Inge UF T Rack Assembly Instructions Manual 45 D02230 en

T-Rack® 3.
0 Series
Assembly Instructions
Legal Notice
Legal Notice
Product
T-Rack® 3.0 Series, parts and components for installation, assembly and disassembly
Manufacturer
inge GmbH
Flurstraße 27
86926 Greifenberg
Germany
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 company/party responsible for the assembly of the system described in this manual should obtain the
current inge® assembly instructions:
◼ Download at: https://www.dupont.com/brands/inge.html
◼ By e-mail to inge@dupont.com
◼ By telephone under +49 8192 997-700
Change History
Version Version date Author History
V0 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
V 2.0 08/2019 MH/GS Minor adjustment
V 2.1 01/2020 GS Minor adjustment
V 3.0 05/2020 MH/GS Components adjustment
T-Rack 3.0 Series – Assembly Instructions Page 2 of 87

© inge GmbH 45-D02230-en, Rev. 5
Index
Table of Contents
Assembly Instructions .......................................................................................................................................1
1 About 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
1.3 Symbols in this Manual .......................................................................................................................8
1.3.1 Instructions .............................................................................................................................8
1.3.2 Symbols .................................................................................................................................8
1.4 Storage and Transfer to Another Party...............................................................................................8
2 Safety ...........................................................................................................................................................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
3 Device 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
4 Loading, Transport and Storage .............................................................................................................24

4.1 General Instructions..........................................................................................................................24
4.2 Warnings ...........................................................................................................................................25

Index
4.3 Loading .............................................................................................................................................27

4.4 Transport ..........................................................................................................................................28
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
4.5.2 Stackability ...........................................................................................................................28
4.5.3 Checking the Available Space .............................................................................................28
5 Installation / 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

Index
5.14.3 Attaching Connectors ..........................................................................................................65

5.14.4 Mounting the Bottom Frame on the T-Rack® 3.0 Anchor Plates .........................................67
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
5.15 Prevention of Possible Assembling Failures ....................................................................................75
6 Service and Maintenance .........................................................................................................................78

6.1 Warnings ...........................................................................................................................................78
6.2 Checks during Operation ..................................................................................................................80
6.2.1 Eliminating Leaks .................................................................................................................80
6.2.2 Exchanging Parts .................................................................................................................80
6.2.3 Return of Modules and Other T-Rack® Components ..........................................................80
7 Disassembly and Disposal ......................................................................................................................81

7.1 Warnings ...........................................................................................................................................81
7.2 Disassembly .....................................................................................................................................83
7.3 Disposal ............................................................................................................................................84
8 Customer Service .....................................................................................................................................85

8.1 Service Hotline ..................................................................................................................................85
8.2 Ordering Spare Parts ........................................................................................................................85
9 Technical Documentation ........................................................................................................................86

9.1 Other Applicable Documents ............................................................................................................86

About these Instructions
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
→ inge_manuals@dupont.com

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.

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
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
2.2.1 Residual Risks

Despite the inherently safe design 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
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.
https://www.dupont.com/brands/inge.html
◼ On request, we can send you the desired number of printed instructions free of charge.
◼ You can reach inge GmbH under info@inge.ag or by telephone +49 8192 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 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
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
Personal injury due to a potentially hazardous situation. If this
situation is not avoided, it may lead to serious injury or death.
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.
NOTE
CAUTION, PROPERTY DAMAGE!
Property damage due to an improper procedure.

Safety
2.6.2 Warning Symbols

The following warning symbols are used in this manual:
WARNING
DESCRIPTION
SYMBOL
GENERAL DANGER SIGN
If the necessary safety instructions are not followed, this may lead to
death, serious injury and serious property damage.
SUSPENDED LOADS
death, serious injury and property damage due to falling loads.
HEAVY WEIGHTS
serious back injury due to lifting of heavy loads.
DANGER OF CRUSHING (BODY)

death or serious injury due to pinching/crushing of the body.
DANGER OF CRUSHING (BODY)

death or serious injury due to pinching/crushing of the body.
DANGER OF CRUSHING AND SHEARING (HAND)

serious injury and property damage due to crushing and shearing of
the hands and other parts of the body.
DANGER OF FALLING
death or serious injury from falling.
DANGER OF SLIPPING
serious injury from slipping.
DANGER OF TRIPPING
serious injury from tripping.
DANGER OF CUTTING
serious injury from cutting on sharp edges.

Safety
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
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!
DANGER
DANGER TO LIFE!
Danger of crushing by industrial trucks and other
equipment at the construction site.
and lifting loads!
WARNING
Danger of injury from faulty and incomplete
assembly.
▪ Do not start up the T-Rack® before it has been
fully assembled!
▪ Wear safety goggles!

Safety
WARNING
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!
▪ Use a safety harness if necessary!
WARNING
Danger of crushing and shearing from work in the
danger zone.
▪ Note the specified number of persons required!
WARNING
Cutting and impact injuries from sharp corners and
edges.
WARNING
Danger of tripping and impact from pallets,
packages and assembled parts at the construction
site.

Safety
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!
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
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
3 Device Description
3.1 Components
3.1.1 Overview Graphic

Parts of the Sub-unit of a T-Rack®

Device Description
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
Threaded pin (DIN 913)
O 32
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

Device Description
3.2 Functional Description
Part Description
Filtrate pipe Clear plastic pipe that conducts the filtrate from the module to the filtrate header.
Filtrate pipe Assembly consisting of a filtrate pipe, two 90° elbow pieces PP 2” and four flexible
assembly composite couplings 2”.
A pipe running parallel to the channel section above each module row; used to collect the
Filtrate header
filtrate from all modules of the respective row.
Mounting clamp Mounted on the channel sections (DIN 1026) of the first and last module pair of a T-Rack®
PE and carries the filtrate header.
Threaded pin Used to connect the upper or lower T-pieces of two neighboring modules with the channel
(DIN 913) sections (DIN 1026).
Part of the frame foot. It is mounted on the bolt head of the frame foot bolt, rests on the
Adjustable foot
ground and, together with all of the other adjustable feet M16 of the frame, carries the
M16
total weight of the T-Rack®.
Connection piece between a 90° elbow piece PP 2”, a filtrate pipe, a filtrate port on the
Flexible 2”
module, and a filtrate port on the filtrate header.
composite
Consists of a two-part coupling shell made of composite, two connecting bolts with nuts
coupling set
and a gasket.
Flexible 6” Connection piece between the T-pieces of two modules or between two filtrate headers of
composite neighboring sub-units. Consists of a two-part coupling shell made of composite material,
coupling set two connecting bolts with nuts and a gasket.
Part of the bottom frame. U profile that runs along the longitudinal direction of the bottom
Channel section
frame.
Smallest filter unit of a module. A cylindrical part made of plastic with inside feed channels
Membrane for the water being purified; filters contamination out of the water in these feed channels
by means of microscopically small pores.
Filter unit for installing in the T-Rack®. A module consists of a defined quantity of
Module
Multibore® membranes installed in a cylindrical shell housing with T-pieces on both sides.
Channel section U profile. Connection of the upper T-pieces of two neighboring modules on which the
(DIN 1026) mounting clamp PE is still to be mounted.
Channel section
U profile. Connection of the lower T-pieces of two neighboring modules.
(DIN 1026)
Channel section
Part of the bottom frame. U profile that runs in transverse direction to the bottom frame.
(DIN 1026)
Part of the bottom frame. It consists of a hex bolt, two nuts with washers and an
Frame foot
adjustable foot M16.
Base of a sub-unit, consisting of U profiles bolted together that are supported on the frame
Lower frame
feet and are inserted in the channel sections (DIN 1026) while still being movable.
Assembled ultrafiltration unit with 4 to 136 modules. A T-Rack® consists of one or more
T-Rack®
sub-units.

Device Description
Part Description
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
Sub-unit headers and the pipes between the modules and filtrate headers (filtrate pipe assembly).
As the smallest unit of a T-Rack®, a sub-unit can also be operated autonomously in
practice.

Device Description
3.3 Technical Data

The T-Rack® 3.0 Series systems are used for commercial ultrafiltration of water.
For details, see the datasheets ‚Multibore® Membrane‘, ‚Composite Coupling Set for T-Rack® 3.0 Series and
Manifold‘ and ‚T-Rack® 3.0 Series‘.
3.3.1 T-Rack® 3.0

◼ dizzer® XL 0.9 MB 80 WT in two-row layout
◼ dizzer® XL 0.9 MB 80 WT in four-row layout
→ See datasheet ”dizzer® XL 0.9 MB 80 WT for T-Rack® 3.0”

→ See datasheet “dizzer® XL 0.9 MB 70 WT for T-Rack® 3.0‘”

→ See datasheet “dizzer® XL 1.5 MB 50 WT for T-Rack® 3.0”
3.3.2 T-Rack® 3.0 S

◼ dizzer® XL 0.9 MB 60 ST in two-row layout
◼ dizzer® XL 0.9 MB 60 ST in four-row layout
→ See datasheet “dizzer® XL 0.9 MB 60 ST for T-Rack® 3.0 S”
◼ dizzer® XL 1.5 MB 40 ST in two-row layout

◼ dizzer® XL 1.5 MB 40 ST in four-row layout
→ See datasheet ‚dizzer® XL 1.5 MB 40 ST for T-Rack® 3.0 S‘

Loading, Transport and Storage
4 Loading, Transport and Storage
4.1 General Instructions

Warranty Claim for Transport Damage and Improper Storage
◼ Modules and components that are irreparably destroyed due to improper loading, transport or
storage shall not be covered by inge GmbH's warranty provisions. Therefore, it is important to
always follow the loading, transport and storage instructions provided in these Assembly
Instructions.
◼ Modules that are still contained within 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 otherwise agreed by inge GmbH in writing.
NOTE
Property damage caused by mechanical impact.
▪ Ensure that the modules are not jarred.
NOTE
Property damage caused by impermissible exposure to weather
conditions.
▪ Adhere to the storage and transport temperatures in a range
from -20 °C to 40 °C.
▪ Ensure that the equipment is transported and stored in an
enclosed area to keep the components from getting wet and to
protect them against excessive heat.
▪ Store all parts and modules under dry, moderately ventilated
conditions.
A detailed description of the inge® packaging can be found in the packaging description and in the corresponding
packaging datasheet ‘DS Packaging TR-30 Modules’, ‘DS Packaging TR-30S Modules’ and ‘DS Packaging TR-
30Series FrameParts’ for the T-Rack® solution and the corresponding modules. Condition of shipment and box
type are subject to modification by inge GmbH without notice.

4.2 Warnings
DANGER
DANGER TO LIFE!
and lifting loads!
DANGER
DANGER TO LIFE!
Danger of crushing by industrial trucks and other
equipment at the construction site.
and lifting loads!
WARNING
WARNING
danger zone.

WARNING
edges.
WARNING
site.
CAUTION
DANGER OF INJURY!
▪ Always note the locally applicable maximum permissible load of
persons!

4.3 Loading
Fork-Lift Truck Requirements
◼ To lift and transport pallets in a longitudinal direction, only use fork-lift trucks or lift trucks with a
fork length of 180 cm or more.
◼ The use of removable fork extensions or telescope extensions is permissible as long as a fork
length of at least 180 cm is ensured when transporting the pallet in the longitudinal direction.
Stackability
The following maximum stacking heights must be observed:
Multi Unit Packaging

Single Unit Packaging
(max. 12 UF elements per
(1 UF element per cardboard box)
plywood box)
Module type Positioning Stacking Height Positioning Staking Height
dizzer® XL (WT) Horizontal 4 Horizontal 3x*
*The maximum height is 4m, as long as this is permitted by the loading room height.
The T-Rack components are also delivered in prefabricated wooden boxes and can be stacked up to a height
of 4 meters.
Weight load
◼ On the basis of the delivery scope, check the total weight with respect to the permissible weight
load of the truck.
Transport Protection
◼ Ensure that the equipment is transported safely by securing it properly in the truck.
Load Distribution
◼ When loading, fill the loading surface without gaps to prevent the transported equipment from
tipping, slipping, etc.
◼ Low packages over which other, higher packages could tip in case of emergency braking must
not be positioned at the bulkhead.

4.4 Transport
4.4.1 Transport Conditions

◼ During transport, adhere to a temperature range of -20 °C to 40 °C.
◼ Ensure that the equipment is transported and stored in an enclosed area to keep the components
from getting wet and to protect them against excessive heat and direct sunlight.
4.4.2 Checking the Freight

Check on IPPC Pallets
◼ Check that the freight has been mounted on heat-treated IPPC pallets only.
◼ Freight that is not positioned on IPPC pallets must be remounted on IPPC pallets.
4.5 Storage
4.5.1 Suitability of the Location

◼ Adhere to the storage and transport temperatures in a range from -20 °C to 40 °C.
◼ Ensure that the equipment is transported and stored in an enclosed area to keep the components
from getting wet and to protect them against excessive heat and direct sunlight.
◼ Store all parts and modules under dry, moderately ventilated conditions.
4.5.2 Stackability
◼ See section 4.3 Loading
4.5.3 Checking the Available Space

Check the maximum floor load of the planned warehouse storage area.
The details on the weights can be found in the delivery papers.

Installation / Assembly
5 Installation / Assembly
5.1 Warnings
DANGER
DANGER TO LIFE!
and lifting loads!
WARNING
WARNING
danger zone.
WARNING
edges.

WARNING
site.
CAUTION
DANGER OF SLIPPING!
Be careful when opening the modules, as residual liquid may still
leak from the preservation.

5.2 General Specifications
5.2.1 T-Rack®s and Sub-Units

A T-Rack® 3.0 consists of one or more sub-units, each with 4 to 68 modules in two or four module rows.
Example: T-Rack® consisting of three sub-units, each with 12 modules in two rows:
These instructions describe the installation of a free-standing sub-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 installation of the T-Rack® series.
◼ The existing connecting pipework must be free of contaminants which can cause abrasion or
fouling.
◼ All coated frame parts must be treated with care. If the coatings should become damaged, they
must be resealed with a protective coating or exchanged.
Connecting of a sub-unit to an existing sub-unit is described in the next section:
→ 5.14.1 Assembly of Multiple Sub-Units to one T-Rack®

5.2.2 T-Rack® Geometric Flexibility
NOTE
The T-Rack® 3.0 is designed to allow expansion as well as
contraction and is therefore flexible. This is necessary to allow
differences in temperature and pressure. The maximum difference
between the length of a T-Rack® 3.0 in ‘as-built’ condition to the
length after pressurizing is about 2 mm per T-piece composite
coupling.
2 mm per
coupling
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 connection options on both sides.
If it is required to connect the T-Rack® 3.0 with pipework on both
sides, this pipework should be able to adjust to the full expansion
and contraction possibility of the T-Rack® 3.0. In installations where
both the bottom as well as the top feed headers of the T-Rack® 3.0
are connected to fixed pipework, a device for adjusting to expansion
and contraction can be omitted as long as the feed pressure is below
3 bar.

5.2.3 Calculation of Personnel Requirements

Personnel Requirements for mounting a module without a Crane
CAUTION
DANGER OF INJURY!
persons!
To mount the module without a crane, calculate the number of persons required as follows.
1. Determine the transport weight of a module you are using from the
→ 3.3 Technical Data
2. Determine the maximum permissible load on a person from the locally 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.
Always use the calculated number of persons when a module needs to be lifted and placed on a connecting
brace. In our example configuration, a total of 3 persons was determined and specified. Always replace this
number by the number you actually determined yourself.
The total number of persons required is always one person more since when setting up modules 1 to 3, one
person must hold the already installed modules vertical while the others lift and position another module.
Personnel Requirements for Other Tasks

Unless otherwise specified, all other tasks require one person.
If steps require two or more persons, this is specified in each case.
A maximum of 4 persons are needed.

5.2.4 Tools and Consumables
NOTE
If the tightening torques specified in these instructions are
exceeded, the system parts may become damaged and leaks may
occur during operation.
▪ Always adhere to the specified tightening torques!
NOTE
The 2’’ and 6’’ composite couplings should be tightened until the
contact surfaces of both coupling halves are flush and resting
against each other without a gap. These types of couplings do not
require a specific torque. The usual range of 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 electric), provided that these can be used to reliably and
verifiably set the required torque (size 24)
◼ Open-end wrench or box-end wrench (sizes 17, 19, 24)
◼ Torque wrench (size 17, 19, 24)
◼ Hex key (size 5, 6)
◼ Torx screwdriver T 20
◼ Spirit level 2000 mm
◼ Spirit level 600 mm
◼ Try square 90°
◼ Glycerin (>97%)
5.2.5 Preparation of gaskets and O-rings

Do not use silicone or any lubricants or sealants that contain silicone during assembly. Only glycerin may be
used as a lubricant for gaskets, o-rings, couplings etc. (with a purity of > 99.7 %).
NOTE
USE DISPOSABLE GLOVES!
Use disposable gloves to apply lubricant to the couplings and
gaskets.

5.3 Preparing for Assembly
5.3.1 Checking the Available Space
NOTE
Potential damage due to exposure to the weather or impermissible
temperatures.
Weather and Temperature Protection

At the location where you are planning to erect the T-Rack® sub-unit, ensure the following:
◼ The unit is always protected by a roof
◼ Permanent protection against the weather is provided
◼ The temperatures are always within the permissible temperature range from 1°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. A maintenance space of 80 cm in front of the T-Rack is required.
CAUTION
DANGER OF INJURY!
Danger of injury due to constricted space.
▪ Provide for sufficient space!
Comparison of Room Heights

◼ Compare the existing room height with the required assembly height.
◼ The maximum height of the system and the required clear room height is shown in the following
table:
T-Rack® Unit System height Clear room height

T-Rack® 3.0 mm max. 2,695 min. 2,945
T-Rack® 3.0 S mm max. 2,363 min. 2,613
◼ Ensure that the necessary room height is available.
CAUTION
DANGER OF INJURY!
Danger of injury due to inadequate room height.
▪ Provide for sufficient room height!

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®s.
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/m2.
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

Protecting the Work Area

◼ Protect the defined work area against access by persons who 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
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!

5.3.3 Assembly location and sequence
Mark the area for the planned system. The area can be determined from technical data in section 3.3 of the
T-Rack® variant being erected.
The erection location and orientation 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 first complete the
connecting pipework and then mount the T-Rack® 3.0.
→ 5.14.6 Connection to existing Connecting Pipework
The Flexi Kit from inge® can be used to compensate for small
level differences. This Flexi Kit is not part of the standard scope
of supply but can be ordered optionally.
→ Attaching Compensation Pipes

5.4 Checking the Delivery
5.4.1 Moving the Packages to the Work Area
Move all packages of the sub-unit being mounted to the vicinity of the work area using suitable transport
equipment.
5.4.2 Checking for Damage
Step Activity
1 Checking Packages and Parts
a) Check all packages of the delivery for damage.
b) Open all damaged packages.
c) Check all models and/or parts it contains for damage.
2 Procedure for Damaged Modules or Parts
a) Photograph the damage and the associated package label.
b) Document all damage and the respective module serial numbers and associated package
numbers 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 regarding whether the damaged module or part must be returned or if it can be
used is made by your contact at inge GmbH.
→ 6.2.3 Return of Modules
Further Use of Parts

You are only permitted to continue to use and install the following modules and parts:
◼ All modules and parts without damage
◼ Damaged modules and parts with written approval from inge GmbH with a specific reference to
the damaged module or part
inge GmbH decides on the procedure (approval or block) for all damaged modules or parts that have not been
approved.
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!

5.4.3 Checking the Delivery for Completeness
Step Activity Figure

1 Remove the packing list.
You will find the packing list in a red pouch on the packaging.
2 Check the completeness of the delivery against the packing
list.
All packages on the packing list must be present.
3 Promptly inform your contact at inge GmbH if the number of
pieces differs between the packing list and the existing
packages.
5.4.4 Unpacking the Parts
NOTE
In case of abrupt temperature changes.
▪ Store the modules for at least two days at temperatures above
freezing before opening the packaging carton.

1 Unpacking the Packaging
a) Remove the packaging and labeling.
b) Remove the wooden boards of the modules on the outside
by releasing the screws with a hex key (size 6).
2 Unpacking the Component Crate

a) Remove the cardboard cover.
b) Remove the screws securing the cover plate using a Torx
screwdriver T 20.
c) Open the transparent plastic bags containing the small
parts. Leave the nuts and washers on the bolt.

5.5 Mounting the Bottom Frame
NOTE
Danger of system damage if the bolt head is not fully in place in the
adjustable foot M16.
▪ Insert the bolt head in the adjustable foot M16 so that the head
is noticeably sunk into the adjustable foot M16 (see step 2)!
NOTE
The following description refers to mounting of the bottom frame on
the adjustable foot M16.
▪ Optionally, the bottom frame can be mounted on the anchor
plates that are bolted onto the floor. A description of how to
mount the bottom frame onto 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

1 Prepare the bolts
a) Screw the hexagon nut (DIN 934) M16 closer to the bolt
head toward the bolt head until there is a space of 37 mm
to 38 mm between the bolt head base and the nut.
b) Repeat step a) for all other pre-assembled hexagon bolts
(DIN 933) M16 x 150.
Nut
37 to
38 mm
Bolt head
2 Prepare the frame foot

a) Place an adjustable foot M16 onto the floor with the
opening facing up.
b) Force the bolt head of a pre-assembled hex bolt into the
opening of the adjustable foot M16. The bolt head must
noticeably (by a few millimeters) be sunk into the
hexagonal opening of the adjustment plate.
Otherwise, there is a danger that it will sink down later and
cause strain, leaks and pipe breakage.


3 Mount the channel section (DIN 1026)
(U profile 50 x 38)
a) Remove the upper hexagon nuts (DIN 934) M16 and one
of the two washers (DIN 433) A17 from each of the frame
feet.
b) Place the channel section (DIN 1026) (profile opening
facing up) on two frame feet.
c) Repeat procedure a) and b) for two further U profiles and
four further frame feet.
4 Mount the channel section (U profiles 50 x 50 x 4)
a) Place the three channel sections (DIN 1026) at distances
that correspond to the holes of the channel section.
b) Position the two channel sections with the openings facing
each other, in a position that is aligned 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 several
turns.
c) Repeat the procedure a) to b) for all protruding bolts.
d) Hand-tighten the U profiles onto the frame feet at all
positions.
6 Insert the channel sections (DIN 1026) (U profiles 50 x

38 mm with four holes) in the channel section
The described example configuration (12 modules, two rows)
has 6 installed connecting braces.
In other configurations, this number can vary from 2 to 5 braces.
a) Insert the channel sections (DIN 1026) (profile opening
facing down) into the U profiles of the channel sections
parallel to the channel sections (DIN 1026).
b) Distribute the channel sections (DIN 1026) along the frame
length so that three are positioned in each half of the
frame.
The exact alignment will be made in a later step.

5.6 Positioning and aligning the Bottom Frame
NOTE
Danger of damage in the system and leaks if the frame is not leveled
precisely.
▪ Level the frame in the longitudinal and transverse directions!

1 Position the bottom frame
Number of persons: 2
a) Position the frame at the correct location according to the
system layout.
2 Level the bottom frame
a) Place two spirit levels at right angles to each other on the
frame.
b) Leave two front frame feet in their fixed position.
c) Adjust the four other frame feet so that all feet rest firmly on
the floor and the frame is level in all directions.
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 and all channel sections (DIN 1026)
attached to the channel sections.
(permissible deviation is 2 mm/m)
3 Align the frame at right angles
a) Position the channel sections (DIN 1026) at a distance
from the corner of the frame so that there is space for a 90°
try square.
b) Position the try square against two connected U profiles
and check that they are at right angles.
c) Correct the position of the profiles relative to each other if
necessary.
4 Secure the frame feet bolts
a) Hold the upper nut in position using an open-end wrench
(size 24).
b) Tighten the lower nut with a second open-end wrench (size
24). For indication purposes only: the necessary torque for
secure assembly is 135 Nm.
c) Repeat the procedure a) and b) for all frame feet bolts.

5.7 Mounting Module 1
5.7.1 Assembling the Filtrate Pipe Assembly

1 Lubricate the gaskets with glycerin
a) Remove the gaskets of the flexible couplings 2”.
b) Lubricate the gaskets with glycerin on the inside 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
of the pipe.
c) Repeat the procedures a) and b) for the opposite
opening.
3 Mount the gasket on the filtrate port of the module

a) Remove the protective cap from the filtrate port of the
module.
b) Mount the third lubricated gasket over the opening of
the filtrate port.
c) Push the gasket onto the filtrate port so it is flush with
the end.


4 Mount the 90° elbow pieces PP 2” on the filtrate pipe
a) Position the transparent filtrate pipe and one 90° elbow
piece PP 2“ with the openings facing each other.
b) Pull the gasket of the filtrate pipe over the 90° elbow
piece PP 2“ so it is centered between the grooves of
the two parts.
c) Place a flexible coupling 2” half-shell around the

gasket.
Ensure 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) Tighten the flexible coupling 2” with two nuts M10 and
washers using an open-end or box wrench (size 17)
until the contact surfaces of both coupling halves are
flush and resting against each other without a gap.
Ensure that the nuts are tightened evenly and
alternately.
f) Repeat procedures a) to e) for the other end of the
transparent filtrate pipe.
Ensure that the two 90° elbow pieces PP 2“ are facing
roughly in the same direction. The exact alignment will
be made in a later step.


5 Mount the filtrate pipe assembly on the module
a) Place module 1 on the floor so that the T-piece
opening faces down, which will face the next module of
the sub-unit just mounted.
b) Position the opening of the 90° elbow piece PP 2“ and

the filtrate port so they are flush.
c) Pull the gasket from the filtrate port over the 90° elbow
piece PP 2“ so that the gasket is centered on the
connection surfaces of the 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 half-
shells are resting in the provided grooves.
e) Place the second flexible coupling 2” half-shell on the
first and insert the bolts in the threaded openings of the
half-shell.
f) Position the filtrate pipe assembly parallel to the
longitudinal axis of the module.
g) Tighten the flexible coupling 2” with two nuts M10 and
washers using an open-end or box wrench (size 17)
until the contact surfaces of both coupling halves are
flush and resting against each other without a gap.
Ensure that the nuts are tightened evenly and
alternately.

5.7.2 Mounting the Module on the Channel Section (DIN 1026)

1 Screw the threaded pins (DIN 913) M10 x 50 into the bottom
T piece
Using a hex key (size 5), screw the two threaded pins (DIN 913)
M10 x 50 all the way into the two threaded holes of the middle
rib.
2 Position and mount the module on the channel section (DIN

1026) = actual
Number of persons: 3 back
ATTENTION
Always start with the first module on the

longer side of the frame.
front
a) Remove the protective caps from the T pieces at the top

and bottom.
b) Now lift the module vertically over the first bottom
connecting brace of the frame.
c) Lower the module until both threaded pins (DIN 913) M10 x
50 on the lower T piece are inserted in the two holes in the
channel section (DIN 1026). The front edge of the T piece
and the front edge of the frame must be flush.


d) Continue to hold the module in position and screw the
washers (DIN 125) A10.5 and the nuts (DIN 934) V4A M10
onto the two threaded pins (DIN 913) M10 x 50 with a
torque of 5 Nm. Loosen the nut again by ¼ turn while
simultaneously holding the set screw (DIN 913) with a
hexagon wrench (size 5).
3 Document the module serial number and the corresponding

T-Rack® position from now on.

5.7.3 Mounting the Gaskets on the T Pieces

a) Remove the gaskets of the flexible composite couplings 6”.
outside.
2 Mount the gaskets on the filtrate pipe

a) Continue holding the module in position to prevent tipping.
b) Mount one of the lubricated gaskets over the opening of

the lower T piece, which will face the following module of
the T-Rack®.
c) Push the gasket onto the T piece so it is flush with the end.
d) Repeat procedures b) and c) for the upper T piece.

NOTE
Danger of damage 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!

1 Mount module 2
= actual
a) Continue holding module 1 in position to prevent tipping. back
b) Mount module 2 using the procedure described in section:
→ 5.7 Mounting Module 1 1
2
front


2 Connect the lower T pieces of modules 1 and 2
a) Continue holding modules 1 and 2 in position to prevent
tipping.
b) At the connection of module 1, pull the gasket over the
connection of module 2 so that it is centered between the
grooves of both connections.
c) 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.
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 between two T-
pieces after mounting the
composite coupling
e) Tighten the flexible coupling 6” with two nuts M12 and

washers using an open-end or box wrench (size 19) until
the contact surfaces of both coupling halves are flush and
resting against each other without a gap.
Ensure that the nuts are tightened evenly and alternately.
Ensure that the square screw neck of each screw is
correctly positioned in each threaded hole.
f) Continue holding the two attached modules 1 and 2 in

position to prevent tipping.


3 Connect the upper T pieces of modules 1 and 2
a) Continue holding modules 1 and 2 in position to prevent
tipping.
b) Carefully move module 2 to module 1.
c) At the connection of module 1, pull the gasket over the
connection of module 2 so that it is centered between the
grooves of both connections.
d) Place a flexible coupling 6” half-shell around the gasket.

e) Place the second flexible coupling 6” half-shell on the first
and insert the two bolts in the openings.
f) Tighten the flexible coupling 6” with two nuts M12 and


1 Mount module 3
= actual
a) Continue holding modules 1 and 2 in position to prevent back
tipping.
b) Mount module 3 using the procedure described in section: 1
2
→ 5.7 Mounting Module 1 3
The filtrate pipe assembly faces module 1.
front
2 Screw the threaded pins (DIN 913) M10 x 50 into the upper T
pieces 30 - 31 mm
a) Continue holding modules 1, 2 and 3 in position to prevent
tipping.
b) On the T piece of module 1, screw in two threaded pins
(DIN 913) M10 x 50 using a hex key (size 5).
The pins should protrude by 30 to 31 mm.
c) Repeat step b) for module 3.


3 Mount the channel section (DIN 1026) (U profile 50x38 mm
with four holes) and mounting clamp PE
a) Continue holding modules 1, 2 and 3 in position to prevent
tipping.
b) Hold the other connecting brace (profile opening facing up).

c) Position the channel section (DIN 1026) (profile opening
facing 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 module 1 and one mounting clamp PE on
the threaded pins (DIN 913) M10 x 50 of module 3.
e) Place a washer (DIN 125) A10.5 on each threaded pin

(DIN 913) M10 x 50.
f) Screw a hexagon nut (DIN 934) M10 hand-tight onto each
threaded pin (DIN 913) M10 x 50.
Steps 2 and 3 must be repeated for the end modules

(modules 11 and 12 in this description) in order to mount
the filtrate collector
→ 5.12.1 Mounting the first Filtrate Header


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 with no danger
of tipping.
a) Align the modules 1 to 3 flush with the channel section of
the frame.


1 Mount module 4
Number of persons: 4 = actual
a) Mount module 4 using the procedure described in section:

back
→ 5.7 Mounting Module 1
The filtrate pipe assembly faces module 2. 3
2
4
front

5.11 Mounting Modules 5 to 12
Step Activity
1 Mount modules 5 to 12
Number of persons: 2 – 4
a) Mount all further modules according to the procedure described in sections:
to
b) Mount the channel section (DIN 1026) between the modules 11 and 12 according to the
procedure described in section: 5.9 Mounting Module 3
3 3 3 3
5 4 5 4 4 4
6 7 6 7 6
8
back
front
Module 5 Module 6 Module 7 Module 8
3 3 3 3
4 4 4 4
6 6 6 6
9 8 9 8 8 8
10 11 10 11 10
12
Module 9 Module 10 Module 11 Module 12

5.12 Mounting the Filtrate Header
5.12.1 Mounting the first Filtrate Header

a) Remove the gaskets of the flexible couplings 2”.
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 flush with the
end.
c) Repeat procedures a) to c) for all further filtrate ports.
3 Position the filtrate header

Position the filtrate header on the mounting clamp PE of
modules 1 and 11.
The end of the pipe with the smallest distance to the first
connection must come to rest above module 1.

5.12.2 Connecting the Modules to the Filtrate Header

1 Connect the modules of the first row to the filtrate header
a) Position the openings of the 90° elbow piece PP 2“ (filtrate
pipe assembly) of module 1 and the filtrate port on the
filtrate header so they are flush.
b) Pull the gasket from the filtrate port over the 90° elbow
piece PP 2“ so that the gasket is centered on the
connection surfaces of the 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“.
d) Place the second flexible composite couplings 2” half-shell

on the first and insert the two bolts in the openings of the
half-shell.
e) Tighten the flexible couplings 2” with two nuts M10 and

f) Repeat the procedure as described from a) to e) for

modules 2, 5, 7, 9 and 11.

5.12.3 Mounting the Second Filtrate Header

1 Mounting the filtrate header
a) Mount the second filtrate header on the mounting clamp
PE of modules 3 and 12 according to the procedure 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 bottom). This difference can be up to
approximately 2 mm per T-piece composite coupling.
After completion of the installation and subsequent
pressurizing with water, this difference will significantly
reduce or disappear depending on the applied pressure
during filtration and/or backwash.
2 mm per
coupling

5.13 Tightly screwing together the Channel Sections (DIN 1026)

1 Secure the modules
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 a torque key (size 17) and a torque of
5 Nm.
c) Fasten the channel sections (DIN 1026) to the mounting

clamp PE between modules 1 and 3 and modules 11 and
12 using a torque key (size 17) and a torque of 5 Nm.

5.14 Optional Assembly Variants
5.14.1 Assembly of Multiple Sub-Units to one T-Rack®
NOTE
Danger of damage to the system and leaks if the frame is not leveled
precisely.
▪ Level the frame in the longitudinal and transverse directions!
▪ There is no direct connection between the bottom frames of the
sub-units.


1 Mount the bottom frame of the second sub-unit
Mount the bottom frame as described in section:
→ 5.5 Mounting the Bottom Frame
2 Adjust the bottom frame to the existing sub-unit

a) Position the frame at the correct location according to the
system layout.
b) Place the spirit 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 of the existing
sub-unit using the spirit level.
e) Secure the two connection-side frame feet of the new
bottom frame by hand-tightening the nuts.
f) Align the new bottom frame as described in section:
→ 5.6 Positioning and aligning the Bottom Frame
3 Mount the new sub-unit

Mount the modules and the filtrate headers as described in
sections:
to
→ Tightly screwing together the Channel Sections (DIN 1026)

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 connection or similar).
The two-row T-Rack®s must be positioned side-by-side without a gap.

5.14.3 Attaching Connectors
Options
Option Article no. Article designation Purpose

KT-0162 Flange Adapter Cap DN Connection of 6" grooved coupling system to
150 x 6‘‘ for connection flange with connection dimensions according to
from 6‘‘ grooved coupling ISO 7005 PN 10, ANSI Class 150
systems
KT-0163 Blind Cap 6‘‘ Closing of feed and filtrate headers
for grooved coupling
systems
KT-0164 Blind Cap 6‘‘ with G2‘‘ Connection of equipment for venting, measuring,
Thread for grooved etc.,
coupling systems G2” female thread according to
DIN ISO 228 BSPP
The connectors are attached using original flexible composite couplings 6” from inge®.

outside.
2 Mount the gasket on the end pipe
a) Remove the protective cap from the corresponding pipe.
b) Mount one of the lubricated gaskets over the opening of the
corresponding end pipe.
c) Push the gasket onto the corresponding pipe so it is flush

with the end of the pipe.


3 Attach the connectors
a) Position the connector on the corresponding pipe end.
Pull the gasket from the pipe over the connector so that the
gasket is centered on the connection surfaces of the pipe
and connector.
b) Place a flexible coupling 6” half-shell around the gasket.

c) Place the second flexible coupling 6” half-shell on the first
and insert the two bolts in the openings.
d) Tighten the flexible coupling 6” with two nuts M12 and

5.14.4 Mounting the Bottom Frame on the T-Rack® 3.0 Anchor Plates
Optionally, the subunits can be fixed to the floor with anchor plates. These anchor plates are not included in the
standard scope of supply, but can be ordered as an additional option.

1 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 head
as described in section:
2 Mount the channel section (DIN 1026)

(U profile 50 x 38)
a) Place the channel section (DIN 1026) (profile opening facing
up) on two anchor plates.
b) Repeat the procedure a) for two further U profiles.
3 Continue the procedure as described in sections:

→ 5.6 Positioning and aligning the Bottom Frame


4 Align the anchor plates
Position the anchor plates inward at an angle of 45°.
5 Drill the holes for the floor attachment

Drill holes for the concrete anchors Ø12 mm.
You can use the anchor plate as the drilling template.
6 Attach the anchor plates to the floor
Attach the anchor plates using Ø12 mm concrete anchors and
suitable industrial bolts or stud anchors, depending on the seismic
or structural requirements.

5.14.5 Mounting the Module with a Crane

Requirement
Before beginning the procedure to mount the module with a crane, the threaded pins (DIN 913) M10 x 50 must
be mounted at the bottom T piece and the filtrate pipe assembly must be mounted on the module.
See sections:
→ 5.7.1 Assembling the Filtrate Pipe Assembly
→ 5.7.2 Mounting the Module on the Channel Section (DIN 1026)
Mounting with a Crane

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.
The connection of the T piece must face up.
The mounted filtrate pipe assembly is located on the side.
2 Carefully lift the module using the crane.
3 Hold the module at the T piece and stabilize it throughout the

transport procedure.
4 Move the module to the installation position with a crane.
5 Lower the module until both threaded pins (DIN 913) M10 x 50 are
inserted in the two holes in the channel section (DIN 1026).
6 Keep the mounting strap taut so that the module cannot tip.


7 Mount the module using the procedure described in section:
→ 5.7.2 Mounting Module 1
→ Mounting the Module on the Channel Section (DIN 1026)
8 Slacken the mounting strap with the crane and release it from the
crane hook and the module.
5.14.6 Connection to existing Connecting Pipework
NOTE
If the existing system and the connecting pipework are in an
unstable position or if the connection dimensions are incorrect.
▪ Ensure that the system is stabilized and in the correct position!
▪ Ensure that the connecting pipework is properly fixed and
correctly positioned!
▪ Always adhere to the specified connection dimension
tolerances regarding pipe distances, length offsets and angular
offsets!
▪ Always ensure that the connection is established tension-
free at any time!

Connection Dimensions
410
The permissible
dimensional deviation
between T-Rack® and
the connecting
pipework is 1°or 2 mm
at Ø 168.
1925
120 - 180
88
300 410 ± 2
1420
Requirements
The T-Rack® being mounted must be directly connected to an existing connection pipework that:
◼ ends toward the T-Rack® with pipes whose ends feature a groove for the coupling connection
◼ ends toward the T-Rack® with flange surfaces
If premanufactured collector pipes are used, e.g. "T-Rack® Manifolds" from inge GmbH, it is necessary to first
complete the connection pipework and then mount the T-Rack® 3.0.
The Flexi Kit from inge® can be used to compensate for small level differences. This Flexi
Kit is not part of the standard 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 connecting pipework are secured in a stable and form-fitting
manner.
There must be no change in position and angle between the connection points and the
T-Rack®s during operation.
b) Check all specified connection dimensions for pipe distances, length offsets and angular offsets.
If the specified connection dimensions are not met, stop the mounting procedure of the
T-Rack® and adjust the connecting pipework.
Mounting may continue after the specified connection dimension tolerances have been met.

Step Activity
b) Lubricate the gaskets with glycerin on the inside and outside.
3 Mount the gasket on the pipe end

a) Remove the protective caps from the T-Rack® connection and connecting pipework.
b) Mount one of the lubricated gaskets over the opening of the T-Rack® connection.
c) Push the gasket onto the T-Rack® until it is flush with the end of the pipe.
4 Align both connections with each other
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 connection pipe so it is centered between the grooves of both
connections.
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 bolts in the openings.
d) Tighten the flexible coupling 6” with two nuts M12 and washers using an open-end or box
wrench (size 19) until the contact surfaces of both coupling halves are flush and resting against
each other without a gap.
Ensure that the square screw neck of each screw is correctly positioned in each threaded hole.
Connecting pipework with Flange Connection
Step Activity
1 Check the connecting pipework
a) Ensure that all pipes of the connecting pipework are secured in a stable and form-fitting
manner.
There must be no change in position and angle between the connection points and the
T-Rack®s during operation.
b) Check all specified connection dimensions for pipe distances, length offsets and angular offsets.
If the specified connection dimensions are not met, stop the mounting procedure of the T-Rack®
and have the connecting pipework adjusted.
Mounting may continue after the specified connection dimension tolerances have been met.
2 Prepare the flange bolts

See the scope of supply of the system integrator.

3 Align both connections with each other

Position the two connections (T-Rack® connection and connection pipe) with respect to each other.
4 Insert the 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® connection and connection pipe).
5 Screw the flange together
a) Insert the prepared flange bolts into the drill holes of both flanges from the side of the connecting
pipework.
b) Hand-tighten the nuts by several turns.
c) Tighten the first bolt head with an open-end or box wrench (size 30).
d) Repeat procedure c) for the directly opposite bolt head.
e) Repeat procedure c) for all other bolt heads.
f) Tighten all bolt heads with a torque of 35 Nm. Tighten the bolts /nuts in a criss-cross pattern.
6 Screw all of the connection pipes together

Repeat steps 1–5 for all other connection pipes.

5.14.7 Attaching Compensation Pipes
Options Article no. Article designation Purpose

EP-0112 T-Rack® 3.0 Flexi Kit Flexi Kit M ST for T-Rack® 3.0 Series
M ST – 2-rowed neutralizing up to 3.5 mm of level
differences for T-Rack®s with 2 rows
and single-sided link to connecting
pipework
6 pieces
EP-0113 T-Rack® 3.0 Flexi Kit Flexi Kit M ST
M ST – 4-rowed for T-Rack® 3.0 Series
neutralizing up to 3.5 mm of level
differences for T-Rack®s with 4 rows
and single-sided link to connecting
pipework
12 pieces
The compensation pipes are assembled using flexible 6”composite couplings from inge®.

Step Activity
b) Lubricate the gaskets with glycerin on the inside and outside.
2 Mount the gasket on the end pipe

a) Remove the protective cap from the corresponding pipe.
b) Mount one of the lubricated gaskets over the opening of the corresponding end pipe.
c) Push the gasket onto the corresponding pipe so it is flush with the end of the pipe.
3 Attach the compensating pipe

a) Position the compensating pipe on the corresponding pipe end.
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 bolts in the
openings.
d) Tighten the flexible coupling 6” with two nuts M12 and washers using an open-end or box
wrench (size 19) until the contact surfaces of both coupling halves are flush and resting against
each other without a gap.
◼ Ensure that the nuts are tightened evenly and alternately.
◼ Ensure that the square screw neck of each screw is correctly positioned in each
threaded hole.
5.15 Prevention of Possible Assembling Failures

Assembly failures should be avoided by carefully following the assembly manual. In addition, we mention below
some typical failures and how to prevent them.
NOTE
Pictures in this document are for illustration purposes only.
Actual colour, appearance and size may vary.

Parts Components Failure Possible problems Failure prevention

Bottom Frame
Adjustable feet Adjustable bolt • eventual Proper assembly of
(M16x150mm) head not compression due to adjustable foot‘s bolt
completely inserted weight of T-Rack head into floor disc
into floor disc • failure frame
alignment
Longitudinal- Insufficient • strain on module Use a spirit level (l>

U-Channel leveling of length connectors 1.5m) to
and width • leakages horizontality
• PVC rupture position the frame in
all axes
Lower U- Channel opening • no accessibility to Channel opening to
Channel facing downwards mounting nut for face upwards →
adjustment/alignment accessibility
mounting nut
U-Channel Channel opening • No accessibility for Channel opening

(Mounting of facing upwards mounting of threaded facing downwards
modules pins M10x50 allowing accessibility
to the threaded pins
Module Preparation
Threaded pins Missing pins • difficult access for Proper preassembly
(Feed Bottom) (2) M10 x 50 rework → faster installation
installed at the • additional labor
→ solid rack
bottom face of the required
construction
module • potentially missing
mounting hardware
Composite Gaskets were not • pinching of gaskets Prepare coupling

Couplings treated with • leakages gaskets for
glycerin • increased friction installation using
(2”/6” gaskets)
sufficient glycerin
Transparent Preassembly did • difficult accessibility Proper preassembly

filtrate not take place once module is → faster installation
connector mounted
(Preassembly • potential
on the module) disassembly required

Parts Components Failure Possible problems Failure prevention

Module Assembly
Transparent Tilting of the filtrate • disassembly of all Tilting of the filtrate
filtrate connector inner filtrate connector upwards
connector downwards connectors → faster installation
(Tilting) • difficult accessibility
Alignment > 2 module rows • strain on couplings Align first two

First (2) module are increasingly and connectors installed rows with
rows to the hard to align • connections to the frame‘s outer
frame (required forcing) peripheral piping edge
Composite Couplings not • leakages The grooves must be

Couplings properly seated in • slipping of the visible with installed
(Mounting) grooves couplings gasket; proper
• PVC rupture mounting position of
couplings must be
validated by slightly
spinning the loose
coupling
Composite Wrong mounting • strain inside the Mount both couplings

Couplings sequence of T-Rack after installing each
(Mounting) couplings module:
Bottom → Top
Mounting Upper U-Channel • module not Initially, mount filtrate

filtrate clamp (structural support structurally clamp in first and last
from top) missing supported position of the T-
• level Filtrate Rack
collector
Filtrate Wrong position first • missing alignment Filtrate collector

collector filtrate outlet → of filtrate collector to outlet must be
(Mounting) Collector orientation T-Rack aligned to T-Rack
rotated 180° • connections to module outlets on the
peripheral piping side of the first 2
modules

Service and Maintenance
6 Service and Maintenance
6.1 Warnings
DANGER
DANGER TO LIFE!
and lifting loads!
WARNING
WARNING
danger zone.
▪ Note the specified number of people required!
WARNING
edges.

WARNING
site.
▪ Wear safety helmet!
CAUTION
DANGER OF INJURY!
persons!

6.2 Checks during Operation

Checking for Leak Tightness
Regular general maintenance work on T-Rack®s should include checking the tightness and proper working
order of all joints and connections (flanges, valves, couplings, etc.) and repairing any damage that may have
occurred.
NOTE
Fluid leakage – especially where corrosive agents are involved –
may cause corrosion to appear on the components concerned.
Effective measures should be taken to avoid corrosion before it
occurs.
▪ In the event of fluid escaping due to a leak, the affected area
should be properly gasketed, rinsed down with salt-free or low-
salt water and rubbed dry.
▪ If the coating of a coated coupling has been damaged, the
coating must be repaired or the coupling 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 Installation / Assembly, as applicable.
6.2.2 Exchanging Parts

When exchanging parts, only genuine parts from inge GmbH are permitted to be used.
6.2.3 Return of Modules and Other T-Rack® Components

Returns shall only be accepted if this has been agreed in advance with inge GmbH and authorized in writing.
Returns that have been previously agreed and approved by inge GmbH are subject to the following mandatory
requirements:
◼ All components must be rinsed and cleaned before being returned.
◼ Modules must be preserved during storage and transport.
NOTE
FAILURE TO COMPLY WITH THE ABOVE INSTRUCTIONS!
Failure to comply with any of the requirements stated above will
result in inge GmbH refusing to accept the return of the modules;
inge GmbH reserves the right to invoice the sender for any
transportation or removal costs that may be incurred in this case.

Disassembly and Disposal
7 Disassembly and Disposal
7.1 Warnings
DANGER
DANGER TO LIFE!
and lifting loads!
WARNING
WARNING
danger zone.
WARNING
edges.

WARNING
site.
CAUTION
DANGER OF INJURY!
persons!

7.2 Disassembly
Disassembly work may only be performed by trained and qualified personnel or by a suitable specialist
company.
Adequate clear 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.
To disassemble a module, the corresponding T-Rack must be isolated and drained.
Modules of the first module row can be directly disassembled.
With a 4-row’s T-Rack, modules of the 1st row have to be removed first before removing modules of the 2nd
row.
Number of persons for disassembly are at least 2.
The disassembly of a single module is performed in reverse order to the assembly.
→ For details, see section 5 Installation / Assembly
In case of a 4-row T-Rack the following steps must be followed.

1 Identify defective module
Identify the defective module in the rack.
2 Disassembly surrounding modules

a) Remove the module of the 1st row directly in front of the
defective module. The defective module becomes visible.
b) Close the feed and filtrate ports.


c) If you want to facilitate the access to the defective module,
remove necessary surrounding modules.
d) Close the feed and filtrate ports.
3 Defect Module disassembly

a) The defective module can now be removed.
b) Close the feed and filtrate ports.
7.3 Disposal
When disposing of the T-Rack, note the following requirements:

◼ Adhere to the applicable local disposal regulations.
◼ Adhere to the legal regulations regarding environmental protection.

Customer Service
8 Customer Service
8.1 Service Hotline

Contact the following address if you have problems with T-Rack® 3.0 Series and to order spare parts:
inge GmbH
Flurstraße 27
86926 Greifenberg
Germany
Tel: +49 8192 997-700
Fax: +49 8192 997 999
E-Mail: inge@dupont.com
https://www.dupont.com/brands/inge.html
8.2 Ordering Spare Parts

The following details are required to place an order:
◼ Parts designation
◼ Article number
◼ or serial number of the module in case of module replacement
NOTE
A detailed list of the individual components can be found in the spare
parts lists.
The spare parts lists will be made available to you by inge GmbH on
request.

Technical Documentation
9 Technical Documentation
9.1 Other Applicable Documents

The following other applicable documents are available:
◼ Process and Design Guidelines
◼ 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 60 ST for T-Rack® 3.0‘
◼ Data Sheet ‚dizzer® XL 1.5 MB 40 ST for T-Rack® 3.0‘
◼ Spare parts lists
As a components supplier, inge® refers to the system supplier for further documents (for example ‚System
operating instructions‘).

Note
The descriptions, designs, data and product information contained herein are presented in good faith and are
based on inge GmbH’s current knowledge and experience. inge GmbH cannot accept any liability for the
accuracy of this product information, which is provided at no charge and for guidance only.
inge GmbH
Flurstrasse 27 inge® products are designed to be operated in accordance with the corresponding inge ® product documentation.
86926 Greifenberg The product information and products are protected by copyright and/or other intellectual property laws
worldwide. However, inge GmbH cannot guarantee that the product information and products can be used
Germany without infringing third party intellectual property rights. The products and product information may only be used,
Phone: +49 8192 997-700 distributed and marketed with the express prior permission of inge GmbH.
Fax: +49 8192 997-999
Email: inge@dupont.com No warranties of any kind regarding the products, either expressed or implied, including, but not limited to,
warranties of merchantability, fitness for a particular purpose or no third party rights are made, other than as
expressly set out in the contractual agreement with the customer. Mechanical stability and full functionality of
https://www.dupont.com/brands/inge.htm
inge® products can only be provided by genuine inge ® parts.
inge GmbH reserves the right to modify products and product information at any time without prior information.
Current product information can be obtained from the website https://www.dupont.com/brands/inge.html.
DuPont™, the DuPont Oval Logo, and all trademarks and service marks denoted with ™, ℠ or ® are owned
by affiliates of DuPont de Nemours, Inc. unless otherwise noted. © 2021 DuPont


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T-Rack® 3.

T-Rack 3.0 Series – Assembly Instructions Page 2 of 87

1 About these Instructions............................................................................................................................6

4 Loading, Transport and Storage .............................................................................................................24

T-Rack 3.0 Series – Assembly Instructions Page 3 of 87

4.3 Loading .............................................................................................................................................27

5 Installation / Assembly .............................................................................................................................29

T-Rack 3.0 Series – Assembly Instructions Page 4 of 87

5.14.3 Attaching Connectors ..........................................................................................................65

6 Service and Maintenance .........................................................................................................................78

7 Disassembly and Disposal ......................................................................................................................81

8 Customer Service .....................................................................................................................................85

9 Technical Documentation ........................................................................................................................86

T-Rack 3.0 Series – Assembly Instructions Page 5 of 87

1 About these Instructions

1.1 Objective of these Instructions

T-Rack 3.0 Series – Assembly Instructions Page 6 of 87

1.2 Target Groups

1.2.1 Qualified Persons

1.2.2 Skilled Persons with a Supervisory Capacity

1.2.3 Involvement of Other Persons

1.2.4 Involvement of Multiple Persons

T-Rack 3.0 Series – Assembly Instructions Page 7 of 87

1.3 Symbols in this Manual

SYMBOL DESCRIPTION (EXAMPLES)

1.4 Storage and Transfer to Another Party

T-Rack 3.0 Series – Assembly Instructions Page 8 of 87

2.1 Follow the Instructions!

2.2 Intended Use

T-Rack 3.0 Series – Assembly Instructions Page 9 of 87

2.2.1 Residual Risks

In these instructions, these residual risks are indicated by

2.2.2 Conversions and Modifications

T-Rack 3.0 Series – Assembly Instructions Page 10 of 87

2.3 Standards and Laws

2.4 Obligations of the System Integrator

2.5 Obligations of the Operator

T-Rack 3.0 Series – Assembly Instructions Page 11 of 87

2.6 General Information on Safety and Warning Instructions

2.6.1 Categories and Structure

T-Rack 3.0 Series – Assembly Instructions Page 12 of 87

2.6.2 Warning Symbols

DANGER OF CRUSHING (BODY)

DANGER OF CRUSHING (BODY)

DANGER OF CRUSHING AND SHEARING (HAND)

T-Rack 3.0 Series – Assembly Instructions Page 13 of 87

2.6.3 Signs Giving Instructions

WORKING WITH SAFETY SHOES

WORKING WITH SAFETY GLOVES

WORKING WITH EYE PROTECTION

WORKING WITH A SAFETY HARNESS

T-Rack 3.0 Series – Assembly Instructions Page 14 of 87

2.6.4 Safety Instructions

T-Rack 3.0 Series – Assembly Instructions Page 15 of 87

T-Rack 3.0 Series – Assembly Instructions Page 16 of 87

T-Rack 3.0 Series – Assembly Instructions Page 17 of 87

2.6.5 Position of Warnings

T-Rack 3.0 Series – Assembly Instructions Page 18 of 87

3.1.1 Overview Graphic

T-Rack 3.0 Series – Assembly Instructions Page 19 of 87

3.1.2 Parts List of the Sub-unit of a T-Rack®

Part Quantity 1) Single part Consisting of

1) Number of parts of a T-Rack® sub-unit with 12 modules