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Installation / Assembly

T-Rack

3.0 Series

– Assembly Instructions 1.1(2019-03) E inge

Page 36 of 84

Floor Characteristics

Ensure that the floor characteristics meet the following minimum requirements



Level, smooth surface with the necessary strength



Recommendation: gullies and drainage channels ensure adequate water drainage, e.g. when
emptying the T-Rack

Checking the Floor Load



Ensure that the maximum permissible floor load of the planned system footprint is not exceeded.
The maximum permissible floor load must be at least 2,500 kg/m

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

Structure of the Work Area

The work area consists of the following areas:



The single parts of the sub-unit that are in storage, have been unpacked, are being tested and/or
are being processed,



The pre-assembled assembly groups,



The sub-unit currently being processed,



The final location of the sub-unit and the T-Rack

and additionally on all routes:



All required access routes to the areas specified above,



All required walking and driving distance between the areas specified above,



All escape routes from one of the area or routes specified above

Содержание T-Rack 3.0 Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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