RAE Systems ToxiRAE Pro CO2

The RAE Systems ToxiRAE Pro CO2 is a personal monitor dedicated to carbon dioxide hazards in safe-area industrial environments. Its nondispersive infrared CO2 sensor measures directly in ppm, delivering finer resolution than percentage-volume instruments and supporting more meaningful alarm setpoints. Real-time concentration, STEL, TWA and peak values are continuously displayed, helping workers and safety teams recognise trends early and avoid prolonged exposure where CO2 can accumulate, such as cellars, cold stores, process rooms and confined plant areas.

The device is widely deployed in food and beverage production, breweries, wineries, bottling lines, wider food processing, chemical manufacturing, water and wastewater treatment and landfill gas monitoring. In these applications it helps manage CO2 released from brewing processes, pressurised dispense and packaging lines, or biological and chemical processes, supporting safer working practices and clearer understanding of site-specific risk profiles.

The ToxiRAE Pro CO2 is engineered for all-day wear. A compact housing, low weight and robust rubber boot combine with a metal alligator clip to secure the monitor to clothing or belts without adding significant burden. The large graphical LCD, with white LED backlighting that activates on demand or in alarm, provides clear visibility of readings and status in dark cellars, storage areas and industrial plants.

Simple two-button operation keeps use and configuration straightforward, reducing training requirements and the likelihood of operator error. Diffusion-based sampling provides continuous ambient monitoring without a pump, eliminating associated maintenance tasks and power consumption. The rechargeable Li-ion battery is designed to cover typical shifts and recharges quickly using the supplied cradle, with options for multi-unit chargers to support fleet deployment.

The instrument combines multiple alert channels to make hazardous conditions hard to miss. Audible, vibrating and visual alarms are reinforced by clear on-screen messages and, on wireless models, remote alarm transmission. This five-way alarm approach supports recognition of dangerous CO2 levels even in noisy, busy production environments where a single alert type might be missed.

A built-in Man Down function adds further protection by detecting falls or loss of motion. If a worker is incapacitated, the device can trigger a local pre-alarm and escalate to a full alarm, with wireless variants forwarding the event to connected monitoring systems. This capability supports faster intervention where workers operate alone or in low-visibility areas.

As the world’s first wireless personal CO2 monitor, the ToxiRAE Pro CO2 extends protection beyond the individual to the control room. Models equipped with an RF modem operate in licence-free bands and connect to mesh routers, EchoView Host handhelds and RAELink mesh modems as part of ProRAE Guardian or similar networks. This enables safety teams to see live readings, alarms and Man Down events from multiple monitors across a site or fleet.

Centralised visibility supports faster incident response, more coordinated evacuations and informed decisions on re-entry to affected areas. When combined with other ToxiRAE Pro monitors, sites can standardise on a common platform, interface and accessories across different gases, simplifying training, procedures and logistics.

The ToxiRAE Pro CO2 is designed to minimise downtime and simplify compliance management. Its intelligent CO2 sensor stores its own calibration data, so pre-calibrated sensors can be swapped in the field without a full recalibration cycle. Field-replaceable filters and batteries further shorten service windows and reduce the need for off-site maintenance.

Integration with the AutoRAE 2 automatic test and calibration system allows push-button bump testing and calibration, supporting consistent application of site policies and reducing manual intervention. Policy enforcement features within the broader ecosystem help ensure that bump tests and calibrations are carried out on schedule, supporting audit readiness.

Continuous datalogging, with user-configurable intervals, records months of exposure history. Data can be downloaded via the PC cradle or AutoRAE 2 and managed in ProRAE Studio II or Honeywell SafetySuite software, enabling detailed post-incident analysis, trend reporting, fleet configuration management and maintenance planning.

The ToxiRAE Pro CO2 combines intrinsically safe electronics with a rugged, IP65-rated enclosure suitable for demanding industrial use, while this safe-area CO2 model is explicitly not intended for hazardous (Ex) zones. Each instrument is supplied ready to deploy, including a rechargeable battery, alligator clip, protective boot, charging and communication cradle, calibration adapter, documentation and configuration software.

Defined warranties on non-consumable parts and consumables, together with extensive technical documentation, support confident long-term use. Across breweries, bottling lines, chemical plants, wastewater facilities, landfill operations and cold storage, the RAE Systems ToxiRAE Pro CO2 provides a reliable, standardised way to make CO2 risks visible, protect personnel and manage personal monitoring fleets effectively.