DERC SALOTECH MAGTRACK Manual de usuario

MAGTRACK & MAGTRACK

mini

Magnetic cleaning robot

M.MAGTRACK.E

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 2 of 67

Manufacturer

DERC

Salotech

Jan van der Heijdenstraat 44

3261 LE Oud-Beijerland

Netherlands

Tel: +31 186 62 14 84

Website: www.salotech.nl

Version of document

Version

Date of document

2022

This authorized English manual is a translation of the original Dutch manual. It is the property of Salotech

International B.V. No rights can be derived from this translation.

Although Salotech International B.V. has taken great care in providing an accurate and (wherever necessary)

comprehensive description of particular components, it renounces all liability for damage as a result of

inaccuracies and/or insufficiencies found in this manual.

Salotech International B.V. retains the right to change, at any point in time, machine components or the

contents of this manual, without prior notice to the owner of the machine. No part of this publication may

be reproduced and/or made public via printing, photocopy, microfilm, audio tape, electronic form or any

other form, without prior written consent from Salotech International B.V. Breaches are punishable by law

and necessitate compensation.

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 3 of 67

INTRODUCTION

Thank you for purchasing the DERC MAGTRACK or MAGTRACK Mini. Working with high-pressure equipment

can be dangerous. Therefore, it is in your interests to read the safety regulations in this user manual

thoroughly and follow all instructions carefully.

This manual describes the use, maintenance and repair of the DERC MAGTRACK / DERC MAGTRACK mini. The

information in this manual is important for the proper and safe functioning of the magnetic cleaning robot

If you are not familiar with the installation, preventive maintenance, etc. of the DERC MAGTRACK, please

read through this user manual carefully from start to finish. Always keep this manual as a reference. You can

quickly find the information you need using the table of contents.

In this user manual, the words DERC MAGTRACK / DERC MAGTRACK mini and ‘robot’ and ‘equipment’ are

used interchangeably. All of these words refer to the DERC MAGTRACK or DERC MAGTRACK mini. This also

applies to the words user manual, document and user’s guide; all these words refer to this document and its

annexes. The words ‘machine’ and ‘installation’ denote the DERC MAGTRACK or DERC MAGTRACK mini.

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 4 of 67

INDEX

INTRODUCTION .................................................................................................................................... 3

1. USING THE MANUAL ..................................................................................................................... 6

1.1 Guarantee ...................................................................................................................................... 6

1.2 Safety regulations .......................................................................................................................... 6

1.3 Intended use of the DERC MAGTRACK .......................................................................................... 7

1.4 Legislation and standards .............................................................................................................. 8

1.5 Tip markings .................................................................................................................................. 8

1.6 Safety pictograms .......................................................................................................................... 9

1.6.1 Pictograms on the MAGTRACK ................................................................................................ 9

1.7 Personal protection equipment .................................................................................................. 10

2. TECHNICAL DATA ........................................................................................................................ 11

2.1 General ........................................................................................................................................ 11

2.2 Ex code ......................................................................................................................................... 13

2.3 Type plates................................................................................................................................... 13

3. OPERATING PRINCIPLE ................................................................................................................ 15

4. PARTS 19

4.1 DMT.3000.Carrier ........................................................................................................................ 19

4.1.1 Front assembly DMT.2.100 .................................................................................................... 20

4.1.2 Rear assembly DMT.200 ........................................................................................................ 22

4.1.3 Wheel assembly DMT.300 ..................................................................................................... 24

4.2 DMT.3000.SWING - Swing arm .................................................................................................... 25

4.2.1 DMT.650 - Manifold............................................................................................................... 26

4.3 DMT.3000.Blastcan ...................................................................................................................... 27

4.4 DMT.3000.CONTROL.XXX ............................................................................................................ 30

4.4.1 Remote control system ......................................................................................................... 31

4.4.2 DMT.3000.CABLE-50M .......................................................................................................... 31

4.5 DMT.800 – Transport plate ......................................................................................................... 31

4.6 DERC MAGTRACK MINI ................................................................................................................ 32

4.7 DERC safety devices ..................................................................................................................... 37

4.7.1 Control unit ............................................................................................................................ 37

4.7.2 Control unit atex .................................................................................................................... 37

4.7.3 Carrier .................................................................................................................................... 37

4.7.4 Swing arm .............................................................................................................................. 37

4.7.5 Blast can ................................................................................................................................. 37

4.7.6 MAGTRACK mini .................................................................................................................... 37

4.7.7 Other accessories .................................................................................................................. 37

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 5 of 67

5. SETTING UP AND INSTALLING ...................................................................................................... 38

5.1 Presenting the carrier to the wall ................................................................................................ 38

5.2 Connecting the MAGTRACK ......................................................................................................... 38

5.3 Connect cleaning tools ................................................................................................................ 40

5.3.1 Swing arm .............................................................................................................................. 40

5.3.2 Blast can ................................................................................................................................. 42

5.4 Connecting high pressure water.................................................................................................. 43

5.5 Changing nozzles ......................................................................................................................... 44

6. START-UP ................................................................................................................................... 45

6.1 Operation of wireless console ..................................................................................................... 46

6.1.1 Start- up ................................................................................................................................. 47

6.1.2 Pairing .................................................................................................................................... 47

6.1.3 Calibrate................................................................................................................................. 48

6.1.4 Charging ................................................................................................................................. 48

6.2 Adjustments MAGTRACK ............................................................................................................. 49

6.2.1 Magnet adjustment ............................................................................................................... 49

6.2.2 Adjusting swing arm angle ..................................................................................................... 51

6.2.3 Adjustment of vacuum valve ................................................................................................. 52

6.3 Adjustments MAGTRACK Mini ..................................................................................................... 52

6.3.1 Omniwheel height adjustment .............................................................................................. 52

6.3.2 Adjusting blastcan angle ........................................................................................................ 53

6.3.3 Vacuum pressure blast can adjustment ................................................................................ 54

6.3.4 Magnet Adjustment ............................................................................................................... 54

7. TRANSPORT ................................................................................................................................ 56

7.1 Transport on site ......................................................................................................................... 56

7.2 Transport by road or air............................................................................................................... 56

8. MAINTENANCE ........................................................................................................................... 57

8.1 General ........................................................................................................................................ 57

8.2 Preventive daily maintenance ..................................................................................................... 58

8.3 Preventive weekly maintenance ................................................................................................. 58

8.4 Preventive half-yearly maintenance ............................................................................................ 58

8.5 Preventive annual maintenance .................................................................................................. 58

8.6 Spare parts ................................................................................................................................... 59

9. FAULTS AND REPAIRS .................................................................................................................. 60

9.1 Faults DERC MAGTRACK .............................................................................................................. 60

9.2 Repairs to the DERC MAGTRACK ................................................................................................. 61

9.2.1 Replacing wheels ................................................................................................................... 61

9.2.2 Replacing a drive .................................................................................................................... 62

10. DISASSEMBLY AND DISPOSAL ...................................................................................................... 64

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 6 of 67

1. USING THE MANUAL

This manual has been written for authorized and technically-qualified persons. Tasks have only been assigned

to specific persons (technically qualified or not) in the chapters ‘maintenance' and ‘configuration’. All

concerned parties must familiarize themselves with the contents of this user manual. These persons are

distinguished as follows:

Authorized persons are people who: Have built up a certain level of knowledge via schooling or training and

who have enough experience to operate the machine.

Technically qualified persons are people who: Are technically qualified and have sufficient technical

knowledge via schooling and/or on-the-job experience. Further, these persons are, due to their knowledge

of mechanics, well aware of possible risks and dangers (a mechanic, for example).

The word ‘operate’ means: Configuring the machine, working with the equipment and performing simple

maintenance activities. The aim/purpose of this user manual is to create safe and efficient interaction

between people and the machine.

1.1 Guarantee

The guarantee conditions and the conditions concerning liability can be found in the supply conditions

(Metal Union, submitted to the Registry at the District Court in Rotterdam).

1.2 Safety regulations

 Safety is the first priority! Everyone is responsible for a clean, safe and well-lit workplace.

Immediately report danger and/or dangerous situations to your supervisor.

 DERC Salotech advises you to train operators and maintenance personnel to operate, maintain and

troubleshoot for this equipment.

 Operators must be at least 18 years old. Only personnel authorized by the equipment manager may

operate this machine or perform activities in the proximity of the machine.

 It is strictly recommended that operators are familiar with the directives laid down by your national

branch organization, and that they also possess the required certificates and have sufficient

experience with high pressure equipment.

 It is paramount that the user is well aware, via training and/or experience (legally recognized), of

high-pressure technology, high pressure cleaning and all accompanying safety measures – which

must be implemented in full.

 Never use high pressure apparatus with a maximum working pressure that is lower than the

maximum working pressure of the high-pressure unit.

 Use clean water with an advised maximum temperature of 40°C (110°F), in order to prevent

cavitation.

 Provide a minimum filtration of 1 µm for the water, to prevent clogging and rapid wear of the

nozzles and seals.

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 7 of 67

 Never point the jet at people or animals. A high-pressure liquid jet enters deep into the skin and

can lead to serious wounds, permanent injury and even death. Anyone who is struck by a high-

pressure water jet must always seek immediate professional medical care.

 All personnel assigned the task of operating the machine must be able to demonstrate that they

have read and understood those parts of the user manual that describe the machine’s operation

and safety considerations.

 All personnel assigned the task of assembling, putting into operation, maintaining and/or repairing

the machine must be able to demonstrate that they have read and understood the entire manual.

 The user(s) of the machine is (are), under all circumstances, responsible for the interpretation and

use of the manual. In cases of doubt, contact the supplier/manufacturer.

 The manual must be kept in close proximity to the machine and must be easily accessible to

operators and maintenance personnel.

 If prescribed configurations are altered or use is made of unauthorized spare parts or repair

methods, this absolves the manufacturer of any liability.

 The surroundings of the machine must comply with workplace health and safety regulations. The

user is responsible for taking steps to ensure that the machine can be operated safely and that the

environment is sufficiently illuminated.

 The owner of the machine is responsible for adhering to the instructions stated in this manual.

 Safety features (e.g. screens) may never be removed or in any way disengaged.

 Do not get near the magnets with devices such as telephones, watches, pacemakers or other

devices that are sensitive to magnetism

1.3 Intended use of the DERC MAGTRACK

The DERC MAGTRACK is an electrically driven cleaning robot (Crawler) with all four wheels driven separately

and is specifically designed and made for cleaning flat and slightly curved steel surfaces with ultra high

pressure water, e.g. for the internal and external cleaning of storage tanks, and external cleaning in the

maritime sector.

The wall thickness of the steel must be at least 6 mm for sufficient magnetic force.

The DERC MAGTRACK MINI is specifically designed for cleaning small flat surfaces or pipes (min. diameter

1200 mm) with ultra high pressure water The DERC MAGTRACK MINI is specifically designed for cleaning

small flat surfaces or pipes (min. diameter 1200 mm) with ultra high pressure water. Cleaning of smaller pipes

is possible with a specific seal for the diameter of the pipe, every pipe diameter needs a different seal.

Any other use of the DERC MAGTRACK or DERC MAGTRACK mini that does not have the prior written

permission of the machine’s manufacturer releases the manufacturer from any responsibility and

liability.

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 8 of 67

1.4 Legislation and standards

The DERC MAGTRACK and MAGTRACK MINI is designed and built in accordance with the requirements set

out in the Machinery Directive (2006/42/EC), EMC Directive (2014/30/EU), Low Voltage Directive

(2014/35/EC), Radio Equipment and Telecommunications Terminal Equipment Directive (2014/53/EU) and

the ATEX Directive (2014/34/EU). For an overview of the standards applied during the design and

construction of the system, please refer to the EC declaration of conformity for machines (in the back of

this user manual).

1.5 Tip markings

Tip markings are symbols in the user documentation and are not displayed on the machine. The following tip

markings are used to make you aware of risks and/or dangerous situations:

Tip: Suggestions and advice to make tasks easier.

Note! Additional information that makes you aware of possible problems.

Caution: Deviating from procedures can damage the machine/equipment.

Danger: Deviating from procedures can lead to serious injury.

Reference: Further information about this subject is available elsewhere in this manual.

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 9 of 67

1.6 Safety pictograms

Respect these signs; they have been placed for your own safety!

The risk analysis for this machine has indicated a number of safety measures for warning the user. The used

safety pictograms are repeated in the user manual and on the machine’s work instructions. This clearly

provides the user with an insight into the present risks. We have highlighted three different pictogram types.

Prohibition sign: Not allowed to perform an action.

Obligation sign: Obligatory process or action by the user.

Warning sign: Making user aware of present danger.

1.6.1 Pictograms on the MAGTRACK

Check regularly that all pictograms are still visible and readable. If any pictograms are unreadable, they

need to be replaced.

Pictogram or text Description Position on the equipment Number

Warning:

Magnetic field! Top of the MAGTRACK 1

CE mark:

Indicates compliance with

European directives.

The CE mark is on the type

plate of the equipment 1

Indicates compliance with ATEX

directive.

The EX brand is on the type

plate of the equipment 1

Warning:

Electrical voltage Control unit door 1

Table 1

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 10 of 67

1.7 Personal protection equipment

All operators and persons in close proximity must wear the following personal protection equipment:

Body protection:

A strong waterproof suit to protect against surrounding

water and dirt. Arms and legs must also be covered;

Hand protection:

Waterproof gloves made from rubber or a laminated

textile or reinforced with metal;

Foot protection:

Waterproof boots with steel toe

caps. It is recommended

to wear boots with a special air cushion in the instep;

Face protection:

All personnel must wear suitable head protection (plastic

helmet). If possible, personnel must wear a face visor;

Ear protection:

Ear plugs or ear muffs to protect the ear (regularly in

excess of 80 dB(A));

Eye protection:

Safety goggles or face visor. Protection equipment for the

eyes must fit properly and, if necessary, must have side

protection;

Protection of air

passages:

The air passages must be protected if this can prevent

possible injuries.

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