The DERC MAGTRACK and MAGTRACK Mini are electrically driven cleaning robots (crawlers) designed for cleaning steel surfaces with ultra-high-pressure water. These devices are suitable for both flat and slightly curved steel surfaces, such as internal and external cleaning of storage tanks, and external cleaning in the maritime sector. The MAGTRACK Mini is specifically designed for smaller flat surfaces or pipes with a minimum diameter of 1200 mm. Cleaning even smaller pipes is possible with specific seals tailored to the pipe diameter.
Function Description
The DERC MAGTRACK system comprises a carrier, a transport plate, a control unit, a wireless console, and various cleaning tools. By attaching cleaning tools like a swing arm or a blast can, the MAGTRACK can efficiently clean surfaces using high-pressure water. The carrier, when combined with a swing arm or blast can, is suitable for operation in ATEX Zone 2 environments, as indicated by its certification. The remote control is also certified for ATEX Zone 2.
The swing arm is designed for cleaning wide paths (1400 mm) and does not require the collection and extraction of wastewater. Its stroke and speed can be adjusted as needed. The blast can, on the other hand, is specifically for applications where the extraction of wastewater and drying of the steel surface are crucial, such as stripping paint from storage tanks or cleaning ship hulls.
Important Technical Specifications
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 or 240VAC (depending on model)
- Max. current fuse: 20 Amp (110VAC) / 16 Amp (240VAC)
- 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: Approximately 45 hours
- Charging time: Approximately 4 hours (0 -> 100%)
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
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
MAGTRACK Mini with Blast Can:
- 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
Usage Features
The DERC MAGTRACK is designed for safe and efficient operation. Users must be familiar with high-pressure technology and safety measures. The wall thickness of the steel surface must be at least 6 mm for sufficient magnetic force.
Setting Up and Installation:
- The carrier is placed on a transport plate with steel plates and gently positioned against the steel surface. Handles are provided for this purpose to prevent entrapment.
- The MAGTRACK connects to the control unit via a cable, with a pull relief mechanism.
- For ATEX certified control units, compressed air (at least 6 bar) and an earth connection are required. The control unit has a pressure reduction valve to ensure correct air pressure.
- High-pressure hoses must be flushed and checked for damage before connection. Assembly paste should be used on male threads, and non-metal hose whip checks are recommended to avoid interfering with swing arm sensors.
- The wireless console is used for operation, and fall protections must always be secured.
Wireless Console Operation:
- The console features an emergency stop button, swing arm ON/OFF, high-pressure pump controls, step function, automatic driving, swing arm direction reversal (spot stopper), and a start button.
- Joysticks control forward/backward drive and left/right steering.
- Adjustments for drive speed, step duration, trim function (for automatic drive without swing arm), swing arm angle, and swing arm speed are available.
- LED indicators provide status updates for power, actuator activity, temperature protection, battery level, signal strength, and charging status.
- The remote control can be calibrated by turning potentiometers and joysticks within a specific sequence.
- The battery is charged via a supplied USB cable, with specific instructions for connecting the battery and ensuring the stop button is in "sleep" mode.
Safety Devices:
- Control Unit: Emergency stop on the cabinet door. ATEX versions are protected by overpressure, disconnecting power if pressure drops below a set value. A pressure relief valve prevents excess pressure.
- Carrier: Stops if wireless connection is lost. Requires two fall protections, catching the robot after approximately 1 meter if it detaches. Not for use above water without fixed lines. An optional wall contact sensor switches off the MAGTRACK and high-pressure pump if contact with the steel surface is lost.
- Swing Arm: Equipped with sensors to limit arm stroke.
- Blast Can/MAGTRACK Mini: A vacuum valve limits underpressure. MAGTRACK Mini also requires two fall protections and is not for use above water without fixed lines.
- Transport: The MAGTRACK must be transported on a specially designed transport plate to reduce magnetic force, allowing passage through manholes and safe mounting/removal from walls.
Maintenance Features
Regular maintenance is crucial for safe and efficient operation. All maintenance tasks should be performed by authorized and technically qualified personnel, adhering to safety regulations.
General Maintenance:
- Visual checks for play, wear, defects, tightness, and leakage.
- High-pressure water and power supply must be removed before maintenance.
- A complete check is recommended after the first 50 hours of operation.
- Clean the exterior, ensure pictograms are legible, check screw thread quality, secure connections, and listen for unusual noises.
Preventive Daily Maintenance:
- Visually check for contaminants.
- Before each use, check high-pressure hoses and connections for leakage.
Preventive Weekly Maintenance:
- Check high-pressure hoses for damage.
- Check operating throughput.
- Inspect the rubber seal of the blast can for cleanliness.
- Verify proper nozzle function.
Preventive Half-Yearly Maintenance:
- Check and readjust all moving parts. More frequent checks are advised in extremely polluted or hot environments.
Preventive Annual Maintenance:
- Check for defects.
- Inspect wheels for wear and tear.
- Perform inspection in accordance with NEN 3140.
- Conduct HD inspection of the cleaning tool.
- Perform ATEX inspection.
Adjustments:
- Magnet Adjustment (MAGTRACK): As wheel profiles wear, the distance between magnets and the cleaning surface changes, affecting magnetic tensile force. Magnets can be adjusted on the surface by loosening bolts and turning them clockwise (away from the wall) or counter-clockwise (towards the wall). The gap between magnet and wall should not be less than 3mm.
- Swing Arm Angle Adjustment: Sensors control the swing arm's stroke. The distance between the sensor and arm should be between 2 and 4 mm.
- Vacuum Valve Adjustment: To increase vacuum pressure in the blast can, turn the bolt on the vacuum valve clockwise; counter-clockwise to decrease pressure.
- Omniwheel Height Adjustment (MAGTRACK Mini): Omniwheel height can be adjusted using a nut, depending on whether the robot is riding on a tube or a flat surface.
- Blast Can Angle Adjustment (MAGTRACK Mini): Pivot points must be loosened and re-locked to adjust the angle of the blast can parallel to the surface.
- Magnet Adjustment (MAGTRACK Mini): Magnets can be adjusted for both flat surfaces and pipes. This involves disassembling wheels, removing bolts, and setting magnets to the desired height (advised 6 mm distance from the surface).
Faults and Repairs:
- A troubleshooting guide provides possible faults, causes, and solutions.
- Repairs are categorized for qualified and trained personnel ('T') or operators ('B').
- Replacing Wheels: Wheels should be replaced when the polyurethane layer is worn. This involves placing the carrier on a non-magnetic workbench, removing the guard bracket, and detaching the wheel and axle from the gearbox. New wheels are fitted in reverse order using Loctite 243.
- Replacing a Drive: This is a dangerous task due to powerful magnets. Non-magnetic tools must be used. It involves disconnecting motor connectors, turning the carrier with magnets upwards, placing a wooden guard block, removing the domed nut and end cap, splitting the machine, and disassembling socket head screws to remove the motor from the gearbox. Reassembly is done in reverse order, with Loctite 243 for the domed nut.
Disassembly and Disposal:
- All replaced parts, materials, and liquid substances must be disposed of in accordance with applicable environmental regulations.
The DERC MAGTRACK and MAGTRACK Mini are designed and built in accordance with various EU directives, including Machinery (2006/42/EC), ATEX (2014/34/EU), EMC (2014/30/EU), Low Voltage (2014/35/EU), and Radio Equipment (2014/53/EU). The ATEX code for the MAGTRACK/MAGTRACK Mini with Blastcan or Swingarm is II 3G Ex mc h IIC T4 Gc. The ATEX code for the DERC Control unit is II 3G Ex p IIC T4 Gc. The ATEX code for the DERC Remote EXREM001 – RECEIVER EXRCV0001 is II 3G Ex i IIB T6 Gc and II 3D Ex t IIIC T85°C Dc.
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