ATEX Zone 1 Certified Pipe Crawler Designed for Extreme Safety and Precision.
Safely conduct infrastructure inspections in potentially explosive atmospheres with the Proteus™ ExZ1 inspection robot. This advanced equipment is designed specifically for Zone 1 hazardous environments, enabling risk mitigation, enhanced clarity, and asset protection through robust and reliable technology.
The Proteus™ ExZ1 is an industrial pipe robot that delivers professional-grade quality, reliability, and accuracy, manufactured in accordance with ISO 9001 and ISO 14001 standards.
The system features a modular design and a variety of optional components, allowing you to configure a solution that is tailored to meet your specific operational requirements.
Safely conduct infrastructure inspections in potentially explosive atmospheres with the Proteus™ ExZ1 inspection robot. This advanced equipment is designed specifically for Zone 1 hazardous environments, enabling risk mitigation, enhanced clarity, and asset protection through robust and reliable technology.
The Proteus™ ExZ1 is an industrial pipe robot that delivers professional-grade quality, reliability, and accuracy, manufactured in accordance with ISO 9001 and ISO 14001 standards.
The system features a modular design and a variety of optional components, allowing you to configure a solution that is tailored to meet your specific operational requirements.
EXPLOSION-PROOF PIPE INSPECTION ROBOT Proteus ExZ1
Proteus™ ExZ1 Key Features
Certified to ATEX/IECEx standards — built for crews who can’t afford downtime.
ATEX Zone 1 Certification
Full compliance for petro-chem, gas and confined-space jobs in highly explosive environments.
Pan & Rotate (Laser, Zoom) Cameras
Pressurized camera heads with 360º continuous rotation and +/- 135º pan. Optional laser and zoom.
Up to 1,640ft. (500m) Working Length
Kevlar-reinforced cable. Manual and Motorized reels with a cable layering mechanism.
For Small and Large Pipes Inspections
Tractors available to inspect pipelines from 4" to 86".
Range of wheels, camera raisers and AUX lights.
Range of wheels, camera raisers and AUX lights.
The Explosion-Proof Pipe Inspection Crawlers Proteus™ ExZ1 are compact, portable units consisting of a robotic tractor with a camera head, a cable reel, and a control unit.
Control Unit CCU208-ExZ1
Explosion Proof Pipe Inspection Robot Control Unit with ATEX Zone 1 Override Key Switch
- Certified to Control the Proteus ATEX Zone 1 Pipe Crawler for Potentially Explosive Atmospheres.
- Override Key Switch to Cut off Power Supply If the System Detects ATEX Uncompliant.
- Pre-installed ProPIPE+ and WinCan Software.
- 10” XGA (1024 x 768 pixels) Sunlight Viewable Display.
- Twin Integral Joysticks for Camera and Crawler Control.
- Ergonomic Soft-touch Keypad.
- Adjust the Frequency of the Sonde (33kHz, 512Hz, or 640Hz).
- Footage Reset Key.
- Image/Video Recording, Organizing, and Sharing via WiFi or USB Port.
- Inspection Report Generation with Pipe Graph, Defects, Material, Location & Pipe Size.
- Up to 5 Hrs of Autonomous Work.
+ Full Specifications
ExZ1 Crawler | Tractor
Explosion-proof Pipe Robot CRP 140 ExZ1
- ATEX Zone 1 Certified for Explosive Atmosphere
- For Pipes from 6" to 24" in Diameter
- Motorized Elevator to Center Camera in 8" Pipes
- Speed, Internal Pressure, Inclination, and Temperature Monitoring
- Multi-Frequency Sonde
- Steerable, All-Wheel Drive
- IP68 Waterproof (1 bar)
- Quick Change Wheel Lock
- Articulating ‘Knuckle-type’ Connector
- Optional Crawler Cradle for Pipes up to 40" Diameter
- Optional High-output AUX Lights
+ Full Specifications
ExZ1 Camera Heads
ATEX ExZ1 CAM026L Pan, Tilt, Laser
- ATEX Zone 1 Explosion Proof Camera Head
- Continuous 360° Rotation and +/-135° Pan
- Accurate Pipe Diameter, Defect, and Object Measurement
- Nitrogen Pressurized for Explosive Environments
- Waterproof up to 1 bar (14.50psi)
ATEX ExZ1 CAM028L Pan, Tilt, Zoom, Laser
- ATEX Zone 1 Explosion Proof Camera Head
- Continuous 360° Rotation and +/-135° Pan
- Optical and Digital Zoom
- Accurate Pipe Diameter, Defect, and Object Measurement
- Nitrogen Pressurized for Explosive Environments
- Waterproof up to 1 bar (14.50psi)
+ Full Specifications
Cable Reels
Motorized/Manual Reels RAP/RMP 300
- ATEX Zone 1 Crawler Connector Certified for Hazardous Locations.
- Sturdy, Rugged, and Reliable.
- Motorized and Manual Models Available.
- Powder-coated Frame Houses 1,148ft (350m) Kevlar Reinforced Cable.
- Cable Layering Mechanism for Smooth Pay-out and Rewinding.
- Heavy-duty Turning Handle (RMP 300).
- Powerful Three-Phase Motor with an Emergency Stop Button (RAP 300).
- The Reel is Operated Remotely from the Proteus ExZ1 Control Unit (RAP 300).
Automatic Reel ACR 500
- ATEX Zone 1 Crawler Connector Certified for Hazardous Locations.
- For Vans, Pickup Trucks, and UTV Installation.
- Powered Winding in Both Directions.
- Heavy-duty Frame Houses 1,640ft (500m) Kevlar Reinforced Cable.
- Cable Layering Mechanism for Smooth Pay-out and Rewinding.
- Hand-held Bluetooth® Joystick Remote Controller.
- Control Panel Buttons with Dedicated Keys.
- Powerful Three-Phase Motor with an Emergency Stop Button.
- Operated Remotely from the Proteus ExZ1 Control Unit.
- Extendable Van Guide Pulley.
+ Full Specifications
Explosion Proof Pipe Crawler PROTEUS ExZ1 Intro
Recommended Accessories
ATEX ExZ1 AUX Lights with Back-eye Camera
Explosion-proof ExZ1 Ultra-bright LED AUX light head with a backup camera head.
ATEX ExZ1 Pipe Inspection Robot Cradle
Adapts the explosion-proof Proteus ExZ1 pipe crawler for use in pipes up to 40" diameter.
Carbide, Diamond, Carborundum, and Pneumatic Wheels
To provide improved traction in PVC, wet, and greasy pipes.
Mobile Storage Cart
To securely hold and move around a control unit, reel, optional battery pack, and accessory box.
ATEX Nitrogen Pressurization Kit
Comply with ATEX Z1 requirements by presurizing the explosion-proof Proteus Tractor and Camera head
Portable Power Pack
Enables portable operation in the most remote locations with up to 5 hours of inspection time.
Fiberscope.net is an authorized dealer of the MiniCam Explosion Proof Pipe Inspection Robots Proteus™ ExZ1
Don’t Gamble with Ignition Risk
Explosion-proof Proteus™ ExZ1 pipe robots offer reliable, high-quality inspection solutions that significantly reduce operational risks.
ATEX approval guarantees intrinsically safe operation in Zone 1 explosive atmospheres, preventing sparks and heat build-up that could ignite flammable gases or dust.
ATEX approval guarantees intrinsically safe operation in Zone 1 explosive atmospheres, preventing sparks and heat build-up that could ignite flammable gases or dust.
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Questions and Answers
- What are the key differences between intrinsically safe (Ex I) and explosion-proof (Ex d) pipe inspection equipment?Both explosion-proof and intrinsically safe pipe-inspection robots comply with ATEX Zone 1 regulations, yet they operate on different safety principles.
An intrinsically safe (Ex i) robot ensures that every circuit operates at such low voltage and current that it can never spark or reach a surface temperature capable of igniting surrounding gas. With their electronics running on milliamps, these systems typically can not provide sufficient illumination and image quality in the inspection area.
On the other hand, explosion-proof (Ex d) pipe inspection systems take a different approach. They allow for higher-powered motors, batteries, and lighting, but these components are securely sealed inside a rugged metal enclosure featuring threaded joints or flame paths. If an internal ignition occurs, the housing contains the pressure and cools the hot gases, preventing anything from escaping into the atmosphere.
In practice, if your priorities are maximum lighting, better image quality, high-torque, and heavy-duty durability, then an explosion-proof crawler would better suit your needs. Both protection concepts comply fully with ATEX Zone 1; the right choice depends on your needs and requirements. - Which UL standard provides an equivalent level of protection to ATEX Zone 1 certification?The closest direct match to ATEX Zone 1 is a piece of equipment that is UL-listed for Class 1, Division 1 (C1D1)—or, under the newer harmonised scheme, UL Class 1, Zone 1. Class I tells inspectors that the hazard is a flammable gas or vapour. At the same time, Division 1 / Zone 1 means that an ignitable atmosphere will likely be present during normal operation, which is exactly the condition ATEX defines for Zone 1.
- Are operators required to hold specific training or licenses to deploy an explosion-proof pipe-inspection crawler?Operators of explosion-proof pipe crawlers are not required to obtain a special government-issued license. However, legislation stipulates that any individual who operates powered equipment in hazardous areas must possess the necessary competency and formal training in explosive-atmosphere safety.
In North America, the Occupational Safety and Health Administration (OSHA) regulations, as outlined in 29 CFR 1910.307, along with the Canadian Electrical Code, indicate that electrical equipment utilized in Class 1, Division 1 environments (which corresponds to the UL/CSA equivalent of ATEX Zone 1) must be installed and serviced by qualified personnel. This designation refers to workers who have completed hazards-specific training and can demonstrate their ability to identify and mitigate ignition risks. While individual states or provinces may impose additional requirements regarding confined space entry, hot-work operations, or gas-testing certifications, there remains no distinct "crawler operator license."
In summary, a crew is not required to possess a specialized government license to operate the pipe robot. Nonetheless, it is imperative that they have documented training related to hazardous areas, compliant with either ATEX or OSHA standards, as well as any customer-mandated certifications, such as CompEx. It is essential to demonstrate competence, adhere to the permit system, and ensure that the Explosion Protection Document is kept current. - What are the required inspection intervals for ATEX Zone 1-certified explosion-proof pipe crawlers to maintain compliance?To maintain compliance, adhering to specific inspection intervals for ATEX Zone 1-certified equipment is essential. The ATEX and IEC standards regard inspection as a life-cycle requirement, rather than a singular occurrence. Below are the mandated practices for equipment designed for C1Z1/C1D1 applications, such as a pipe inspection robot:
- Initial Detailed Inspection Before First Use: A qualified Ex technician must conduct a comprehensive assessment to ensure that the crawler’s protection concept, markings, and installation conform to the site's Explosion Protection Document. This initial examination is mandated by EN / IEC 60079-14 and must be completed and documented before the robot is permitted to operate within a Zone 1 environment.
- Shortened Intervals for Movable or Portable Ex Equipment: As a pipe crawler is classified as movable electrical equipment, IEC 60079-17 recommends a maximum interval of twelve months between close inspections, supplemented by a brief visual check by the operator each time it is deployed in a hazardous zone. Adverse conditions, frequent openings of enclosures, or a history of rough maintenance may warrant even shorter inspection intervals.
- May any repair facility service ATEX Z1-certified explosion-proof pipe inspection robots, or must work be carried out exclusively by accredited Ex service centres?The answer is negative; you cannot simply deliver a Proteus™ ExZ1 explosion proof pipe crawler to any local shop and anticipate that the certification will remain valid. Once equipment is placed on the market, any repairs, overhauls, or modifications that may affect its explosion protection features must be performed by a workshop that adheres to the requirements of IEC 60079-19 and operates under a documented Ex-quality system.
Should an unqualified workshop open the Ex d enclosure, replace a gland, or re-pot an Ex i board without these controls in place, the protection concept will be deemed "no longer verified." Consequently, the crawler will:
1. Lose its ATEX certification until it undergoes re-testing and re-certification by a notified body.
2. Face possible exclusion from any Zone-classified plant as determined by the site's permit-to-work team or insurer.
Field services are only permissible for straightforward, low-risk tasks, such as replacing a user-replaceable battery, when explicitly sanctioned by the manufacturer's instructions and signed off by a CompEx-qualified individual. Any alteration that disrupts flame paths, encapsulation, or intrinsic safety barriers must be directed back to an Ex-compliant service center.
In summary, disassembling the camera, coiler, control unit, or any part of the Proteus™ ExZ1 explosion-proof pipe inspection robot without the manufacturer's approval is forbidden!
Only Minicam-certified appointed Service Centres are permitted to perform any servicing, internal examination, or any repairs on ATEX equipment. You must not have the equipment serviced, internally examined, or repaired by an unauthorised person. Not only will this invalidate any warranty, but it can also immediately invalidate any ATEX compliance certification.
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The System Full Description
The Proteus™ ExZ1 Explosion-proof Pipe Inspection Crawler is an advanced robotic solution engineered specifically for safe and effective inspections in potentially explosive environments. Certified to stringent ATEX Zone 1 standards, this explosion-proof pipe robot ensures intrinsically safe operation, enabling detailed assessments in hazardous locations common to oil and gas, petrochemical, mining, food processing, power generation, and waste management industries.
Compact, portable, and ruggedly designed, the Proteus™ ExZ1 system integrates seamlessly into field operations, featuring a robust robotic tractor equipped with a pan-and-tilt camera head, versatile cable reels, and an intuitive control unit.
The tractor is specially constructed for inspecting pipes ranging from 6" to 24" in diameter and can be expanded for larger diameters up to 40" with the optional crawler cradle. Its motorized elevator precisely positions the camera within pipes, ensuring optimal visibility and accurate diagnostics.
At the core of the system, the Proteus™ ExZ1 control unit offers superior operational control through twin ergonomic joysticks and a soft-touch keypad. The 10” XGA sunlight-readable display provides crystal-clear imaging even in challenging outdoor environments. Integrated ProPIPE+ and WinCan software streamline inspection processes by enabling immediate image and video capture, advanced report generation, and seamless data management through WiFi or USB connectivity. A built-in override key switch immediately cuts power upon detection of any ATEX noncompliances, ensuring unmatched operational safety.
Equipped with motorized or manually operated cable reels, including the ACR 500, RAP/RMP 300, and Light System Reel, the Proteus™ ExZ1 offers exceptional cable management solutions. The reels feature Kevlar-reinforced cables of up to 1,640 feet, with mechanisms designed to maintain smooth cable deployment and retrieval under varying conditions.
Two interchangeable explosion-proof camera heads are available, one featuring optical and digital zoom capabilities, continuous 360° rotation, and +/-135° pan, enabling comprehensive inspections. These nitrogen-pressurized camera heads are ATEX Zone 1 certified, waterproof up to 1 bar, suitable for reliable operation in extreme environments, providing precise measurements of pipe diameters, defects, and objects.
Further enhancing versatility, the Proteus™ ExZ1 can be supplied with optional explosion-proof auxiliary lights with integrated backup cameras, carbide and diamond wheels for superior traction, and a nitrogen pressurization kit for compliance with ATEX Zone 1 requirements. An optional portable power pack ensures uninterrupted inspection capabilities in remote locations for up to five hours, significantly improving field productivity.
The Proteus™ ExZ1 Explosion-proof Pipe Inspection Robot exemplifies cutting-edge technology combined with intrinsically safe design, making it an indispensable tool for thorough, efficient, and secure pipe inspections in hazardous, explosion-prone environments.
Note: Proteus™ ExZ1 pipe inspection robot is a specially ordered product. Conditions apply. Call for details.
Compact, portable, and ruggedly designed, the Proteus™ ExZ1 system integrates seamlessly into field operations, featuring a robust robotic tractor equipped with a pan-and-tilt camera head, versatile cable reels, and an intuitive control unit.
The tractor is specially constructed for inspecting pipes ranging from 6" to 24" in diameter and can be expanded for larger diameters up to 40" with the optional crawler cradle. Its motorized elevator precisely positions the camera within pipes, ensuring optimal visibility and accurate diagnostics.
At the core of the system, the Proteus™ ExZ1 control unit offers superior operational control through twin ergonomic joysticks and a soft-touch keypad. The 10” XGA sunlight-readable display provides crystal-clear imaging even in challenging outdoor environments. Integrated ProPIPE+ and WinCan software streamline inspection processes by enabling immediate image and video capture, advanced report generation, and seamless data management through WiFi or USB connectivity. A built-in override key switch immediately cuts power upon detection of any ATEX noncompliances, ensuring unmatched operational safety.
Equipped with motorized or manually operated cable reels, including the ACR 500, RAP/RMP 300, and Light System Reel, the Proteus™ ExZ1 offers exceptional cable management solutions. The reels feature Kevlar-reinforced cables of up to 1,640 feet, with mechanisms designed to maintain smooth cable deployment and retrieval under varying conditions.
Two interchangeable explosion-proof camera heads are available, one featuring optical and digital zoom capabilities, continuous 360° rotation, and +/-135° pan, enabling comprehensive inspections. These nitrogen-pressurized camera heads are ATEX Zone 1 certified, waterproof up to 1 bar, suitable for reliable operation in extreme environments, providing precise measurements of pipe diameters, defects, and objects.
Further enhancing versatility, the Proteus™ ExZ1 can be supplied with optional explosion-proof auxiliary lights with integrated backup cameras, carbide and diamond wheels for superior traction, and a nitrogen pressurization kit for compliance with ATEX Zone 1 requirements. An optional portable power pack ensures uninterrupted inspection capabilities in remote locations for up to five hours, significantly improving field productivity.
The Proteus™ ExZ1 Explosion-proof Pipe Inspection Robot exemplifies cutting-edge technology combined with intrinsically safe design, making it an indispensable tool for thorough, efficient, and secure pipe inspections in hazardous, explosion-prone environments.
Note: Proteus™ ExZ1 pipe inspection robot is a specially ordered product. Conditions apply. Call for details.
Explosive Atmosphere and Visual Inspection
What is an explosion-proof pipe inspection robot, and what are its applications in various industries?
An explosion-proof pipe crawler is a remote-controlled robotic platform that carries a high-resolution camera, lighting, and optional sensors through pipelines for inspection and survey purposes in hazardous (ATEX Zone 1/ UL CI D1) atmospheres. Its sealed flame-proof (Ex d) or intrinsically safe (Ex i) enclosure contains any internal spark or hot surface, so the robot can operate where flammable gases, vapours, or combustible dusts are present without becoming an ignition source. By keeping inspectors safely outside the hazard zone and eliminating plant shutdowns for manual entry, it delivers fast, detailed visual data while guarding both personnel and production uptime.
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Oil and gas
Explosion-proof pipe crawlers inspects flowlines, gathering systems, and crude-export pipes for corrosion, scale, and wax build-up while wells stay online, avoiding the cost of nitrogen purging or hot-work permits in hydrocarbon-rich environments. -
Petrochemical & Refining
Navigates complex process and flare headers to verify weld integrity, detect coke or catalyst deposits, and confirm pipe cleanliness during turnarounds, all within areas where benzene, propane, or hydrogen vapours are common. -
Power generation
Explosion-proof pipe robots can be employed to traverse fuel-gas, hydrogen-cooling, and condensate-return lines in fossil-fuel, combined-cycle, and nuclear plants, identifying corrosion, pitting, or deposit build-up without interrupting turbine operations or venting explosive gases. -
Wastewater & Utilities
Inspects digester-gas, biogas, and sewer force mains where methane and hydrogen sulphide accumulate, helping municipalities detect root intrusion, infiltration, or H₂S-induced corrosion without shutting down critical infrastructure. -
Food & Beverage Production
Examines starch, sugar, and flour transfer lines—locations prone to combustible dust explosions—without contaminating product or violating hygienic standards, supporting preventive maintenance in bakeries, grain terminals, and distilleries. -
Pharmaceutical Manufacturing
Checks stainless-steel process piping and solvent-recovery lines that may contain ethanol, acetone, or isopropanol vapours, ensuring GMP compliance while maintaining the stringent ATEX zoning inside active cleanrooms. -
Mining & Mineral Processing
In mining operations, explosion-proof pipe robots can be used to survey slurry, vent-gas, and concentrate pipelines in gold, copper, and coal operations where methane pockets or sulphide dust can create explosive atmospheres, reducing confined-space entries in remote sites.. -
Waste management
Examines landfill-gas collection headers, anaerobic-digester piping, and solvent-recovery lines in recycling facilities where methane, VOCs, or dust can ignite, supporting safe maintenance and regulatory compliance without halting processing lines.
Need advice? Ask our technical consultants who know the subject. They will answer your questions and help to scout out the best inspection solution for your application.
