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ExRobotics ExR-2 Operating Manual

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Operating Guide

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Ian Peerless
June 17, 2025

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Summary of Contents for ExRobotics ExR-2

  • Page 1 ExR-2 Robot Operating Guide...
  • Page 2 Owner: Date: ExR-2 Robot 20220412IP1 Page 1 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 3 Owner: Date: ExR-2 Robot 20220412IP1 Page 2 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 4: Table Of Contents

    Owner: Date: ExR-2 Robot 20220412IP1 Page 3 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 5 Owner: Date: ExR-2 Robot 20220412IP1 Page 4 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 6: Introduction

    In future we expect field engineers, customer success teams, supply chain partners, and customers to augment the material in this guide. If these additions are shared with ExRobotics’ Quality Owner they’ll be shared more widely and will inform future versions of the guide. Existing supporting material is referenced in Section 13 of this document.

  • Page 7: Robots

    2. Robots ExR-2 robots are assembled from a number of modules mounted on a skeleton that’s clad in sheet steel. Many of these modules are optional. The main features of our basic robot are identified on this picture of a clad robot.

  • Page 8: Control Stations & Communication

    Owner: Date: ExR-2 Robot 20220412IP1 Page 7 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 9: Docking Stations & Charging

    Owner: Date: ExR-2 Robot 20220412IP1 Page 8 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 10: Lidar Based Navigation

    There’s a video with more detail – Reference 1. 5. LiDAR Based Navigation ExR-2 robots are usually supplied with a LiDAR module. This is at the heart of autonomous navigation and object avoidance (see Section 7). Object avoidance doesn’t work when the robot is being remotely-controlled by a driver.
  • Page 11 Owner: Date: ExR-2 Robot 20220412IP1 Page 10 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 12 Owner: Date: ExR-2 Robot 20220412IP1 Page 11 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 13: Cloud Software

    Owner: Date: ExR-2 Robot 20220412IP1 Page 12 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 14: Driver Screen

    Owner: Date: ExR-2 Robot 20220412IP1 Page 13 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 15 Owner: Date: ExR-2 Robot 20220412IP1 Page 14 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 16 Owner: Date: ExR-2 Robot 20220412IP1 Page 15 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 17: Click And Inspect" & Mission Editor

    Owner: Date: ExR-2 Robot 20220412IP1 Page 16 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 18: Teach & Repeat" & "Line Following" Navigation

    Owner: Date: ExR-2 Robot 20220412IP1 Page 17 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 19: Click And Inspect" Navigation

    Owner: Date: ExR-2 Robot 20220412IP1 Page 18 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 20 Owner: Date: ExR-2 Robot 20220412IP1 Page 19 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 21 Owner: Date: ExR-2 Robot 20220412IP1 Page 20 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 22 Owner: Date: ExR-2 Robot 20220412IP1 Page 21 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 23 Owner: Date: ExR-2 Robot 20220412IP1 Page 22 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 24: Skills

    Owner: Date: ExR-2 Robot 20220412IP1 Page 23 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 25 Owner: Date: ExR-2 Robot 20220412IP1 Page 24 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 26 Owner: Date: ExR-2 Robot 20220412IP1 Page 25 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 27 Owner: Date: ExR-2 Robot 20220412IP1 Page 26 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 28 Owner: Date: ExR-2 Robot 20220412IP1 Page 27 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 29 Owner: Date: ExR-2 Robot 20220412IP1 Page 28 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 30: Deploying & Operating Robots

    (HRS). An HRS can monitor multiple autonomous missions and intervene if anything unexpected occurs. (see Section 7). Customers may contract ExRobotics or one of its partners to perform some of these roles, e.g. HRS and planning. However, because of safety, environmental, security and confidentiality reasons we will only drive the robot within constraints that have been agreed in writing with the customer.
  • Page 31 New drivers should be trained by existing drivers that have experience of navigating around the site: ▪ Operating instructions – Drivers must be familiar with the ExR-2 Operating Instructions. ▪ Control stations – demonstrate the driver screen and controller (see Section 6.2).

  • Page 32: Security, Authorisation & Authentication

    Owner: Date: ExR-2 Robot 20220412IP1 Page 31 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 33: Deployment Support

    8.3. Deployment Support ExRobotics and/or a partner are able to provide deployment support that has been proven to accelerate the first flawless missions. This is especially beneficial for the first robots deployed at a location. With this support, customers can expect their first flawless mission within a few days of the robot arriving on location, and to be able independently to programme and execute complex missions within 3 months.

  • Page 34: Software Releases

    Energy Robotics can update and upgrade software remotely over the internet. The Customer will be informed before any significant updates/upgrades so that they can monitor for any issues that may arise. The ExRobotics account manager will handle any concerns or issues. ExRobotics B.V.

  • Page 35: Servicing, Maintaining & Transporting Robots

    ▪ Clear the area around the docking station of debris and leaves. ▪ Inspect the robot for visible damage. In particular, if the wire antennas are too bent they should be replaced. New wires will be sourced from ExRobotics to maintain the robot’s Ex status. They screw onto their bases.

  • Page 36: Replacing Tracks

    The longevity of the tracks will vary based on the terrain and routes the robot traverses. However, under normal conditions, the tracks should last for at least 50 kilometres. To ensure the robot's anti-static performance is maintained, ExRobotics will supply replacement tracks. NOTE: It’s crucial to follow the instructions carefully to maintain the robot's optimal performance.
  • Page 37 Owner: Date: ExR-2 Robot 20220412IP1 Page 36 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 38 ▪ Ensure the tracks face in the right direction as indicated in this diagram. NOTE: The correct track deflection and direction are essential for optimal ExR-2 performance and safety. Here are some key reasons why track alignment is important: • Stability and Maneuverability: Correct track alignment ensures smooth and safe navigation, providing stability and improved maneuverability for the machine.
  • Page 39 Owner: Date: ExR-2 Robot 20220412IP1 Page 38 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 40: Opening The Hull

    9.4. Opening the Hull ExR-2’s hull is composed of a skeleton and cladding panels that are attached to each other and to the skeleton with button screws. The hull contains most user-serviceable parts. To access these parts, you need to remove one or more panels. This must be done in a safe, dry area.
  • Page 41 Owner: Date: ExR-2 Robot 20220412IP1 Page 40 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 42: Changing Sim Cards

    Owner: Date: ExR-2 Robot 20220412IP1 Page 41 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 43 Owner: Date: ExR-2 Robot 20220412IP1 Page 42 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 44 Owner: Date: ExR-2 Robot 20220412IP1 Page 43 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 45 ▪ Carefully inspect the flamepath (shown in this picture) before reinstalling the front of the enclosure. If there are any scratches or dents, contact an ExRobotics Field Engineer. Do not redeploy the robot in a potentially explosive location. ▪ Gently push the enclosure front onto the enclosure back, ensuring the O Ring is correctly seated.
  • Page 46 Owner: Date: ExR-2 Robot 20220412IP1 Page 45 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 47: Calibrating Gas Detectors

    Owner: Date: ExR-2 Robot 20220412IP1 Page 46 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 48: Replacing Batteries

    9.7. Replacing Batteries To maintain the robot's certification and performance standards, only use batteries supplied by ExRobotics. Should you encounter any difficulties or find yourself unsure about any step of the process, please seek assistance from ExRobotics. By adhering to these safety precautions, you can guarantee a secure and successful battery replacement procedure.
  • Page 49 Owner: Date: ExR-2 Robot 20220412IP1 Page 48 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 50 Owner: Date: ExR-2 Robot 20220412IP1 Page 49 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 51 Owner: Date: ExR-2 Robot 20220412IP1 Page 50 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 52 Once adjusted, remove the third battery. 9.7.3. Battery Replacement & Re-assembly ▪ New foam strips supplied by ExRobotics should be installed on the batteries. Place a strip in the middle of each battery. ▪ To replace the batteries, follow the reverse order of the above steps. Insert the new batteries into the battery pack, starting with the third battery and working towards the leftmost battery.
  • Page 53 Owner: Date: ExR-2 Robot 20220412IP1 Page 52 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 54 Owner: Date: ExR-2 Robot 20220412IP1 Page 53 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 55: Maintaining Robots

    Transport guidelines are provided in Reference 5. ExR-2 robots typically weigh between 120 and 140kgs so it’s best to transport them in their flight cases, to drive them in and out of those flight cases, and to drive them around the site. Flight cases and robots have been shipped offshore in containers and cages.

  • Page 56: Questions & Answers

    Owner: Date: ExR-2 Robot 20220412IP1 Page 55 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 57: Why Can't I Connect To A Robot

    10.6. Why am I Surprised by the Battery Level Reported by the Cloud Software? ExR-2 robots have a chip that calculates battery charge percentage based on power used. In most situations this will be accurate. However, if the robot is switched on after the quick charger has been plugged into the robot the battery percentage will always be reported as 0%.

  • Page 58: How Do I Refresh My Control Screen

    Owner: Date: ExR-2 Robot 20220412IP1 Page 57 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 59: Robot & Docking Station Specifications

    Owner: Date: ExR-2 Robot 20220412IP1 Page 58 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 60: Availability & Recovery

    Owner: Date: ExR-2 Robot 20220412IP1 Page 59 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 61 Owner: Date: ExR-2 Robot 20220412IP1 Page 60 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 62: Hardware Options

    Owner: Date: ExR-2 Robot 20220412IP1 Page 61 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 63 Owner: Date: ExR-2 Robot 20220412IP1 Page 62 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 64: Noses For Honeywell 3000 Mk Ii

    Owner: Date: ExR-2 Robot 20220412IP1 Page 63 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 65: Risk Assessment & Reduction

    12. Risk Assessment & Reduction This section is copied from ExRobotics’ document [20230430IP1]. It’s intended to help customers to identify, quantify, and control the risks associated with operating robots. The RAM scores are left blank so that Customers can use their own evaluation criteria.
  • Page 66 Owner: Date: ExR-2 Robot 20220412IP1 Page 65 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 67 Owner: Date: ExR-2 Robot 20220412IP1 Page 66 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 68 Owner: Date: ExR-2 Robot 20220412IP1 Page 67 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.
  • Page 69 Owner: Date: ExR-2 Robot 20220412IP1 Page 68 of 69 Operating Guide Version No.: 3 Ian Peerless 2023-07-25 This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version. Copyright 2023 ExRobotics B.V.

  • Page 70: References To Supporting Material

    UI-v2 user guide (Site-centric Digital Twin). Presentation by Energy Robotics. Energy Robotics Data Security: Version 3 dated 2020-05-04. Customer Success Journey Templates: ExRobotics Document Number 20221020IP1 Version 4. ExR-2: Instructions for packing and unpacking: ExRobotics Document Number 202300301RS1. Energy Robotics’ support portal: Help Desk - Jira Service Management (atlassian.net) Manufacturers’...

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