thus, AirMax breather reduces as well as stabilizes the relative humidity inside the gear drive leading to a lower dew point.

NOTE: AirMax is to be used with drives in operation only (not suitable for drives in storage). Also, drive should be restricted to breathe only through the breather (use a non-vented type of dipstick). Contact Falk for available sealed dipstick options.

Features and Benefits

Media: Prevents moisture ingression into the gear drive. It also is pleated to maximize surface area (high dirt holding capacity) and provides high efficiency (99.7% at 3µ) with very low pressure drop.

Reversible Flow through Media: Allows moisture to exit the gear drive.

Easy Installation: Lightweight design only needs to be hand tightened.

Oil Attractant on Media: Coalesces oil droplets to drain back into the gear drive.

Rugged Housing: Protects media from external elements. Housing material is ABS plastic (corrosion resistant).

Plated Steel Core: Prevents media distortion.

Long Life: Change out schedule calls for replacement every 2 years.

“A Rugged Performer”

The AirMax breather is designed to withstand even the most rugged environments and has an operating temperature range of -40° to +200° F (-40° to +93° C). The filter housing is designed to protect the proprietary media from all external elements. In addition, the internal medial surface incorporates a layer of oil attractant, which coalesces the oil droplets from splashes.

AirMax is supplied with the following items:

1. Adapter: Falk p/n 2923652 (7/8-14 SAE x 0.50-14 NPT)
2. NPT Pipe Nipple: Falk p/n 915735 (0.50-14 x 1.50”)
3. NPT Pipe Bushing: Falk p/n 914654 (1.00 x 0.50) 
4. NPT Pipe Bushng: Falk p/n 914656 (1.25 x 0.50)

Installation Instructions

1. Determine port size in drive housing (required thread size)
   a) Kit is furnished to fit the following port sizes
   
   1) 0.500 – 14 NPT
   2) 1.000 – 11.5 NPT
   3) 1.250 – 11.5 NPT
2. Assemble pipe nipple into SAE/NPT adapter (use pipe sealant), hand tighten (no tools)
3. Assemble pipe bushing onto pipe nipple, if required (use pipe sealant), hand tighten (no tools)
4. Thread above assembly into housing port (use pipe sealant) hand tighten
5. Tighten entire assembly by tightening the SAE/NPT adapter
6. The extra parts can be discarded 
7. Thread AirMax Breather onto SAE/NPT adapter (hand tighten only)
8. Write the installation date in the space provided on decal located on the top of the AirMax Breather
9. The AirMax Breather must be replaced after 2 years of service

NOTE: Breather is to be used with drives in operation only (not suitable for drives in storage). Also, drive should be restricted to vent only through the AirMax Breather (use a non-vented type dipstick).

RAM® Mixer Drives

Born and Bred for Mixing Service

RAM Mixer Drives are engineered and built specifically to handle the unique and demanding requirements of waste and water treatment mixing applications.
 
RAM Mixer Drives can handle the tough mixing requirements in industries like food processing, waste and water treatment, chemical processing, pulp and paper, pharmaceutical, power generation, and mining.

With a wide range of sizes available, there's a RAM Mixer Drive for virtually any mixing application. Best of all, every RAM is fully backed by Falk - one of the most trusted names in industry for over 100 years.

What Sets RAM Apart is its Unique Design.

Ordinary commercial drives can't stand up to typical waste and water treatment mixing requirements -high bending and thrust loads on the output shaft, reliable round-the-clock operation, and absolutely no leakage of gear lubricant into the product being mixed.

RAM is no ordinary drive. It's designed specifically for the rigorous requirements of waste and water treatment mixing service by Falk, a company that's been supplying mixer drives for over 40 years.

The unique RAM features that make a difference include:

• Large-diameter, high-capacity output shafts to accommodate the high-bending moment loads common in mixing applications.
• Extended bearing life -minimum 30,000 hours L-10 at 1.25 service factor even at high thrust and moment loads.
• No-leak drywell design physically separates the oil sump from the output shaft to eliminate gear oil contamination of your product.
• Rugged cast or fabricated housings designed to withstand the stresses of waste and water treatment mixing while maintaining accurate gear alignment.
• Helical and spiral-bevel gearing for quiet operation and high drive efficiency.

Product flexibility for handling almost any type of installation.

RAM Mixer Drives are available with solid or hollow output shafts, and can be adapted to top, bottom, or side entry waste and water treatment mixing.

Ratings equal to or higher than original equipment drives allow you to easily enhance system performance when replacing your existing drive.

Excellent availability lets Falk ship an HMX or MDX replacement unit in just 72 hours. 24 hours on an emergency breakdown basis.

Quick, direct, drop-in replacement

RAM MDX Series Mixer Drives are designed for fast, easy, drop-in interchangeability with many popular Lightning®, Chemineer®, and Philadelphia® units.

Now you can easily upgrade your existing Lightning, Chemineer or Philadelphia drive with a quick, bolt-in RAM replacement. Standard interchange adapters provide the connection.

Custom-engineered adapters are also available to enable you to easily replace other types and makes of mixer drives.

A reliable RAM for every mixing need

RAM Mixer Drives are available in three basic size ranges, each with flexible accessories to fit virtually any waste and water treatment requirement.

RAM HMX Mixer Drive & Accessories for Small-Capacity Mixing

• Hollow Shaft
• Top or Side Entry
• Up to 30 Hp
• Up to 22,000 lb-in Output Torque
• 5.06:1 to 31.30:1 Ratios
• Up to 350 Output Rpm

RAM MDX Mixer Drive & Accessories for Medium-Capacity Mixing

• Solid/Hollow Shaft
• Top, Bottom, or Side Entry
• Up to 514 Hp
• Up to 166,000 lb-in Output Torque
• 5.06:1 to 1207:1 Ratios
• Up to 350 Output Rpm

RAM LHXV Mixer Drive Parallel-Shaft Drive for Large-Capacity Mixing

• Solid/Hollow Shaft
• Top, Bottom, or Side Entry
• Up to 2349 Hp
• Up to 1,060,000 lb-in Output Torque
• 5.60:1 to 437.9:1 Ratios
• Up to 310 Output Rpm

RAM LBX Drive & Accessories Right-Angle Shaft Drive for Large-Capacity Mixing

• Solid/Hollow Shaft
• Top, Bottom, or Side Entry
• Up to 1083 Hp
• Up to 1,060,000 lb-in Output Torque
• 13.95:1 to 357.5:1 Ratios
• Up to 125 Output Rpm

RAM Mixer Drives: Features and Benefits

RAM HMX Mixer Drives sizes 20-22

Designed for small-capacity, tough-duty mixing applications, the RAM HMX is a hollow shaft unit for top or side entry applications. It incorporates many of the same construction and performance features found on our medium-and large-capacity mixer drives.

Rugged Cast-Iron Housing
Accepts mixing stresses while maintaining accurate gear alignment and resisting corrosion.

Convenient C-Face Motor Adapter
This fully registered adapter ensures fast, positive motor alignment, eliminates hassles with V-belts, sheaves and guards, and simplifies installation with a flexible coupling.

Mounting Flexibility
Various mounting configurations, including vertical and horizontal shaft with ASA flange and solid drive shaft options, accommodate a wide range of applications. All configurations feature a male register for accurate alignment.

High-Strength Helical Gearing
All-helical gearing is designed for high efficiency and maximum load-carrying capacity with reserve strength rating.

No-Leak Drywell Construction
Oil sump is isolated from output shaft to prevent gear lubricants from leaking and contaminating the product being mixed.

Optional Stub Shaft
Available with high-strength, alloy-steel stub shah and coupling hub to easy connect/ disconnect to mixer shaft.

Severe-Duty Seals
Shielded, grease-purgeable upper seals provide a grease barrier that traps water, dirt and abrasive contaminants before they can enter the unit and cause damage.

Low-Speed Tapered Bushing/Adapter
Ensures a solid connection with the mixer shah and allows for easy installation and positive removal of shafts for various diameters.

Unique Low Speed Bearing Arrangement
High-capacity, spherical-roller, mixer shaft bearing isolates impeller loads from gearing and provides a high moment capacity. Tapered roller bearings accept high thrust loads in either direction.

Re-greasable Low Speed Bearings
Upper tapered roller bearing and bottom spherical roller bearing are grease lubricated and field re-greasable for easy maintenance. Lower tapered roller bearing is flood oil-lubricated.

Readily Available Replacement Components
Seals, bearings, and high speed couplings are readily available from your local distributor. Manufacturers part numbers for these items are published in the HMX Service Manual.

Simple, Positive Lubrication
Sealed, grease-lubricated upper high-speed and intermediate bearings and flood oil-lubricated lower bearings reduce oil levels, churning and foaming for cooler operation. Large oil capacity also helps keep the unit cooler for maximum life. A magnetic oil drain plug is provided.

Easy Maintenance
Easily accessible oil fill opening and oil drain plugs let you perform required maintenance without removing any covers or guards. Standard, automotive-type, quick-check dipstick allows fast, easy oil checks.

RAM MDX Mixer Drives sizes 300-900

Ideal for medium-capacity mixing needs, the rugged RAM MDX has been performance-proven through years of operation in a diverse range of demanding installations.

RAM LHXV & LBX Mixer Drives sizes 1100-1500

Available in both right angle and parallel gear drive configurations, the RAM LHXV and LBX Series Mixer Drives are heavy-duty units designed for the largest capacity mixing applications.

Rugged Steel Housing
Fabricated steel housing effectively resists shock loads and stresses associated with mixing applications and maintains accurate gear alignment.

Large Oil Capacity
Lowers operating temperatures to help oil retain higher viscosity, extending gear, bearing and seal life. Auxiliary cooling systems are also available.

Larger, Long-Life, Grease-Lubricated Bearings
With a minimum L-10 life three times that of standard commercial drives -and in excess of industry standards for most applications - the upper and lower output shaft tapered roller bearings withstand high impeller loads and insure maximum life. A grease baffle on the upper bearing retains grease and prevents it from entering the unit.

Proven High-Hardness Helical Gearing
Engineered to exceed ALMA standards with a reserve strength rating, the surface-hardened, precision-ground, long-life helical gears deliver a smooth, strong, efficient power flow. Large tooth profile provides extra strength to handle high-shock loads.

Precision Spiral Bevel Gearing
Surface hardening and finish lapping ensure smooth, quiet operation and greater gear efficiency.

Oversized Alloy Steel Alloy
Considerably larger in diameter than standard drive output shafts, the solid alloy steel shaft has adequate stiffness to withstand high mixer shaft loads.

Comprehensive Leak Protection
Covers, shims, gaskets and blind-tapped end cover holes help retain lubricant, eliminate oil leakage and keep contaminants out to reduce maintenance and downtime.

No-Leak Dry well Low-Speed Construction
A drywall isolates the low-speed output shaft from the oil sump to prevent lubricants from leaking and contaminating your product.

Fast, Easy Ratio Changes
With helical gearing contained in the high-speed head, the RAM MDX LHXV and LBX give you maximum ratio flexibility. To change ratios, simply replace the pinion and gear. For a reduction change, just replace the high-speed head with optional helical gears readily available from stock.

Optional Hollow Output Shaft
The RAM MDX LHXV and LBX are also available with a hollow shaft output connection for direct mixer shaft insertion.