Manual Del Tricotec

Equipment Documentation
TRICOTECT TRT S
TRICOTECT TRT S
Page 1 of 46
TRICOTECT TRT S
-Original Instructions-
TRICOTECT TRT Typ S
Updates and Versions:

Date Version Topic Changes
07/07/2008 001 First description before installation ----------
15/07/2008 002 Stabilize step to relieve pressure in the add the stabilize steps,
unit see chapter 8
06/11/2008 003 Changing hard- and software for displaced
steps
13/01/2009 004 Equipment installation - connection Pressure Air for process (displace step)
0.5 bar; See chapter 9.3
06/04/2009 005 Up date design changes, Design changes valve +S1-Y10.004,
Separation of Screen Manual (former Housing service unit, housing pump
chapter 10)
03/01/2011 006 CE-Certification - changes
22/05/2012 007 Minor change of the text in the word documentation

Page 13, 16, 37,
Project No.: C10 203 004 (TRT 200 S)

C10 202 004 (TRT 400 S)
© Copyright - 2008 ATOTECH Deutschland GmbH

Printed in Germany, All rights, including technical changes reserved
This document may not, as a whole or in part, be copied, photocopied, reproduced,
translated into other languages or passed on to third parties without the prior written
consent of ATOTECH.
ATOTECH Deutschland GmbH

GMF Production Technology
Erasmusstraße 20
D –10553 Berlin
Germany
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TRICOTECT TRT S
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TRICOTECT TRT S
Contents
1 Introduction ........................................................................................................................5
2 General Safety ...................................................................................................................6
3 General description ..........................................................................................................12
3.1 Functional Description ...............................................................................................12
3.2 Design description .....................................................................................................14
4 Process Data....................................................................................................................16
5 Connection requirements .................................................................................................17
6 Specification .....................................................................................................................18
6.1 Tricotect TRT 200S....................................................................................................18
6.2 Tricotect TRT 400S....................................................................................................19
7 Schematic representation of the main parts .....................................................................20
7.1 Rack – Front View .....................................................................................................20
7.2 Sectional view............................................................................................................22
7.3 Rack - Right hand side (valve side) view ...................................................................23
7.4 Additional Tanks ........................................................................................................26
8 Process Steps ..................................................................................................................27
8.1 Overview....................................................................................................................27
8.2 Description of the process steps................................................................................28
9 Equipment installation ......................................................................................................32
9.1 Transport, handling and storage ................................................................................33
9.2 Filling column.............................................................................................................36
9.3 Exchange of the resin ................................................................................................37
9.4 Connection.................................................................................................................37
10 Preventive Maintenance Tasks ......................................................................................40
11 Trouble shooting.............................................................................................................43
12 Spare parts.....................................................................................................................44
13 Critical component list ....................................................................................................46
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TRICOTECT TRT S
1 Introduction
Atotech is one of the world’s largest suppliers of chemistry and equipment to the GMF
(General Metal Finishing) and PCB (Printed Circuit Board) industries.
The production systems are designed for various process technologies and meet your
individual production needs.
This technical documentation covers the operation and service of your TRICOTECT TRT
typ S.
The documentation is divided into two main parts.
The first part describes the unit itself and all important tasks for the operation and
maintenance of the TRICOTECT TRT typ S.
The second part contain supplier’s operating instructions for specific components of the
unit.
Addditional documentation:
x P&I diagram
x Cycle sequence
x Chemicals:
- safety data sheets
x Electrical:
- layout diagram
- wiring diagram
x Screen Manual
x Mechanical:
- manuals from the sub suppliers
Please find the additional documents attached in a folder – two different ways are
possible:
1. Folder (Hardcopy)
2. Electronically folder (CD or DVD)
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TRICOTECT TRT S
2 General Safety
In order to operate ATOTECH equipment safely, thorough knowledge of the safety
instructions and regulations is required.
All personnel, who work on the ATOTECH equipment must follow the instructions in this
documentation, particularly with regard to safety.
In addition, all the local safety rules and regulations must be fully observed.
Symbols
The signs below (in line with ANSI Z535.4) are used in the documentation to highlight
alerts and information you should pay particular attention to:
D
DAAN
NGGE
ERR
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury
W
WAAR
RNNIIN
NGG
Indicates an potentially hazardous situation which, if not avoided, could result in death or
serious injury
C
CAAU
UTTIIO
ONN
Indicates an potentially hazardous situation which, if not avoided, may result in minor or
moderate injury and possibly property damages.
A
ATTTTEEN
NTTIIO
ONN
Indicates a potentially hazardous situation which, if not avoided, may lead to property
damages.
NNO
OTTEE
Indicates a situation which, if not avoided, may lead to faulty products or to production
downtime.
IIN
NFFO
ORRM
MAATTIIO
ONN
Indicates information and tips how best to utilize the equipment.
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TRICOTECT TRT S
Responsibility of the personnel

Before starting to work at the equipment, all personnel, who are supposed to operate or
service the machine,
x are responsible for observing all relevant regulations concerning safety at work and
accident prevention
x must be familiar with the safety chapter and safety instructions in this operation
manual.
Use of equipment
The ATOTECH TRICOTECT TRT S is solely manufactured to remove selectively iron and
zinc from trivalent chromium passivates.
The use of the equipment for other purposes or the use beyond the specifications is not
permitted.
In the case of use beyond the specified scope, ATOTECH Deutschland GmbH shall not
be responsible for any damage caused.
Responsibility of the user

The user is responsible for giving permission to operate or service the ATOTECH
equipment only to those people who:
x are fully qualified and trained to operate the machine
x are fully aware of the regulations concerning safety at work and accident prevention
x have read and understood the safety chapter and the safety instructions in this
operation manual.
The safety awareness of the personnel operating and working on the machine has to be
verified regularly.
Guarantee and liability

The ATOTECH "General Conditions of Sale and Delivery" are absolutely binding. These
are available to the user either before or at the time of signing the contract. Guarantee
and liability claims for injury to personnel or damage to equipment cannot be accepted if
these arise from one or more of the following causes:
x the equipment is not used for its designed application
x incompetent operation and or maintenance of the equipment
x operation of the equipment with defective safety devices or incorrectly mounted or
non-functioning safety and protective devices
x non-compliance with the instructions in this documentation as regards start-up,
operation, maintenance and set-up of the equipment
x unapproved constructional changes made to the equipment by the user
x insufficient monitoring of equipment parts which are subject to wear- and tear
x repair work carried out incompetently
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TRICOTECT TRT S
x damage caused by foreign bodies or excessive force being applied to the equipment,
including natural causes.
Safety and protection devices

Before every equipment start-up, it must be ensured that all safety and protection devices
are properly mounted and in good working condition.
Safety and protection devices may only be removed
x after the machine has stopped completely and
x after ensuring that the machine cannot be restarted.
For components that are not supplied by ATOTECH, the user must install safety and / or
protective devices according to the valid local regulations.
Emergency stop switches

x Emergency stop switches have red buttons and are mounted on a yellow background.
x Emergency stop switches comply with German VDE 0100 and VGB 4 requirements.
x The operation of the emergency stop switch turns off the control voltage for all
electrical components (contactors for pumps, motors, etc. will be switched off).
Training of personnel
x Only personnel who are specifically trained and instructed how to use the equipment
correctly may get permission to operate.
x The responsibilities of personnel for machine operation, set-up, maintenance and
repair must be clearly defined.
x Trainees may only operate the equipment under the supervision of experienced
personnel.
Equipment control
x Only trained and authorized personnel may operate the equipment.
x The software program must not be changed without consultation of Atotech!
x Software functions, except the entering of product parameters, are password
protected. Change the password at least every 3 months!
Safety guidelines and rules

The ATOTECH equipment is built according to current technical standards and prevailing
safety regulations, that are in force.
Nevertheless it may be possible that its operation could present risks of damaging the
machine or other items can also arise.
x The Atotech equipment may only be used:
- for the application for which it is designed and manufactured
- when all safety related functions are in perfect condition.
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TRICOTECT TRT S
x Any defects that could be dangerous to safety must be fixed immediately.

x A copy of this documentation must always be accessible in the immediate vicinity of
the equipment.
x In addition to this documentation, the general and local regulations regarding accident
prevention and environmental protection must be observed.
x All safety and warning notices attached to the equipment must be maintained in a
legible condition.
Instruction for reducing noise or vibrations

x Before every piece of equipment is installed, it must be ensured that the
foundations are solid and level to provide stability against collapse. The equipment
has to be installed upright.
x Ensure at periodic intervals that all components are stably mounted. Loose
components have to be fixed and tight.
Covers of pumps, tanks etc. should not be removed except in case of
maintenance. Make sure the silencer is functioning correctly.
Doors of control and distribution cabinets need to be closed during operation.
Chemicals
x The use of chemicals beyond the specifications is not permitted.
x Aggressive chemicals are used in the equipment.
x Follow all instructions documented in the safety data sheets, operation manual and
analysis procedures.
x Maintenance work may only be carried out when wearing appropriate protective
clothing.
x Maintenance work on pipes may only be carried out, after the inside pressure is
released.
x Wear protective clothing when taking samples for analysis purposes. Switch off the
drive and pumps.
Read and respect the material safety data sheets (MSDS) of the
chemicals used for the regeneration-chemistry make-up.
Exhaust system, gases and vapours

The risk of inhaling dangerous gases and vapours can arise if the exhaust system is not
working correctly!
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TRICOTECT TRT S
Electrical system
x Only trained electricians may be permitted to work on the electrical system.
x Check the equipment’s electrical system regularly. Repair loose connections and
damaged cables immediately.
x The control cabinet should always be kept locked. Access should only be permitted to
authorized personnel with a key.
x Should work be necessary on live wires or equipment the local health and safety
regulations have to be observed.
x Ensure that no possible short circuits can occur due to tools or other metallic objects
have been left in/on the equipment.
Precautions at regular operations

x Check the security equipment visually before starting up the line.
x The equipment may only be operated when all the safety and protection devices are
fully functional.
x Before switching on the equipment, check that nobody is in danger of suffering injuries
by the machine start-up.
x At least once per shift the equipment should be checked for any visible external
damage and the correct operation of the safety devices.
Maintenance and repair

x The required set-up, maintenance and inspection work must be carried out according
to plan.
x Inform the machine operators before starting any maintenance or repair work.
x Before carrying out any maintenance, repair or inspection work, switch off the line and
protect the main switch securely against unexpected activation.
x switch off and lock the main switch
x attach a warning sign to prevent switching on
x When exchanging large and / or heavy items fix them carefully and securely to the
lifting device.
x Check loose screw connections for tight fit.
x Exchange immediately any part of the equipment that is not in good condition.
x Use original spare parts only.
x For spare parts from other suppliers (than ATOTECH) it cannot be guaranteed that
they have been designed and manufactured according to safety standards to meet the
necessary performance.
x After finishing maintenance work, check all safety and protection devices for correct
function.
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TRICOTECT TRT S
Equipment modifications
x No changes or modifications to the equipment may be made without prior permission
of the manufacturer. All modifications require written confirmation from ATOTECH
Deutschland GmbH.
Cleaning and disposal of materials

All materials used, must be handled and disposed according to the applicable regulations
and procedures in force.
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TRICOTECT TRT S
3 General description
3.1 Functional Description
The TRICOTECT TRT S unit is an ion exchanger unit which is designed to regenerate Cr-
III passivations, contaminated with zinc and iron.
By using a special ion exchanger resin the metallic ions are removed selectively from the
passivation bath.
The removing process is based on the circulation of the trivalent passivate solution
between the working tank and the ion exchanger unit in a closed loop.
The program sequence is fully automatic.
The TRICOTECT TRT S unit is designed to be adapted to the passivate solution needed
to meet the customer requirements.
It works with a large range of Atotechs Cr- III passivations.
The time of one cycle is mainly depending on the capacity of the ion exchanger unit and
the metallic contamination of the passivate solution.
TRICOTECT Passivation
(Atotech) (Costumer)
1
3
Diagram
3 ion of the TuR
exchanger nitICOTECT TRT S 1 passivation tank
4 tank for ion exchanger regenration chemistry 2 filter unit
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TRICOTECT TRT S
The passivate solution is pumped out of its tank through the column with resin by using a
pneumatic diaphragm pump.
The unit operates in up-flow.
The temperature of the passivate solution input to the ion exchanger unit must
be less than 60°C.
Higher temperatures lead to reduction/ decrease of the resin lifetime.
If the ion exchange resin is loaded with iron and zinc, the resin must be regenerated.
Therefore a regeneration cycle will follow, to remove this ions from the resin.
The regeneration process is based on the circulation of the regeneration chemistry (HCl
18 w/w %) solution through the column, followed by a compressed air flow to displace the
solution and finally a DI water flow to rinse the system and to remove the chemistry
residues.
After a spezified number of regeneration cycles (can be selected between 1 – 30) the
regeneration chemistry is discharged.
The operator is responsible for the new make up of the regeneration

chemistry.
When the TRICOTECT TRT S is proper installed, provided with electrical energy, DI
water and compressed air and supplied with resin and chemical products, it’s totally
automatic, controlled by a software program.
The operator is responsible to switch on the equipment and input the ideal time of the
process steps through the touch panel on the electro cabinet.
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TRICOTECT TRT S
3.2 Design description
The TRICOTECT TRT S consist basically of:

x One column (1) for the granulated ion exchanger resin to catch the metallic
contaminations zinc and iron,
x Pneumatic diaphragm pump (7) for the circulation of the passivate solution, the rinse
water and the regeneration chemistry through the ion exchanger unit,
x Diaphragm valves (10) and solenoid valves,
x Pressure relief valve (3),
x Gauge glass for process inspection (9),
x Compressed air service unit (6),
x Flow control (4),
x Air flow control (5),
x pH- meter (12),
x rack, powder coated steel (11),
x Electrical cabinet (2) with touch panel,
x Storage tank for regeneration chemistry including level control,
x Interim tank for passivate solution including level control.
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TRICOTECT TRT S
1 9
2 10
4 9
6 11
7
8 12
Tricotect TRT S front view Tricotect TRT S right hand side
Pos Part designation Pos Part designation

1 Column 7 Pneumatic diaphragm pump
2 Electrical cabinet 8 Temperature sensor (behind the pump
housing)
3 Pressure relief valve 9 Gauge glass for process inspection
4 Flow control fluid 10 Diaphragm valve
5 Flow control air 11 Rack, powder coated steel
6 Compressed air service unit 12 pH- probe
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TRICOTECT TRT S
4 Process Data
TRICOTECT TRT 200S
loading time with passivate solution Depending on the contamination
one regeneration cycle of the resin app. 3 h
DI- water consumption per cycle approx. 2000 l / app. 528 gal
Flow rate passivate solution approx. 400 l/h / app. 106 gal/h
Flow rate regeneration solution (HCl 18 w/w %) approx. 400 l/h / app. 106 gal/h
Flow rate DI- water approx. 1600 l/h / app. 423 gal/h
Flow rate air approx. 100 Nm³/h
TRICOTECT TRT 400S

loading time with passivate solution Depending on the contamination
one regeneration cycle of the resin app. 3 h
DI- water consumption per cycle approx. 4000 l / app. 1057 gal
Flow rate passivate solution approx. 800 l/h / app. 211 gal/h
Flow rate regeneration solution (HCl 18 w/w %) approx. 800 l/h / app. 211 gal/h
Flow rate DI- water approx. 3200 l/h / app. 845 gal/h
Flow rate air approx. 100 Nm³/h
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TRICOTECT TRT S
5 Connection requirements
Power Management Standard version:

380V AC, 50 Hz
Water DI water
Compressed air 6 bar / 88 psi; dry and oil free continuously
Inlet from the passivate solution tank DN 20 with a manually operated valve
Outlet of the passivate solution to DN 25
waste treatment
Wastewater treatment is same like used passivate solution
(see also the technical documentation of the passivate solution)
Outlet of the rinse water HCl and the Concentrated acidic waste water treatment
HCl solution to the wastewater treat-
ment plant
The connections to the unit and in between the modules have to be

accomplished by Atotech region or customer.
Electric and welding operations are allowed by qualified personal only.
The required chemistry and media (e.g. DI-water, electricity, etc.) has to be
ordered and/or provided by the customer.
The required types of resin have to be ordered and provided by Atotech region
or customer.
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TRICOTECT TRT S
6 Specification
6.1 Tricotect TRT 200S
200 Liter Unit
53 gal Unit
Length approx. 1400 mm
approx. 55 in
Width approx. 1400 mm
approx. 55 in
Height approx. 2600 mm
approx. 102 in
Volume of the column approx. 310 liter
approx. 82 gal
Volume of the resin approx. 200 liter
approx. 53 gal
Volume of the inert material approx. 75 liter
approx. 20 gal
Volume of regeneration chemistry tank approx. 1000 liter
approx. 265 gal
Dimensions of the regeneration chemistry tank approx. 1000 mm x height 1450 mm
(HCl 18 w/w %) approx. 39 in x height 57 in
Volume of interim tank B3 for diluted passivation approx. 1000 liter
solution
approx. 265 gal
Dimension of Interim tank B3 for diluted approx. 1000 mm x height 1450 mm
passivation solution
approx. 39 in x height 57 in
Volume of interim tank B4 for pure passivation approx. 1000 liter
approx. 265 gal
Dimension of interim tank B4 for pure passivation approx. 1000 mm x height 1450 mm
Total weight of the unit ready approx. 1300 kg
for operation (without liquid) approx. 2870 lbs
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TRICOTECT TRT S
6.2 Tricotect TRT 400S

400 Liter Unit
106 gal Unit
Length approx. 1400 mm
approx. 55 in
Width approx. 1400 mm
approx. 55 in
Height approx. 2800 mm
approx. 110 in
Volume of the column approx. 450 liter
approx. 119 gal
Volume of the resin approx. 400 liter
approx. 106 gal
Volume of the inert material approx. 50 kg
approx. 110 lbs
Volume of regeneration chemistry tank approx. 1000 liter
for HCl 18 w/w % approx. 265 gal
Dimensions of the regeneration chemistry tank approx. 1000 mm x height 1450 mm
Volume of interim tank B3 for diluted passivation approx. 1000 liter
solution
approx. 265 gal
Dimension of Interim tank B3 for diluted approx. 1000 mm x height 1450 mm
passivation solution
Volume of interim tank B4 for pure passivation approx. 1000 liter
approx. 265 gal
Dimension of interim tank B4 for pure passivation approx. 1000 mm x height 1450 mm
Total weight of the unit ready approx. 1300 kg
for operation (without liquid) approx. 2870 lbs
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TRICOTECT TRT S
7 Schematic representation of the main parts

7.1 Rack – Front View
9
3
10
4
5
6
7 11
Pos Part designation, Function Pos Part designation, Function

1 Touch Panel 7 Pneumatic diaphragm pump
(+S1-M70.001 or +S1-M70.002)
2 Electrical Cabinet 8 Gauge glass for process inspection
(ID-101)
3 Pressure switch (+S1-S35.0) 9 Fluid flow control (+S1-S36.3, +S1-S36.4)
4 Inlet for compressed air 10 Air flow control (FICA1)
5 Compressed air service unit 11 Thermo couple (+S1-B16.1) (not visible,
behind the pump housing)
6 Solenoid valve for pump control
(+S1-Y10.024, +S1-Y10.025)
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TRICOTECT TRT S
Compressed air service unit and pressure switch
The compressed air will be connected at the service unit with a quick connection coupling
(1) on the customer side.
The pressure switch (2) is a safety device to secure the process valves.
The pressure switch is checking the incoming air pressure. In case of a pressure drop
below 5.5 bar the unit turns off and the alarm message “no compressed air” occurs in the
display.
2
5

1 Inlet compressed air 4 Pressure regulator with gauge
2 Pressure switch (+S1-S35.0) 5 Non return valve
3 Filter 6 Solenoid valve for pump control
(+S1-Y10.024, +S1-Y10.025)
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TRICOTECT TRT S
7.2 Sectional view
1
2
5
3
4
6

1 Thermo couple (+S1-B16.1) 5 Sediment strainer (YF-001)
2 Non return valve DI water inlet (NR-001) 6 Ball valve passivate solution inlet (BV-001)
Pressure transmitter bottom of the column 1
(+S1-S35.2)
3 Ball valve for sampling from the bottom of 7 Ball valve for DI water inlet (BV-002)
column 1 (column inlet) and to empty
(BV-101)
4 Pressure transmitter bottom of the column
(+S1-S35.2)
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TRICOTECT TRT S
7.3 Rack - Right hand side (valve side) view
6
1
3 9

1 Diaphragm valve DN 20 6 Ball valve for sampling from the top of
column (outlet) (SV-101)
2 Diaphragm valve DN 32 7 Gauge glass process inspection outlet
bottom of the column (ID-102)
3 pH- electrode (+S1-B33.1) 8 Pressure transmitter bottom of the column
(+S1-S35.2)
4 Gauge glass process inspection outlet top 9 Ball valve for sampling from the bottom of
of the column (ID-101) column (outlet) (BV-101)
5 Pressure transmitter top of the column
(+S1-S35.1)
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TRICOTECT TRT S
Valve identification and description
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TRICOTECT TRT S
identification description
+S1-Y10.001 inlet column passivate solution/ DI water/ HCl
outlet column (on the top) HCl tank/ waste water/ passivate solution/ interim
+S1-Y10.003 tanks
+S1-Y10.004 inlet column compressed air
outlet column (o the bottom) HCl tank/ waste water/ passivate solution/ interim
+S1-Y10.007 tanks
+S1-Y10.009 inlet HCl tank
+S1-Y10.010 outlet HCl tank suction side of pump
+S1-Y10.013 outlet passivate solution tank
+S1-Y10.014 outlet interim tank B3
+S1-Y10.017 outlet interim tank B4
+S1-Y10.019 outlet interim tank B4 suction side of pump
+S1-Y10.020 inlet passivate solution the suction side of pump
+S1-Y10.1 inlet DI water suction side of the pump
+S1-Y10.3 outlet waste water
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TRICOTECT TRT S
7.4 Additional Tanks

The TRICOTECT TRT S has basically two tanks:
x 1000 liter tank for regeneration chemistry (HCl 18 w/w %)

- outlet pipe DN 32 (to suction side of the pump)
- inlet pipe DN 25 (from the column)
- overflow pipe DN 25
- outlet for air exhaustion
- level control 3 set points (300 liter, 500 liter, 800 liter)
- level control 2 set point (0 liter - tank empty, 900 liter - overflow)
- level switch material = PP
- level switch voltage = 24 V
- level switch degree of protection = IP65
x 1000 liter interim storage tank B4 for passivate solution

- outlet pipe DN 32 (to the column)
- level control 2 set points (0 liter, 900 liter)
A third tank is optional:

x 1000 liter interim storage tank B3 for diluted passivation solution (can be used to
balance evaporation losses in the passivate solution bath)
- outlet pipe DN 32 (to suction side of the pump)
- level control 2 set points (0 liter, 900 liter)
- optional with a pump and solenoid valve
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TRICOTECT TRT S
8 Process Steps
8.1 Overview
flow
step process step direction remark
1 loading.1 up from interim tank B4 to interface E
2 loading.2 up from interface E to interface E
3 displace.1 down with air to interim tank B4
4 stabilize.1
5 rinse.1*) up with DI water to waste water
5.1 rinse.1.1*) up with DI water to interim tank B3
6 displace.2*) down wir air to waste water
6.1 displace.2.1*) down with air to interim tank B3
7 stabilize.2
8 regeneration.1 up from HCl tank to waste water
9 regeneration.2 up from HCl tank to HCl tank
9.1 regeneration.2.1**) up worst case: HCl tank full
10 displace.3 down with air to HCl tank
10.1 displace.3.1**) down worst case: HCl tank full
11 stabilize.3
12 rinse.2 up with DI water to waste water
13 displace.4 down with air into waste water
14 stabilize.4
*) Basically: Tricotect without interim tank B3 = need step 5 (rinse.1) and step 6 (displace.2),
Optional: Tricotect with interim tank B3 = need step 5.1 (rinse.1.1) and step 6.1 (displace.2.1)
**) in case of overfill the HCl solution is pumped/ displaced into the waste water
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TRICOTECT TRT S
8.2 Description of the process steps

The following process steps run automatically.
All steps are time controlled.
Stabilize step is to relieve pressure in the pipes (it isn’t described below).
See the cycle sequence diagram (additional documents).
Loading 1:
The ion exchanger unit is filled upstream with passivate
solution from the interim storage tank B4. The resin
remove the metallic contamination. The cleaned
passivate solution is discharged to the passivate solution
tank.
Loading 2:
The ion exchanger unit is filled upstream (pump +S1-
M70.001) with passivate solution flow directly from the
passivate solution tank through the column, back to the
passivate solution tank.
In step loading 2 the temperature in the inlet flow of passivate solution is

checked. The process is stopped, if the temperature is higher than 63°C
Displace 1:
The passivate solution in the pipes and in the ion
exchanger unit is displaced downstream to the interim
storage tank B4 by injecting compressed air.
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TRICOTECT TRT S
Rinse 1:
The pipes and the ion exchanger unit is rinsed upstream
with DI water. The rinsing water is discharged to the
waste water (G)
or to interim storage tank B3 (option)
Displace 2:
The rinse water is displaced downstream from the pipes
and the ion exchanger unit and send to the wastewater
(G) or the interim storage tank B3 (option)
Regeneration 1:
The HCl- solution is pumped upstream through the ion
exchanger unit. This heavily contaminated HCl solution is
discharged direct to the waste water.
Chemistry for regeneration - HCl 18 w/w % - solution!
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TRICOTECT TRT S
Regeneration 2:
The HCl- solution is pumped upstream through the ion
exchanger unit to the HCl solution tank in a closed loop.
This step is necessary for regeneration of the resin in
the ion exchanger unit.
Displace 3:
The HCl solution is displaced downstream from the pipes
and the ion exchanger unit and send to the HCl- tank by
injecting compressed air.
Rinse 2:
The pipes and the ion exchanger unit were rinsed
upstream with DI water. The liquid is discharged to the
waste water treatment.
In this step the pH- value is checked.
In the step rinse 2 the pH- value is checked. When the step is finished and the
value is lower than the adjusted value, the operator must restart the step
manually.
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TRICOTECT TRT S
Displace 4:
The rinse water is displaced downstream from the pipes
and the ion exchanger unit and send to the waste water
treatment by injecting compressed air.
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TRICOTECT TRT S
9 Equipment installation
Where the unit and the regeneration tanks are located depends on the locality of the
customer workshop.
It is recommended to set up the equipment beside or close to the passivate

solution tank.
Choose a protected place.
Space requirement:
Tricotect TRT 200S Tricotect TRT 400S

Rack length approx. 1400 mm approx. 1400 mm
(incl. Column, electrical
panel, valves, pump,…)
width approx. 1400 mm approx. 1400 mm
height approx. 2600 mm approx.2800 mm
working height approx. 3000 mm approx. 3200 mm
HCl storage tank hight approx. 1450 mm approx. 1450 mm
diameter approx. 1000 mm approx. 1000 mm
Interim storage tank B4 hight approx. 1450 mm approx. 1450 mm
Interim storage tank B3 hight approx. 1450 mm approx. 1450 mm
It is recommended to set up the interim storage tanks B3 and B4 beside or

close to the Tricotect TRT.
Choose a protected space.
Page 32 of 46
TRICOTECT TRT S
9.1 Transport, handling and storage

Upon reception please check the unit for transport damage (especially: loose parts,
dents, scratches etc.).
Transport damages are to be documented with photos and the freight service has to be
informed immediately.
Please report any damages with photos to Atotech.
Please check the packing material very carefully for trapped components before disposal.
The unit has to be transported and stored in upright position only.
Trouble free operations and reliability of the device can only be guaranteed if the device
is not subjected to any climatic storage conditions -25 to 70°C.
In case of transport after a initial operation the unit has been transported under these
conditions:
the unit has been emptied of all liquids

mechanical and electrical connections has been disconnected
the column has been emptied of gravel and resin
the rack has been transported without the column
All work on the unit should be performed by skilled personnel only. All relevant safety and
environmental protection and regulations must be observed.
If the device is transported from a cold to a warm environment condensation may cause
in a failure of the function. In such a case make sure the device temperature has adjusted
to the ambient temperature before trying a new start up.
Avoid accidents. Use the proper handling equipment. Do not drop the
package. Use qualified people for the transport.
Page 33 of 46
TRICOTECT TRT S
Unit rack
length approx. 1400 mm
width approx. 1400 mm
height approx. 2800 mm
Total weight of the unit ready for operation (without approx. 395 kg
liquid) approx. 870 lbs
Tanks
diameter approx. 1000 mm
approx. 50 kg
Total weight without liquid
approx. 110 lbs
Column
diameter approx. 610 mm
approx. 50 kg
Total weight without liquid
approx. 110 lbs
Page 34 of 46
TRICOTECT TRT S
Position of the centre of gravity and application points for lifting equipment:
application points for lifting equipment
position of the centre of gravity
Please note: The unit is top- heavy. Make sure that the unit is sufficient fixed during the
transport with a fork lift.
Page 35 of 46
TRICOTECT TRT S
9.2 Filling column
1. Put the column in a vertical position on the basic platform. Connect the bottom of
the column with the pipe.
2. Open the column on the top. Open the screw couplings (2) and disconnect the
nozzle (1) with the distributor system.
1 3
Pos Part designation,

1 nozzle
2 screws (12 x)
3 union (2 x)
Take care that no unwanted or foreign material can fall into the top hole of the
column.
3. Fill in the resin, e. g. with a bucket and a funnel.

4. Fill the column first with RESIN XL3 (TRT 200S = 200 L, TRT 400S = 400L).
5. Fill up the column close to the distributor system with RESIN IN.
6. Clean the surface around the flange to avoid a leakage
7. Put the nozzle in the hole on top of the column (1) and connect the top of the
column with the pipe (3).
Put the column in a position, which avoid mechanical stresses when the pipes
are connected with the column.
Page 36 of 46
TRICOTECT TRT S
9.3 Exchange of the resin
1. Open the column on the top (see chapter 9.2.2)

2. Now it is possible to remove the resin by an industrial vacuum cleaner or, if water
is added to the resin, by a membrane pump.
Be careful when you reach the bottom of the columne. Do not destroy the
distributor system at the bottom of the columne.
9.4 Connection
3. See the P&I Diagram with regard to S/C connection points (S/C: Interface
Supplier/Costumer) and see also “Connection requirements” in this document in
order to assure that all requirements are achieved.
4. Connect the Tricotect TRT with the passivate solution tank according to the
diagram next page (page 38). The preferred connection (S/C interface E) is the
pressure side of the filter unit (e.g. with a T-fitting) of the passivate solution tank.
The passivation – outlet (S/C interface E) should be close to the inlet from the filter
unit to receive an optimal mixture in the passivation tank.
To establish the other connections of the Tricotect TRT unit and the additional tanks,
connections are generally located on the opposite side of the valve side, see next page.
Page 37 of 46
TRICOTECT TRT S
1 2 3 4 5 6 7
Rack connection
rack connection outside diameter valve
number of the butt fusion identification
(see image) ends (see P&I Diagram)
Discharge side of the Waste water 1 DN25 +S1-Y10.3
pump
(from the ion Interim storage tank B4 2 DN25 +S1-Y10.017
exchanger unit to …) HCl storage tank 3 DN25 +S1-Y10.009
Interim storage tank B3 4 DN25 +S1-Y10.014
Passivate solution tank 5 DN25 +S1-Y10.013
Suction side of the HCl storage tank 6 DN32 +S1-Y10.010
pump
(to the ion exchanger Interim storage tank B4 7 DN20 +S1-Y10.019
unit from …) DI water 8 DN32 +S1-Y10.1
Passivate solution tank 9 DN20 +S1-Y10.020
Page 38 of 46
TRICOTECT TRT S
Tank connection
Tricotect TRT 200S Tricotect TRT 400S
Inlet pipes HCl storage tank DN25 DN25
(from the rack, from Interim tank B3 DN25 DN25
external)
Interim tank B4 DN25 DN25
Outlet pipes all tanks overflow (waste water) DN25 DN25
(to the rack, to external) all tanks suction pipe DN32 DN32
Service Unit
2 3 4 5
Pos Part designation, Function

1 Push in fitting connection diameter 12mm for compressed air inlet
2 Connection for the pilot valve block, plastic tubing with outside diameter 10 mm,
required pressure = max 6 bar,
3 Connection to the diaphragm pump +S1-M70.001 or +S1-M70.002, plastic tubing with outside
diameter 12 mm, required pressure = 6 bar), flexible hose
4 Connection to the diaphragm pump +S1-M70.001 + +S1-M70.002, plastic tubing with outside
diameter 12 mm, required pressure = 6bar), flexible hose
5 Connection for the process (displace steps), plastic tubing with outside diameter 12 mm, required
pressure 0.5 bar;
It’s not allowed to use more than 0.5 bar pressure air for the process
(displace steps)!
Page 39 of 46
TRICOTECT TRT S
10 Preventive Maintenance Tasks

The TRICOTECT TRT requires a few preventive maintenance actions, such as:
x Periodic revisions of the pneumatic diaphragm pumps;
x Periodic revisions of the compressed air service unit;
x Periodic cleaning of the Sediment Strainer;
x Periodic calibration of the pH- electrode;
x Cleaning and external conservation;
x Eventual replacement of faulty parts.
The responsibilities of personnel for machine operation, set-up, maintenance and repair
must be clearly defined.
Only personnel who are specifically trained and instructed, are allowed to execute the
work of preventive maintenance or repair.
Electric and welding operations are only allowed by qualified personal.
Make sure that nobody switches on individual functions of the TRICOTECT

TRT while maintenance work is carried out!
Pump
Before any maintenance or repair is attempted, please read and attend the
instructions in the pump manual.
Verify the diaphragm pump operation conditions. If any abnormality is detected, such as
liquid or compressed air leak or strange noise, repair as soon as possible. Annually,
dismount, clean and replace the spare parts if its necessary (see the spare part list in the
pump manual).
More details about the pump can be obtained in the pump manual attached.
Page 40 of 46
TRICOTECT TRT S
Touch Panel
To protect the screen from aggressive moisture, liquid and dirt, a transparent polyester
sheet is attached at the touch panel as protective film.
It is not permitted to operate the TRICOTECT TRT without the protective film
to prevent the risk of damage at the touch panel by aggressive chemistry.
Furthermore it is not permitted to touch the screen with sharp mechanical
objects, like needles etc.
It is recommended to use a PDA pen for touching the control screen. This way the life
time of the film can be several years.
When dirt and smudges on the sheet begin to reduce the visibility of the display, please
replace the protective film by a new one.
pH- Electrode
The calibration and the maintenance of the electrode is the responsibility of the customer.
Please follow the instruction/ manual for the pH- electrode.
The periodic calibration and maintenance of the electrode is absolutely

necessary to avoid incorrect measured data.
Daily
Check the entire unit for leaks (pumps, pipes, tanks).
Verify the general equipment condition.
If any abnormality is detected, such as liquid or compressed air leak in the piping or
connections, provide the repair as soon as possible.
Weekly
Cleaning, checking and calibration of the pH-electrode.
See also the manual of the pH-electrode.
Cleaning and checking the sediment strainer.
Page 41 of 46
TRICOTECT TRT S
Monthly
Check and correct the adjustment of the compressed air service unit.
Every month or according to need, do an external general cleaning of the equipment,

removing any signs of liquid leak, dust or accumulation of dirt.
Quarterly
Change the filter cartridge of the compressed air service unit.
Half-yearly
An electrician should verify all of the electric installation and all electric connections, the
interior of the electric encloser and change the lamps if defective.
Annually
The pressure transmitter must be calibrated and certificate annually.
Page 42 of 46
TRICOTECT TRT S
11 Trouble shooting
problem troubleshooting
FICA 3: Check the inlet pipes and the pipe connections of the tanks. Eliminate
Flow alarm broken and leakage defects.
No flow from the passivate Check all concerned valves for ensure there are in the right position.
solution tank or the interim Check the Sediment Strainer YF-001, if required close BV-001 and clean the
tank B4 strainer.
Check the pump and the compressed air for pump control.
FICA 4: Check the inlet pipes and the pipe connections of the tanks. Eliminate
Flow alarm broken and leakage defects.
No flow from the HCl tank or Check all concerned valves for ensure there are in the right position.
the DI water Check the Sediment Strainer YF-001, if required close BV-001 and clean the
strainer.
Check the pump and the compressed air for pump control.
HCl- tank empty Refill the HCl- tank.
Overflow in HCl- tank Stop the refill procedure.
PICA 0: Check the pressure of the compressed air, required: min 5.5 bar, dry and oil
No compressed air free
Check the connection between the hose and the compressed air service
unit.
The pump doesn’t work Check the pressure of the compressed air (see PICA 0). Required: min 5.5
bar, dry and oil free
Check the connection hose between the pump and the compressed air
service unit.
See the manual of the pump
Overflow in the interim tanks/ Check the float switch – see manual for the level switch
HCl- tank Clean it with DI water injection
Check the process time – if its required, change the time
pH- value is no correct The value is not reached, step rinse 1 have to be started again manually;
Check the pH- electrode (cleaning, calibration)
Page 43 of 46
TRICOTECT TRT S
12 Spare parts
Mechanic
Order No. Description
58506508 pH-electrode glass 0-14pH
58502806 Temperature sensor PP PT100 0-90°C
58501211 Plug MSSD-C for solenoid valve MN1H
58501011 Solenoid valve MN1H-2-1/2-MS
58502511 Solenoid coils MSN1G-24DC-0D for solenoid valve MN1H
58502611 Service unit distributor block LRB-D-O-MINI
58500611 Plastic tubing PLN-12x1,75-NT
58505711 Filter G1/4 service unit Pos.3
58501111 Pressure gauge MA-40-10-1/8
58500711 Non return valve H-G1/4
58504111 Pressure switch 1- 12bar
95275601 Diaphragm valve PP-FPM DN32 NC MV 310
95037904 Ball valve PP-FPM DN15 D20 SS PN10
95031804 Ball valve PP-EPDM DN25 d32 SS PN10
95037804 Ball valve PP-FPM DN20 D25 SS PN10
95031804 Ball valve PP-EPDM DN25 d32 SS PN10
95070205 Pressure relief valve PP-PTFE-FPM DN25, 10 bar
95103608 Pressure transmitter 0-10 bar/ 4-20mA
58500006 Diaphragm pressure gauge guard 0-10bar
95021906 Flow meter PP-FPM 400 - 4000 l/h DN50 (TRT 400S)
95020906 Flow meter PP-FPM 200 - 2000 l/h DN40
95022006 Flow meter PP-FPM 15 - 150 l/h DN20
95172501 Flow meter PP-EPDM 100 - 1000 l/h DN25
8598211 Limit switch for flow meter
95390601 Sediment strainer PP DN20 SM PN10
95391201 Strainer tube PVC-U DN20 D0,5
95069005 Diaphragm pump PP 1,1m³/h-3bar (TRT 200S)
95070305 Diaphragm pump PP 3,2m³/h-3bar (TRT 400S)
58501006 Float switch with 3 switch-point 1055mm (TRT 400S)
Page 44 of 46
TRICOTECT TRT S
Electric
Order No. Description
95007211 Connecting modul left 10V
95007311 Connecting modul right 10V
95007511 Modular pneumatic valve unit 8 x 3/2 way (6524)
95015102 T-Plugconnector POM, D10
95017002 L-Plugconnector 10 10
95017102 L-Screwconnection IG G1/4 10
Measuring transducer GPHU 014 MP pH-W. 0-14 pH 0-
95042408 10V
95062608 Powermodul 24V KL9110
95064608 Powermodul 24V Bus-Endklemme KL9010
95068708 Digital Input 4x 24V 4DI KL1404
95068910 Digital output KL 4x 0,5A 24V KL2404
95070508 Analog input 2x RTD PT100/10k KL3202
95071208 Analog input 4x AI U St.
95073708 Analog input 4x AI I St. KL3454
95077108 Powermodul 24V elongation KL9020
95077208 Powermodul 24V coupler KL9050
95079808 Relais coupler 24V DC 1NCCNO
95094408 Protected switch 24V Diagnose module 6A
95094808 Emergency OFF 24V 3NO
95209301 Main circuit breaker S00 0,7-1A 1NO/1NC
Page 45 of 46
TRICOTECT TRT S
13 Critical component list
Tricotect
Angaben über Typ, Stromstärke,

Leistung,
Transformatorspezifikationsnummer,
Isolationsklasse /
Information about type, current, Prüfzeichen von /
Bauteil / Hersteller / power, transformer specification Test mark from
Kind of component Manufacturer number, insulating class (VDE, BSI, UL etc.)
Main switch / Q01 Sontheimer 3x25A 50/60Hz HLT25 IEC, 690V/25A IEC 60947-3
Power switch / Q1 Siemens 3RV10 11-1EA15, 2,8-4A IEC 60947-1, UL 489/CSA C22.2 No.5-02
IEC/EN 60950-1; EN 61204, EN 61000-6-1, EN 61000-6-2, EN
Power supply / T1 Schneider Electric ABL8RPS24050, 100-500V/5A 61000-6-3, EN 61000-6-4, EN 61204-3
EN/IEC 60204-1, EN 1088/ISO 14119, EN/IEC 60947-5-1,
EN/ISO 13850, EN 50082-2, EN 954-1/ISO 13849-1, UL, CSA,
Emergency stop combination / A40.1 Schneider Electric XPS AF5130, 24V 3NO BG
IEC/EN 60947-5; UL 508; CSA-C22.2 No. 14-05; CSA-C22.2 No.
Double-press push button gn/rd / S04.1 Eaton 216701, M225-DDL-GR-X1/X0 94-91; CE marking
Push button lockable rd/ye emergency IEC/EN 60947-5; UL 508; CSA-C22.2 No. 14-05; CSA-C22.2 No.
stop / S40.1 Eaton 216876, M225-PV 94-91; CE marking
Contact element 1NC / S04.1 Eaton 216378, M22-K01 94-91; CE marking
Contact element 1NO / S04.2 Eaton 216376, M22-K10 94-91; CE marking
Page 46 of 46

Manual Del Tricotec

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Manual Del Tricotec

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Equipment Documentation

TRICOTECT TRT Typ S

Updates and Versions:

22/05/2012 007 Minor change of the text in the word documentation

Project No.: C10 203 004 (TRT 200 S)

© Copyright - 2008 ATOTECH Deutschland GmbH

ATOTECH Deutschland GmbH

Responsibility of the personnel

Responsibility of the user

Guarantee and liability

Safety and protection devices

Emergency stop switches

Safety guidelines and rules

x Any defects that could be dangerous to safety must be fixed immediately.

Instruction for reducing noise or vibrations

Exhaust system, gases and vapours

Precautions at regular operations

Maintenance and repair

Cleaning and disposal of materials

4 tank for ion exchanger regenration chemistry 2 filter unit

The operator is responsible for the new make up of the regeneration

3.2 Design description

The TRICOTECT TRT S consist basically of:

Tricotect TRT S front view Tricotect TRT S right hand side

Pos Part designation Pos Part designation

TRICOTECT TRT 400S

Power Management Standard version:

The connections to the unit and in between the modules have to be

Electric and welding operations are allowed by qualified personal only.

6.2 Tricotect TRT 400S

7 Schematic representation of the main parts

Pos Part designation, Function Pos Part designation, Function

Compressed air service unit and pressure switch

Pos Part designation, Function Pos Part designation, Function

7.2 Sectional view

Pos Part designation, Function Pos Part designation, Function

7.3 Rack - Right hand side (valve side) view

Pos Part designation, Function Pos Part designation, Function

Valve identification and description

7.4 Additional Tanks

x 1000 liter tank for regeneration chemistry (HCl 18 w/w %)

x 1000 liter interim storage tank B4 for passivate solution

A third tank is optional:

8.2 Description of the process steps

In step loading 2 the temperature in the inlet flow of passivate solution is

Chemistry for regeneration - HCl 18 w/w % - solution!

It is recommended to set up the equipment beside or close to the passivate

Tricotect TRT 200S Tricotect TRT 400S

It is recommended to set up the interim storage tanks B3 and B4 beside or

9.1 Transport, handling and storage

Please report any damages with photos to Atotech.

The unit has to be transported and stored in upright position only.

the unit has been emptied of all liquids

application points for lifting equipment

position of the centre of gravity

9.2 Filling column

Pos Part designation,

3. Fill in the resin, e. g. with a bucket and a funnel.

9.3 Exchange of the resin

1. Open the column on the top (see chapter 9.2.2)

Pos Part designation, Function

10 Preventive Maintenance Tasks

Electric and welding operations are only allowed by qualified personal.