Inge T-Rack 3.0 Series User manual

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Assembly Instructions
T-Rack® 3.0 Series

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Legal Notice
Manufacturer Details
Product
T-Rack®3.0 Series, parts and components for installation, assembly and disassembly
Manufacturer
inge GmbH
Flurstraße 27
86926 Greifenberg
Germany
Applies to
T-Rack®3.0 Series, parts and components for installation, assembly and disassembly
Duplication and archiving in any form whatsoever –including of excerpts –is only permitted with the written
consent of the manufacturer.
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 any part thereof at any time in the interest
of continuous product improvement.
The system integrator is required to inquire about the current version of the process and design guidelines at
regular intervals:
Download at: http://www.inge.basf.com
By e-mail to [e-mail]
By telephone under [phone]
Change History
Version
Version date
Author
History
V 0
04/2018
C+P
Initial creation
V 0.1
09/2018
DV/GS
Layout adjustment
V 1.0
09/2018
inge GmbH
Components adjustment
V 1.1
03/2019
MH/GS
Components adjustment

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Table of Contents
1About these Instructions............................................................................................................................6
1.1 Objective of these Instructions ...........................................................................................................6
1.2 Target Groups.....................................................................................................................................7
1.2.1 Qualified Persons ..................................................................................................................7
1.2.2 Skilled Persons with a Supervisory Capacity ........................................................................7
1.2.3 Involvement of Other Persons...............................................................................................7
1.2.4 Involvement of Multiple Persons............................................................................................7
1.3Symbols in this Manual.......................................................................................................................8
1.3.1 Instructions.............................................................................................................................8
1.3.2 Symbols.................................................................................................................................8
1.4 Storage and Transfer to Another Party...............................................................................................8
2Safety ...........................................................................................................................................................9
2.1 Follow the Instructions!.......................................................................................................................9
2.2 Intended 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 General Information on Safety and Warning Instructions.................................................................12
2.6.1 Categories and Structure.....................................................................................................12
2.6.2 Warning Symbols.................................................................................................................13
2.6.3 Signs Giving Instructions .....................................................................................................14
2.6.4 Safety Instructions ...............................................................................................................15
2.6.5 Position of Warnings............................................................................................................18
3Device Description....................................................................................................................................19
3.1 Components .....................................................................................................................................19
3.1.1 Overview Graphic ................................................................................................................19
3.1.2 Parts List of the Sub-unit of a T-Rack®................................................................................20
3.2 Functional Description......................................................................................................................21
3.3 Technical Data..................................................................................................................................23
3.3.1 T-Rack®3.0..........................................................................................................................23
3.3.2 T-Rack®3.0 S ......................................................................................................................23
4Loading, Transport and Storage .............................................................................................................24
4.1 General Instructions..........................................................................................................................24
4.2 Warnings...........................................................................................................................................25
4.3 Loading.............................................................................................................................................27
4.4 Transport ..........................................................................................................................................28

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4.4.1 Transport Conditions ...........................................................................................................28
4.4.2 Checking the Freight............................................................................................................28
4.5 Storage .............................................................................................................................................28
4.5.1 Suitability of the Location.....................................................................................................28
4.5.2Stackability...........................................................................................................................28
4.5.3 Checking the Available Space.............................................................................................28
5Installation / Assembly.............................................................................................................................29
5.1 Warnings...........................................................................................................................................29
5.2 General Specifications......................................................................................................................31
5.2.1 T-Rack®s and Sub-Units......................................................................................................31
5.2.2 T-Rack®Geometric Flexibility..............................................................................................32
5.2.3 Calculation of Personnel Requirements ..............................................................................33
5.2.4 Tools and Consumables......................................................................................................34
5.2.5 Preparation of gaskets and O-rings.....................................................................................34
5.3 Preparing for Assembly ....................................................................................................................35
5.3.1 Checking the Available Space.............................................................................................35
5.3.2 Protecting the Work Area.....................................................................................................36
5.3.3 Assembly location and sequence........................................................................................38
5.4 Checking the Delivery.......................................................................................................................39
5.4.1 Moving the Packages to the Work Area ..............................................................................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 Mounting Module 1...........................................................................................................................44
5.7.1 Assembling the Filtrate Pipe Assembly ...............................................................................44
5.7.2 Mounting the Module on the Channel Section (DIN 1026)..................................................47
5.7.3 Mounting the Gaskets on the T Pieces................................................................................49
5.8 Mounting Module 2...........................................................................................................................50
5.9 Mounting Module 3...........................................................................................................................53
5.10 Mounting Module 4...........................................................................................................................56
5.11 Mounting Modules 5 to 12 ................................................................................................................57
5.12 Mounting the Filtrate Header............................................................................................................58
5.12.1 Mounting the first Filtrate Header ........................................................................................58
5.12.2 Connecting the Modules to the Filtrate Header...................................................................59
5.12.3 Mounting the Second Filtrate Header..................................................................................60
5.13 Tightly screwing together the Channel Sections (DIN 1026) ...........................................................61
5.14 Optional Assembly Variants .............................................................................................................62
5.14.1 Assembly of Multiple Sub-Units to one T-Rack®.................................................................62
5.14.2 Assembly of Four-Row T-Rack®s........................................................................................64
5.14.3 Attaching Connectors ..........................................................................................................65
5.14.4 Mounting the Bottom Frame on the T-Rack®3.0 Anchor Plates.........................................67

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5.14.5 Mounting the Module with a Crane......................................................................................69
5.14.6 Connection to existing Connecting Pipework ......................................................................70
5.14.7 Attaching Compensation Pipes............................................................................................74
6Service 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®Components ..........................................................78
7Disassembly and Disposal ......................................................................................................................79
7.1 Warnings...........................................................................................................................................79
7.2 Disassembly .....................................................................................................................................81
7.3 Disposal............................................................................................................................................81
8Customer Service .....................................................................................................................................82
8.1 Service Hotline..................................................................................................................................82
8.2 Ordering Spare Parts........................................................................................................................82
9Technical Documentation........................................................................................................................83
9.1 Other Applicable Documents............................................................................................................83

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1 About these Instructions
NOTE
READ THE INSTRUCTIONS!
Read these instructions completely before assembling and
disassembling the equipment. The information contained herein
will help you perform the work properly.
It is important to follow the safety instructions to prevent injury and
property damage.
Keep these instructions in a readily accessible place close to the
T-Rack®. Include these instructions if you pass the T-Rack®on to a
third-party.
1.1 Objective of these Instructions
These instructions will enable you to properly, safely and quickly assemble and disassemble a
T-Rack®3.0 Series.
These instructions contain additional important information on maintaining the T-Rack®3.0
Series.
The order in which 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 proper compliance with the Assembly Instructions is a
prerequisite for making a claim under the warranty.
The only language version of these Assembly Instructions for the
T-Rack®3.0 Series that has legal validity is the English version.
In the event of making a warranty claim, the customer agrees to
automatically provide inge GmbH with a complete set of
documentation.
Please contact inge GmbH if you wish to deviate from any of the
guidelines or specifications provided in this document and request
written approval in advance. Otherwise you risk invalidating any
warranty claims that you may make in the future.
The aim of this manual is to help our customers to enjoy the full benefits of our products. If you should notice
any mistake or have other suggestions for improvements, please send an email to
[email protected]

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1.2 Target Groups
1.2.1 Qualified Persons
These instructions are intended for skilled persons with the following qualifications:
Technical education
The skilled person must have technical education as a mechanic or mechatronics technician, for
example.
Several years of experience with the installation of industrial systems
The skilled person must also have several years of experience with the installation of industrial
systems.
Good language skills
The skilled person 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 with a Supervisory Capacity
Skilled persons that meet all requirements in section 1.2.1 are considered to be "skilled persons with a
supervisory capacity".
1.2.3 Involvement of Other Persons
Other persons may only participate in the assembly or disassembly if continuously supervised and instructed
by the skilled persons with a supervisory capacity.
1.2.4 Involvement of Multiple Persons
Some tasks need to be performed by two or more persons for worker protection and safety reasons.
In these cases, the number of persons required is specified in the first step of the procedure.

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1.3 Symbols in this Manual
1.3.1 Instructions
Activities are described as numbered steps that are presented in a table.
The headings of the activity descriptions are primarily intended for personnel with extensive experience in the
application of these instructions. They make it possible for this personnel to assemble or disassemble the
equipment primarily by reading these headings and observing the 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 are used in this manual:
SYMBOL
DESCRIPTION (EXAMPLES)
IMPORTANT NOTE!
Failure to follow the instructions in this note may lead to problems
with the product.
INFORMATION!
Following this information will make it easier to assemble the
T-Rack®.
CROSS REFERENCE!
Detailed information on this topic can be found in other
documentation.
1.4 Storage and Transfer to Another Party
Keep these instructions in a readily accessible place close to the T-Rack®. Include these instructions if you
pass the T-Rack®on to a third-party.

Safety
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2 Safety
2.1 Follow the Instructions!
The T-Rack® 3.0 Series can only be installed or disassembled safely if you first read the instructions,
understand these and follow them when assembling and disassembling the equipment.
The manufacturer has designed and built the product according to the latest engineering knowledge, thereby
ensuring the best possible safety and preventing injury, property damage and/or environmental damage.
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 Intended Use
These instructions describe the requirements and procedures for:
Installation/assembly of a T-Rack®3.0 Series
Disassembly of a T-Rack®3.0 Series
The installed T-Rack®3.0 Series is only intended for the commercial ultrafiltration of water.
The intended installation and disassembly includes adherence to all specifications in these instructions.
Any other method of installation or disassembly is considered to be unintended use. inge GmbH cannot be
held liable for damage that results from unintended use.

Safety
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2.2.1 Residual Risks
Despite the inherently safe design as per DIN EN ISO 12100, the following residual risks remain:
Danger of crushing from falling raised loads
Danger of crushing by industrial trucks and other equipment at the construction site
Danger of injury from faulty and incomplete assembly
Danger of falling when using ladders, scaffolding and other climbing aids
Danger of crushing and shearing from work in the danger zone
Cutting and impact injuries from sharp corners and edges
Danger of tripping 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 height
Danger of injury and system damage due to exceeding the maximum permissible floor load
Danger of injury to bystanders, machines and devices in the work area
Danger of injury during operation due to the installation and use of damaged parts
NOTE
In these instructions, these residual risks are indicated by
appropriate safety and warning instructions.
2.2.2 Conversions and Modifications
Conversion or modification is only permissible with the written approval from the manufacturer.
2.2.3 Repairs
Repairs may only be performed by qualified personnel following consultation with the manufacturer.

Safety
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2.3 Standards and Laws
The T-Rack®3.0 Series of the inge GmbH is subject to the EU Pressure Equipment Directive
2014/68/EU, Article 4, Sector 3.
The locally applicable normative and/or statutory requirements for the installation and
disassembly of the T-Rack®3.0 Series must be complied with.
For tools, equipment, machines and facilities that are not included in the delivery, the conditions
and instructions of the respective manufacturer apply.
2.4 Obligations of the System Integrator
Ensure that every skilled person with a supervisory capacity (= target group) has a printed copy
of these instructions available for the entire duration of the installation and disassembly.
Check for the current version of this manual at the inge website regulary.
http://www.inge.basf.com
On request, we can send you the desired number of printed instructions free of charge.
You can reach inge GmbH under [e-mail] or by telephone [phone].
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 equipment.
2.5 Obligations of the Operator
Ensure that all persons working on the T-Rack®3.0 Series use the personal protective equipment
(safety shoes and helmet) made available to them for the duration of the work.
Ensure that you are immediately informed in case of deficiencies or loss of personal protective
equipment. Provide a replacement immediately, and do not allow work to be performed without
complete personal protective equipment.
Ensure that all persons working on the T-Rack®3.0 Series have read the Assembly Instructions
and follow the safety instructions and procedures described herein.
WARNING
CONSIDERABLE DANGER OF INJURY!
If you begin work without having read the information on the
respective procedural step (including any potential warning
instructions), this may lead to accidents.
Ensure that the operating personnel has the necessary
qualification and is sufficiently trained.
Read the description of a procedural step completely and do
not begin implementing the step before having done so.

Safety
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2.6 General Information on Safety and Warning Instructions
2.6.1 Categories and Structure
Depending on the severity of the impending or potential danger, the following types of safety and warning
instructions are differentiated:
DANGER
DANGER TO LIFE!
Personal injury due to an imminently hazardous 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 situation. If this
situation is not avoided, it may lead to serious injury or death.
Actions to avert danger.
CAUTION
DANGER OF INJURY!
Personal injury due to a potentially hazardous situation. If this
situation is not avoided, it may lead to minor or moderate injury.
Actions to avert danger.
NOTE
CAUTION, PROPERTY DAMAGE!
Property damage due to an improper procedure.
Actions to avert danger.

Safety
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2.6.2 Warning Symbols
The following warning symbols are used in this manual:
WARNING
SYMBOL
DESCRIPTION
GENERAL DANGER SIGN
If the necessary safety instructions are not followed, this may lead
to death, serious injury and serious property damage.
SUSPENDED LOADS
If the necessary safety instructions are not followed, this may lead
to death, serious injury and property damage due to falling loads.
HEAVY WEIGHTS
If the necessary safety instructions are not followed, this may lead
to serious back injury due to lifting of heavy loads.
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 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 the body.
DANGER OF CRUSHING AND SHEARING (HAND)
If the necessary safety instructions are not followed, this may lead
to serious injury and property damage due to crushing and shearing
of the hands and other parts of the body.
DANGER OF FALLING
If the necessary safety instructions are not followed, this may lead
to death or serious injury from falling.
DANGER OF SLIPPING
If the necessary safety instructions are not followed, this may lead
to serious injury from slipping.
DANGER OF TRIPPING
If the necessary safety instructions are not followed, this may lead
to serious injury from tripping.
DANGER OF CUTTING
If the necessary safety instructions are not followed, this may lead
to serious injury from cutting on sharp edges.

Safety
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2.6.3 Signs Giving Instructions
The following signs giving instructions are used in this manual for the required personal protective equipment
(PPE):
SIGNS GIVING
INSTRUCTIONS
DESCRIPTION
WORKING WITH A HELMET
Failure to wear 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 safety gloves may result in hand injuries.
Wear safety gloves!
WORKING WITH EYE PROTECTION
Failure to wear safety goggles may result in eye injuries.
Wear safety goggles!
WORKING WITH A SAFETY HARNESS
Failure to wear a safety harness may result in injuries due to a
fall.
When working at great heights, wear a safety harness.

Safety
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2.6.4 Safety Instructions
The following safety instructions are used in this manual:
DANGER
DANGER TO LIFE!
Danger of crushing from falling raised loads.
Never stand under raised loads!
Keep a sufficient distance 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 sufficient distance when transporting
and lifting loads!
Wear a safety helmet!
Wear safety shoes!
WARNING
CONSIDERABLE DANGER OF INJURY!
Danger of injury from faulty and incomplete
assembly.
Do not start up the T-Rack®before it has been
fully assembled!
Wear a safety helmet!
Wear safety shoes!
Wear safety goggles!

Safety
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WARNING
CONSIDERABLE DANGER OF INJURY!
Danger of falling 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 raised by a fork 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 persons required!
Wear safety gloves!
Wear safety shoes!
WARNING
CONSIDERABLE DANGER OF INJURY!
Cutting and impact injuries from sharp corners and
edges.
Wear safety gloves!
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!

Safety
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CAUTION
DANGER OF INJURY!
Danger of injury due to physical strain.
Determine the weight of the module in use!
Always note the locally applicable maximum permissible load
for personnel!
Note the specified number of persons required!
CAUTION
DANGER OF INJURY!
Danger of injury due to constricted space.
Provide for sufficient space!
CAUTION
DANGER 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 floor load.
Do not exceed the maximum permissible floor load!
CAUTION
DANGER OF INJURY!
Danger of injury to bystanders, machines and devices in the work
area.
Protect the work area against unauthorized access and against
machines and devices that are not involved!
CAUTION
DANGER OF INJURY!
Danger of injury during operation due to the installation and use of
damaged parts.
Only use undamaged parts or parts approved by inge GmbH!

Safety
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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 are located with the corresponding step.

Device Description
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3 Device Description
3.1 Components
3.1.1 Overview Graphic
Parts of the Sub-unit of a T-Rack®

Device Description
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3.1.2 Parts List of the Sub-unit of a T-Rack®
Part
Quantity 1)
Single part
Consisting of
A
1
Bottom frame
B
6
Frame foot
C
6
Hexagon bolt (DIN 933) M16 x 150
D
12
Washer (DIN 433) A17
E
12
Hexagon nut (DIN 934) M16
F
6
Adjustable foot 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 pipe 2"
L
24
90° elbow piece PP 2”
M
48
Flexible coupling 2”
N
12
Module
O
32
Threaded pin (DIN 913)
M10 x 50
P
32
Washer (DIN 125) A10.5
Q
32
Hexagon nut (DIN 934) M10
R
24
Flexible coupling 6”
S
2
Channel section (DIN 1026)
U profile U 50 x 38
T
4
Mounting clamp PE
U
2
Filtrate header
1) Number of parts of a T-Rack®sub-unit with 12 modules