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Technical Documentation

T-Rack

3.0 Series

– Assembly Instructions 1.1(2019-03) E inge

Page 83 of 84

Technical Documentation

9.1

Summary of Contents for T-Rack 3.0 Series

Page 1: ...About these Instructions T Rack 3 0 Series Assembly Instructions 1 1 2019 01 E inge Page 1 of 84 inge GmbH Assembly Instructions T Rack 3 0 Series...

Page 2: ...urer All brand and company names in these Assembly Instructions are registered trademarks of the corresponding companies Change Policy The manufacturer reserves the right to change these guidelines or...

Page 3: ...d Use 9 2 2 1 Residual Risks 10 2 2 2 Conversions and Modifications 10 2 2 3 Repairs 10 2 3 Standards and Laws 11 2 4 Obligations of the System Integrator 11 2 5 Obligations of the Operator 11 2 6 Gen...

Page 4: ...39 5 4 2 Checking for Damage 39 5 4 3 Checking the Delivery for Completeness 40 5 4 4 Unpacking the Parts 40 5 5 Mounting the Bottom Frame 41 5 6 Positioning and aligning the Bottom Frame 43 5 7 Moun...

Page 5: ...ompensation Pipes 74 6 Service and Maintenance 76 6 1 Warnings 76 6 2 Checks during Operation 78 6 2 1 Eliminating Leaks 78 6 2 2 Exchanging Parts 78 6 2 3 Return of Modules and Other T Rack Component...

Page 6: ...h these instructions are presented is designed for optimal learning enabling you to work your way into the subject matter step by step Warranty Policy NOTE ADHERENCE TO ALL INSTRUCTIONS Full and prope...

Page 7: ...on must know the language of these instructions well enough to be able to apply the contents of these instructions and to impart these to other persons under their supervision 1 2 2 Skilled Persons wi...

Page 8: ...graphics Notwithstanding this the detailed description is always binding Always read the entire description of a step before beginning with the work it describes 1 3 2 Symbols The following symbols a...

Page 9: ...e A certain residual risk remains which can only be avoided by following the correct procedures The correct procedures and all points that need to be followed are described in these instructions 2 2 I...

Page 10: ...and impact from pallets packages and assembled parts at the construction site Danger of injury due to physical strain Danger of injury due to constricted space Danger of injury due to inadequate room...

Page 11: ...2 997 700 Make the necessary personal protective equipment available to all people involved for the duration of the work In case of deficiencies or loss immediately replace the personal protective equ...

Page 12: ...rdous situation If this situation is not avoided it will lead to serious injury or death Actions to avert danger WARNING CONSIDERABLE DANGER OF INJURY Personal injury due to a potentially hazardous si...

Page 13: ...r serious injury due to pinching crushing of the body DANGER OF CRUSHING BODY If the necessary safety instructions are not followed this may lead to death or serious injury due to pinching crushing of...

Page 14: ...a helmet may result in head injuries Wear a helmet WORKING WITH SAFETY SHOES Failure to wear safety shoes may result in foot injuries Wear safety shoes WORKING WITH SAFETY GLOVES Failure to wear safet...

Page 15: ...e when transporting and lifting loads Wear a safety helmet Wear safety shoes DANGER DANGER TO LIFE Danger of crushing by industrial trucks and other equipment at the construction site Keep a sufficien...

Page 16: ...k lift truck Wear a safety helmet Use a safety harness if necessary WARNING CONSIDERABLE DANGER OF INJURY Danger of crushing and shearing from work in the danger zone Note the specified number of pers...

Page 17: ...ANGER OF INJURY Danger of injury due to inadequate room height Provide for sufficient room height CAUTION DANGER OF INJURY Danger of injury and system damage due to exceeding the maximum permissible f...

Page 18: ...ructions 1 1 2019 03 E inge Page 18 of 84 inge GmbH 2 6 5 Position of Warnings General warnings on activities are found at the beginning of each main section Special warnings on the individual steps a...

Page 19: ...Device Description T Rack 3 0 Series Assembly Instructions 1 1 2019 03 E inge Page 19 of 84 inge GmbH 3 Device Description 3 1 Components 3 1 1 Overview Graphic Parts of the Sub unit of a T Rack...

Page 20: ...M16 G 3 Channel section DIN 1026 U profile U 50 x 38 H 2 Channel section U profile U 50 x 50 x 4 I 6 Channel section DIN 1026 U profile U 50 x 38 J 12 Filtrate pipe assembly K 12 Transparent filtrate...

Page 21: ...ng set Connection piece between the T pieces of two modules or between two filtrate headers of neighboring sub units Consists of a two part coupling shell made of composite material two connecting bol...

Page 22: ...t Autonomous part of a T Rack consisting of 4 to 12 modules A sub unit consists of the bottom frame the 4 to 12 modules built up on this two filtrate headers and the pipes between the modules and filt...

Page 23: ...layout See datasheet dizzer XL 0 9 MB 80 WT for T Rack 3 0 dizzer XL 0 9 MB 70 WT in two row layout dizzer XL 0 9 MB 70 WT in four row layout See datasheet dizzer XL 0 9 MB 70 WT for T Rack 3 0 dizze...

Page 24: ...n their original sealed packaging may be stored for 12 months from the date they are shipped from the factory Storing the modules for longer than 12 months shall render the warranty void unless otherw...

Page 25: ...on site Keep a sufficient distance when transporting and lifting loads Wear a safety helmet Wear safety shoes WARNING CONSIDERABLE DANGER OF INJURY Danger of falling when using ladders scaffolding and...

Page 26: ...loves Wear safety shoes WARNING CONSIDERABLE DANGER OF INJURY Danger of tripping and impact from pallets packages and assembled parts at the construction site Wear a safety helmet Wear safety shoes CA...

Page 27: ...lity Note the instructions on the packaging Not stackable Stackable max 3 units high All unmarked pallets may be stacked up to a height of 4 m as long as this is permitted by the loading room height W...

Page 28: ...treated IPPC pallets only Freight that is not positioned on IPPC pallets must be remounted on IPPC pallets 4 5 4 6 Storage 4 6 1 Suitability of the Location Adhere to the storage and transport tempera...

Page 29: ...ing when using ladders scaffolding and other climbing aids Only use flawless and approved ladders scaffoldings and other climbing aids Use a secured safety cage or safety harness when you are being ra...

Page 30: ...GmbH WARNING CONSIDERABLE DANGER OF INJURY Danger of tripping and impact from pallets packages and assembled parts at the construction site Wear a safety helmet Wear safety shoes CAUTION DANGER OF SL...

Page 31: ...unit of a T Rack with a total of 12 modules in two rows The procedures and steps similarly apply to variants with fewer modules in two rows In general only inge original parts are approved for install...

Page 32: ...ing NOTE The T Rack can contract further when the T Rack 3 0 is exposed to pressures below atmospheric vacuum The T Rack 3 0 is not designed for vacuum conditions NOTE The T Rack 3 0 is designed with...

Page 33: ...cally applicable laws and safety regulations 3 Calculate the required number of persons required to lift a module by dividing the module transport weight by the maximum permissible load per person Alw...

Page 34: ...torque for the 2 coupling is 10 15 Nm and 20 28 Nm for the 6 coupling For the entire setup of T Rack sub units only the following tools and devices are approved Torque screwdriver pneumatic or electr...

Page 35: ...nge from 0 C to 40 C Space Conditions Check the space conditions around the assembly area Ensure that there is enough space to allow the T Rack to be installed disassembled and operated safely CAUTION...

Page 36: ...kg m 2 CAUTION DANGER OF INJURY Danger of injury and system damage due to exceeding the maximum permissible floor load Do not exceed the maximum permissible for load 5 3 2 Protecting the Work Area St...

Page 37: ...are not involved in the procedures for installing a sub unit Protect the defined work area against all machines or devices that are not required for the procedures for installing a sub unit CAUTION D...

Page 38: ...ion of the system can be found in the system plan of the system integrator NOTE ASSEMBLY SEQUENCE If premanufactured collector pipes are used e g T Rack Manifolds from inge GmbH it is necessary to fir...

Page 39: ...rs in writing c Inform your contact at inge GmbH promptly about the damage Damaged parts of a delivery are not permitted to be installed until a decision has been made by inge GmbH d The decision rega...

Page 40: ...packing list and the existing packages 5 4 4 Unpacking the Parts NOTE CAUTION PROPERTY DAMAGE In case of abrupt temperature changes Store the modules for at least two days at temperatures above freezi...

Page 41: ...o the T Rack anchor plates can be found in section 5 14 4 Mounting the Bottom Frame on the T Rack 3 0 Anchor Plates Step Activity Figure 1 Prepare the bolts a Screw the hexagon nut DIN 934 M16 closer...

Page 42: ...gned with the protruding bolts of the channel section DIN 1026 5 Hand tighten the bottom frame a Place the washers DIN 433 A17 over the protruding bolts b Then screw on the hexagon nut DIN 934 M16 by...

Page 43: ...tions d If necessary loosen the upper and lower nuts of the frame feet and retighten them by hand in suitable positions e Using a spirit level check that the frame is level on both channel sections an...

Page 44: ...and outside 2 Mount the gaskets on the filtrate pipe a Mount one of the lubricated gaskets over one opening of the transparent filtrate pipe b Push the gasket onto the pipe so it is flush with the end...

Page 45: ...ure that the contact surfaces of the coupling half shells are resting in the provided grooves d Place the second flexible coupling 2 half shell on the first and insert the bolts in the openings e Tigh...

Page 46: ...he port and 90 elbow piece PP 2 d Position the flexible coupling 2 half shell onto the filter port and 90 elbow piece PP 2 with the gasket from below Ensure that the contact surfaces of the coupling h...

Page 47: ...middle rib 2 Position and mount the module on the channel section DIN 1026 Number of persons 3 ATTENTION Always start with the first module on the longer side of the frame a Remove the protective caps...

Page 48: ...tep Activity Figure d Continue holding the module in position and screw the two threaded pins DIN 913 M10 x 50 with the washers DIN 125 A10 5 and the hexagon nuts DIN 934 M10 into the channel section...

Page 49: ...mposite couplings 6 b Lubricate the gaskets with glycerin on the inside and outside 2 Mount the gaskets on the filtrate pipe Number of persons 2 a Continue holding the module in position to prevent ti...

Page 50: ...amage to the system and leaks if the top T pieces are connected before the bottom T pieces Always first connect the bottom and then the top T pieces Step Activity Figure 1 Mount module 2 Number of per...

Page 51: ...he coupling half shells are resting in the provided grooves d Place the second flexible coupling 6 half shell on the first and insert the bolts in the openings cut trough section showing the gap betwe...

Page 52: ...nnections d Place a flexible coupling 6 half shell around the gasket Ensure that the contact surfaces of the coupling half shells are resting in the provided grooves e Place the second flexible coupli...

Page 53: ...le 3 using the procedure described in section 5 7 Mounting Module 1 The filtrate pipe assembly faces module 1 2 Screw the threaded pins DIN 913 M10 x 50 into the upper T pieces Number of persons 2 a C...

Page 54: ...cing up on the T pieces of modules 1 and 3 so that the threaded pins DIN 913 M10 x 50 extend through the four drilled holes d Place one mounting clamp PE on the threaded pins DIN 913 M10 x 50 of modul...

Page 55: ...inge GmbH 4 Align the modules By attaching modules 1 2 and 3 with each other via couplings and the channel sections DIN 1026 these are now positioned on the bottom frame on three contact points and wi...

Page 56: ...2019 03 E inge Page 56 of 84 inge GmbH 5 10 Mounting Module 4 Step Activity Figure 1 Mount module 4 Number of persons 4 a Mount module 4 using the procedure described in section 5 7 Mounting Module 1...

Page 57: ...modules according to the procedure described in sections 5 7 Mounting Module 1 to 5 10 Mounting Module 4 b Mount the channel section DIN 1026 between the modules 11 and 12 according to the procedure...

Page 58: ...gs 2 b Lubricate the gaskets with glycerin on the inside and outside 2 Prepare the filtrate header a Mount a lubricated gasket on the filtrate port b Push the gasket onto the filtrate port so it is fl...

Page 59: ...e port and 90 elbow piece PP 2 c Place a flexible coupling 2 half shell around the gasket that connects the filtrate port and the 90 elbow piece PP 2 Ensure that the contact surfaces of the coupling h...

Page 60: ...ure as described in sections 5 12 1 Mounting the first Filtrate Header 5 12 2 Connecting the Modules to the Filtrate Header NOTE The filtrate headers will now be longer than the row of modules top and...

Page 61: ...odules a Before screwing the modules tight check that they are at right angles to each other and correct this if necessary b Fasten all 12 modules of both rows with the channel sections DIN 1026 using...

Page 62: ...al Assembly Variants 5 14 1 Assembly of Multiple Sub Units to one T Rack NOTE CAUTION PROPERTY DAMAGE Danger of damage to the system and leaks if the frame is not leveled precisely Level the frame in...

Page 63: ...level on the channel section DIN 1026 that is closest to the existing sub unit c Loosen the nuts on both connection side frame feet of the new bottom frame d Move the new bottom frame to the height o...

Page 64: ...of 84 inge GmbH 5 14 2 Assembly of Four Row T Rack s To assemble four row T Rack s two two row T Rack s are set up next to each other There is no direct connection between the two row T Rack s screw...

Page 65: ...64 Blind Cap 6 with G2 Thread for grooved coupling systems Connection of equipment for venting measuring etc G2 female thread according to DIN ISO 228 BSPP The connectors are attached using original f...

Page 66: ...round the gasket Ensure that the contact surfaces of the coupling half shells are resting in the provided grooves c Place the second flexible coupling 6 half shell on the first and insert the two bolt...

Page 67: ...Prepare the anchor plates a Insert the hexagon bolts DIN 933 M16 x 150 into the anchor plates b Screw on the hexagon nut DIN 934 M16 with the washer DIN 433 A17 maintaining the distance to the screw h...

Page 68: ...inward at an angle of 45 5 Drill the holes for the floor attachment Drill holes for the concrete anchors 12 mm You can use the anchor plate as the drilling template 6 Attach the anchor plates to the...

Page 69: ...ting with a Crane Number of persons 2 Step Activity Figure 1 Attach the module using a mounting strap min load capacity of 60 kg directly under the upper T piece and place the loop into the crane hook...

Page 70: ...odule 5 14 6 Connection to existing Connecting Pipework NOTE CAUTION PROPERTY DAMAGE If the existing system and the connecting pipework are in an unstable position or if the connection dimensions are...

Page 71: ...ard scope of supply but can be ordered optionally Attaching Compensation Pipes Connecting Pipework with Coupling Connection Step Activity 1 Check the connection pipework a Ensure that all pipes of the...

Page 72: ...nnections with each other Number of persons 2 Position the two connections T Rack connection and connection pipe with respect to each other 5 Connect the two connections a Pull the gasket over the con...

Page 73: ...e flange gasket Flange gaskets are not included in the scope of supply from inge GmbH Inserts the flange gasket profiled flat ring DN 150 made of EPDM in the grooves of both flange surfaces T Rack con...

Page 74: ...exi Kit M ST for T Rack 3 0 Series neutralizing up to 3 5 mm of level differences for T Rack s with 2 rows and single sided link to connecting pipework 12 pieces EP 0113 T Rack 3 0 Flexi Kit M ST 4 ro...

Page 75: ...of the pipe 3 Attach the compensating pipe a Position the compensating pipe on the corresponding pipe end b Place a flexible coupling 6 half shell around the gasket Ensure that the contact surfaces o...

Page 76: ...lling when using ladders scaffolding and other climbing aids Only use flawless and approved ladders scaffoldings and other climbing aids Use a secured safety cage or safety harness when you are being...

Page 77: ...of tripping and impact from pallets packages and assembled parts at the construction site Wear safety helmet Wear safety shoes CAUTION DANGER OF INJURY Danger of injury due to physical strain Determi...

Page 78: ...ling replaced 6 2 1 Eliminating Leaks Eliminate leaks by exchanging the corresponding coupling components and pipe connections When doing so note the warnings and instructions provided in section 5 In...

Page 79: ...alling when using ladders scaffolding and other climbing aids Only use flawless and approved ladders scaffoldings and other climbing aids Use a secured safety cage or safety harness when you are being...

Page 80: ...of tripping and impact from pallets packages and assembled parts at the construction site Wear a safety helmet Wear safety shoes CAUTION DANGER OF INJURY Danger of injury due to physical strain Determ...

Page 81: ...ar space for movement must be provided to perform the work The danger area should if necessary be marked for third parties and or cordoned off The disassembly is performed in reverse order to the asse...

Page 82: ...tra e 27 86926 Greifenberg Germany Tel 49 8192 997 700 Fax 49 8192 997 999 E Mail info inge ag Web www inge basf com 8 2 Ordering Spare Parts The following details are required to place an order Parts...

Page 83: ...s Data Sheet Multibore Membrane Data Sheet T Rack 3 0 Series Data Sheet dizzer XL 0 9 MB 80 WT for T Rack 3 0 Data Sheet dizzer XL 0 9 MB 70 WT for T Rack 3 0 Data Sheet dizzer XL 1 5 MB 50 WT for T R...

Page 84: ...opyright and or other intellectual property laws worldwide However inge GmbH cannot guarantee that the product information and products can be used without infringing third party intellectual property...

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