DERC SALOTECH MAGTRACK User manual

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: [phone]
Website: www.salotech.nl
Version of document
Version
3.
1
Date of document
20
-
0
4
-
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.
© Copyright 2022
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

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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

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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.

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 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.

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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.

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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

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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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2. TECHNICAL DATA
2.1 General
MAGTRACK
Carrier
Carrier voltage 48 VDC
Weight 80 kg
Dimensions (L x W x H) 718 x 510 x 348 mm
Control unit
Dimensions (L x W x H) 700 x 600 x 900 mm
Weight 35 kg
Control unit voltage 110VAC 240VAC
Max. current fuse 20 Amp 16 Amp
Frequency 50/60 Hz
Cable length 50 metres
Wireless console
Dimensions (L x W x H) 210 x 135 x 150 mm
Wireless console voltage 5 VDC
Battery life circa 45 hours
Charging time circa 4 hours (0 -> 100%)
Table 2
Swing arm (optional)
Dimensions (L x W x H) 1000 x 500 x 100 mm
Weight 15 kg
Max. cleaning path 1400 mm
High pressure connection M30x2
Max. working pressure 3000 bar
Max. flow 30 l/ min
Nozzle type 8x 965.xxx
Table 3
Blast can (optional)
Dimensions (Ø x H) 700 x 160 mm
Weight 25 kg
Cleaning path 400 mm
Vacuum connection 3" female camlock
High pressure connection M30x2
Max. working pressure 3000 bar
Max. flow 40 l/ min
Nozzle type 20x 965.xxx
Table 4

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MAGTRACK MINI with blastcan
Dimensions (L, W,H) 700 x 330 x 350 mm
Weight 15 kg
Cleaning path 200 mm
Vacuum connection 2”
High pressure connection 9/16"UNF LH
Max. working pressure 3000 bar
Max. flow 20 l/ min
Nozzle type 8x 965.xxx
Table 5

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2.2 Ex code
Below you can see what the ex code contains:
CE II 3G Ex mc h IIC T4 Gc
Explanation:
CE logo Complies with European directive (without notified body since this is GC or Cat 3
equipment which is module A and this is without notified body).
EX logo Specific marking for Explosion protection
II Equipment group, for above ground operations
3G Equipment category as defined in directive 2014/34/EC -> Gases Vapours / Zone 2
Ex Explosion protection
m Encapsulation Ex m EN IEC 60079-18, Normal level of protection -> Category 3 EPL c
h Control of ignition sources
IIC Gas Group
T4 Temperature class
Gc Equipment protection level
2.3 Type plates
Several type plates are mounted on the machine. This is because each part can be sold separately. When
you order spare parts or contact the manufacturer about fault-finding, provide the data on the type plate.
The type plate contains the following information:

DERC MAGTRACK & MAGTRACK MINI Version 3.1 / 20-4-2022 Page 14 of 67
II 3G Ex mc h IIC T4 Gc
Swing arm
Type : DMT.3000.Swing
Salotech International B.V. Serial number : SP …
Jan van der Heijdenstraat 44 Connection type : …….
3261 LE Oud-Beijerland Year of build : …/20…
Tel: [phone] Weight : 15 kg
The Netherlands Max working pressure : 3000 bar
WWW.SALOTECH.NL
Control unit
Salotech International B.V. Type : DMT.3000.Control.xxx
Jan van der Heijdenstraat 44 Serial number : SP …
3261 LE Oud-Beijerland Power Supply : ……../ …..
Tel: [phone] Year of build : …/20…
The Netherlands Weight : 35 kg
WWW.SALOTECH.NL
MAGTRACK mini
Type : DMT.4000
Salotech International B.V. Serial number : SP …
Jan van der Heijdenstraat 44 Connection type : 9/16”- 18 UNF
3261 LE Oud-Beijerland Year of build : …/20…
Tel: [phone] Weight : 45 kg
The Netherlands Max working pressure : 3000 bar
WWW.SALOTECH.NL
II Gc Ex
-
m h T4 IIC
II 3G Ex p IIC T4 Gc
Control unit EX
Salotech International B.V. Type : DMT.3000.Control.xxxEX
Jan van der Heijdenstraat 44 Serial number : SP …
3261 LE Oud-Beijerland Power Supply : ……../ …..
Tel: [phone] Year of build : …/20…
The Netherlands Weight : 35 kg
WWW.SALOTECH.NL
Blast can
Type : DMT.3000.Blastcan
Salotech International B.V. Serial number : SP …
Jan van der Heijdenstraat 44 Connection type : M30x2
3261 LE Oud-Beijerland Year of build : …/20…
Tel: [phone] Weight : 25 kg
The Netherlands Max working pressure : 3000 bar
WWW.SALOTECH.NL
II 3G Ex mc h IIC T4 Gc

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3. OPERATING PRINCIPLE
The DERC MAGTRACK is an electrically driven cleaning robot with all four wheels driven separately and is
specifically designed and made for cleaning flat and slightly curved steel surfaces with high pressure water,
e.g. for the internal and external cleaning of storage tanks, and external cleaning in the maritime sector.
The system comprises a carrier with transport plate, control unit, wireless console and cleaning tools. By
attaching cleaning tools such as a swing arm or blast can, the DERC MAGTRACK can clean quickly and
efficiently using high pressure.
Combined with swing arm or blast can, the carrier is suitable for working in an ATEX zone 2. See certificate
for coding. The remote is suitable for working in an ATEX zone 2. See certificate for coding.
Caution! the standard control unit is not suitable for placement in an ATEX zone! There is an option to
upgrade this to ATEX zone 2.
Figure 2 Carrier (ATEX certified) Figure 1 Control unit (standard non-ATEX)

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Figure 3 Wireless Controller (ATEX certified)
The swing arm is specifically for cleaning a wide path (1400 mm) where the collection and extraction of the
waste water is not necessary. The stroke and speed of the swing arm can be set up as required.
Figure 4 Carrrier with swing arm (ATEX certified)

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The blast can is specifically for cleaning steel surfaces in which extraction of the waste water and drying of
the steel surface is important. An example would be stripping paint from a storage tank that needs to be
repainted or stripping/cleaning a ship's hull.
Figure 5 Carrier with blast can

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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.
Figure 6 MAGTRACK Mini

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4. PARTS
4.1 DMT.3000.Carrier
Figure 7 Exploded view carrier
Pos No. Qty Description Part number
1 2 Hexagon Domed Cap Nuts DIN1587.M10-A4
2 4 Int. hex. socket head bolt DIN912.M8x130-A4
3 8 Hex. head bolt full thread DIN933.M12x35-A4
4 1 Threaded rod DIN975.M10-A4
5 4 Parallel key DIN6885.8x7x20-A4
6 1 Front assembly DMT.2.100
7 1 Rear assembly DMT.2.200
8 1 Frame center pipe DMT.2.510
9 4 Wheel Shaft Lock DMT.140
10 4 Wheel assembly DMT.300
11 2 Weld assembly protection bar DMT.400
12 2 Frame end cap DMT.530
Table 6

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4.1.1 Front assembly DMT.2.100
Figure 8 Exploded view front assembly