Rae UltraRAE PGM-7200 User manual

UltraRAE
COMPOUND SPECIFIC
PID MONITOR
PGM-7200
OPERATION AND MAINTENANCE
MANUAL
(Document No.: 012-4001)
April 2003, Revision F2
RAE SYSTEMS INC.
1339 Moffett Park Drive
Sunnyvale, CA 94089

ATTENTION!
For European Applications
A. 0575 II 1G
DEMKO 03 ATEX 0204759X
Eex ia IIC T4
B. Recharge batteries only in non-hazardous locations.
C. Do not connect external cable to serial interface jack in
hazardous locations.
D. Use RAE Systems Adapter P/N 500-0072 for connection
to communication port and charging jack only in a non-
hazardous area.

ii
Table of Contents
1. GENERAL INFORMATION 1-1
1.1 General Specifications.......................................... 1-3
2. OPERATION OF ULTRARAE 2-1
2.1 Physical Description............................................. 2-2
2.2 Keys and Display.................................................. 2-3
2.3 Power On/Off ....................................................... 2-4
2.4 Operation .............................................................. 2-5
2.4.1 Idle Operation.............................................. 2-5
2.4.2 Measurement Overview............................... 2-9
2.5 Alarm Signals ..................................................... 2-12
2.6 Preset Alarm Limits and Calibration.................. 2-14
2.7 Integrated Sampling Pump ................................. 2-15
2.8 Backlight ............................................................ 2-16
2.9 Datalogging ........................................................ 2-17
3. OPERATION OF ACCESSORIES 3-1
3.1 Battery Charging Operation ................................. 3-1
3.2 Alkaline Battery Adapter ..................................... 3-3
3.3 Dilution Fitting ..................................................... 3-4
4. PROGRAMMING OF ULTRARAE 4-1
4.1 Programming Mode.............................................. 4-2
4.2 Keys for Programming Mode............................... 4-3
4.3 Entering into Programming Mode........................ 4-4
4.4 Calibration of the UltraRAE Monitor .................. 4-5
4.4.1 Fresh Air Calibration................................... 4-7
4.4.2 Span Calibration .......................................... 4-8
4.4.3 Modify Span Value...................................... 4-9
4.5 Change Alarm Limits ......................................... 4-10
4.5.1 Change High Alarm Limit......................... 4-10
4.5.2 Change Low Alarm Limit ......................... 4-12
4.6 View or Change Datalog .................................... 4-13
4.6.1 View Data.................................................. 4-13

iii
4.6.2 Clear All Data............................................ 4-15
4.6.3 Change Data Log....................................... 4-16
4.7 Change Monitor Setup........................................ 4-17
4.7.1 Change Site ID .......................................... 4-18
4.7.2 Change User ID ......................................... 4-19
4.7.3 Change User Mode .................................... 4-20
4.7.4 Change Date .............................................. 4-21
4.7.5 Change Time ............................................. 4-22
4.7.6 Change Backlight ...................................... 4-23
4.7.6 Change DAC/Alarm Output...................... 4-24
4.7.8 Change DAC Range .................................. 4-25
4.7.9 Change Bar Code Reader .......................... 4-26
4.8 Change Sensor Configuration........................... 4-28
4.8.1 Change Measure Wait Time ........................... 4-28
4.8.2 Change PID Lamp........................................... 4-29
4.8.3 Change Dilution Ratio .................................... 4-30
4.9 Exit Programming Mode .................................. 4-31
5. UltraRAE COMPUTER INTERFACE 5-1
5.1 Install ProRAE-Suite Software ............................ 5-2
5.2 Connecting the UltraRAE to a PC........................ 5-4
5.3 Start ProRAE-Suite Software............................... 5-5
5.4 Setup Communication Port .................................. 5-7
5.5 Configure UltraRAE from PC.............................. 5-8
5.6 Send Configuration to UltraRAE ....................... 5-12
5.7 UltraRAE Data ................................................... 5-13
5.8 Password of UltraRAE Configuration................ 5-14
6. THEORY OF OPERATION 6-1
7. MAINTENANCE 7-1
7.1 Battery Replacement ............................................ 7-1
7.2 PID Sensor Cleaning / Replacement .................... 7-4
7.3 Sampling Pump .................................................... 7-7
7.4 Tube Tip Reservoir............................................... 7-9
7.5 Inlet Connector and Filter .................................. 7-10

iv
8. TROUBLESHOOTING 8-1
8.1 Special Diagnostic Mode................................... ...8-2
8.2 Troubleshooting Table ......................................... 8-8
APPENDIX A. QUICK REFERENCE GUIDE A-1
APPENDIX B. TUBE DATA SHEETS B-1
APPENDIX C. TECHNICAL NOTES C-1
APPENDIX D. APPLICATION NOTES D-1
APPENDIX E. LITERATURE REQUEST E-1
APPPENDIX F. REQUEST RMA FORM F-1
Main Contact Numbers Outer Back Cover

v
! WARNING !
- Do NOT proceed before reading -
This manual must be carefully read by all
individuals who have or will have the responsibility
for using, maintaining, or servicing this product.
The product will perform as designed only if it is used,
maintained, and serviced in accordance with the manufacturer's
instructions.
CAUTION!!
To reduce the risk of electric shock, turn off power
before removing the monitor cover. Disconnect the
battery before removing sensor module for service.
Never operate the monitor while the cover is
removed. Remove monitor cover and sensor
module only in an area known to be non-hazardous.
CAUTION!!
The model PGM-7200 equipment is classified as to
intrinsic safety for use in class I, division 1, groups
A, B, C, D, or non-hazardous locations only.

vi
Special Notes
-1-
When the UltraRAE Monitor is taken out from the
transport case and turned on for the first time, there may be
some residual organic or inorganic vapor trapped inside the
detector chamber. The initial PID sensor reading may
indicate a few ppm. Enter an area known to be free of any
organic vapor and turn on the monitor. After running for
several minutes, the residual vapor in the detector chamber
will be cleared and the reading should return to zero.
-2-
The battery of the UltraRAE monitor will discharge slowly
even if it is turned off. If the monitor has not been charged
for 5-7 days, the battery voltage will be low. Therefore, it is
a good practice to always charge the monitor before using it.
It is also recommended to fully charge the monitor FOR AT
LEAST 10 HOURS before first use. See Section 7 for more
information on battery charging and replacement.
-3-
The instrument default condition for the tube barcode
reader is to be “OFF”. In this condition, once a tube is
selected, the instrument assumes that the same type of tube
will be used until a different tube type is programmed.
CAUTION
If the incorrect tube type is programmed or the Measure
Wait Time is otherwise set too short, it is possible to
underestimate the VOC concentration and thereby cause
overexposure. The automatic barcode reader can be enabled
in the program mode (see Section 4).

vii
WARNING:
Use only RAE Systems battery packs, part nos. 012-
3050, 012-3051 or 012-3052. This instrument has not
been tested in an explosive gas/air atmosphere having
an oxygen concentration greater than 21%.
Substitution of components may impair intrinsic safety.
Recharge batteries only in non-hazardous locations.
AVERTISSEMENT:
Utiliser seulement l'ensemble de batterie RAE Systems,
la reference 012-3050, 012-3051 au 012-3052. Cet
instrument n’a pas été essayé dans une atmosphère de
gaz/air explosive ayant une concentration d’oxygène
plus élevée que 21%. La substitution de composants
peut compromettre la sécurité intrinsique. Ne charger
les batteries que dans emplacements désignés non
dangereuse.
STATIC HAZARD:
Clean only with damp cloth
DANGER RISQUE D'ORIGINE
ELECTROSTATIQUE:
Nettoyer uniquement avec un chiffon humide.
CAUTION:
For safety reasons this equipment must be operated and
serviced by qualified personnel only. Read and
understand instruction manual completely before
operating or servicing.

viii
ATTENTION:
Pour des raisons de sécurité, cet équipment doit être
utilisé, entretenu et réparé uniquement par un
personnel qualifié. Étudier le manuel d’instructions en
entier avant d’utiliser, d’entretenir ou de réparer
l’équipement.
WARNING:
The calibration of all newly purchased RAE Systems
instruments should be tested by exposing the sensor(s)
to known concentration calibration gas before the
instrument is used or put into service.
For maximum safety, the accuracy of the UltraRAE
should be checked by exposing the sensor(s) to known
concentration calibration gas before each day’s use.
AVERTISSEMENT:
La calibration de toute instruments de RAE Systems
doivent être testé en exposant l’instrument a une
concentration de gaz connue par une procédure
diétalonnage avant de mettre en service l’instrument
pour la première fois.
Pour une securite maximale, la sensibilité du UltraRAE
doit être verifier en exposant l’instrument a une
concentration de gaz connue par une procédure
diétalonnage avant chaque utilisation journalière.

GENERAL INFORMATION
1 - 1
1. GENERAL INFORMATION
The UltraRAE is a hand-held, programmable Compound
Specific PID monitor designed to provide instantaneous
exposure monitoring of a specific organic gas for workers in
hazardous environments. It monitors a specific gas by utilizing
a gas separation tube and the Photo-Ionization Detector (PID)
with a 9.8 eV, 10.6 eV, or 11.7 eV gas discharge lamp. It also
can be used to measure total Volatile Organic Compound
(VOC) by utilizing a straight through tube and the PID as a
broad band monitor.
Figure 1-1 UltraRAE

GENERAL INFORMATION
1 - 2
Features are:
•Lightweight and Compact
- 20 oz (567 g), Cellular phone size
•Dependable and Accurate
-10 hours monitoring with micro controller
•User Friendly
- menu driven, intuitive end-use operation
•Programmable Alarm Thresholds
-
audio buzzer & flashing display alarm
UltraRAE (PGM-7200) consists of: a Compound Specific
PID monitor, gas separation tubes, a battery charger,
leather case, alkaline battery adapter, water and dust filter
plus calibration accessories.

GENERAL INFORMATION
1 - 3
1.1 General Specifications
Table 1.1
Compound Specific PID monitor Specification
Size: 9.25"L x 3.0"W x 2.0"H
Weight: 21 oz (567 g) with battery pack
Detector: photo-ionization sensor with 9.8 eV UV
lamp, optional 10.6 or 11.7 eV UV lamps
Battery: rechargeable NiMH, NiCd, or Alkaline
battery pack (snap in, field replaceable)
Battery charging: 10 hours charge through built-in charger
or an external battery charger
Operating Hours: 10 hours continuous
Display: 1 line by 8 characters, 5x7 dot matrix
LCD (0.4” character height)
LED Backlight: automatic activation in dim light or alarm
condition
Total VOC Range, Resolution & Response time (t90):
Calibrated to 100 ppm isobutylene:
0-99 ppm 0.1 ppm 5 sec
100-2000 ppm 1.0 ppm 5 sec
Specific Range, Resolution & Measurement time :
Measurement Gas
Benzene 0.1-200 ppm 0.1 ppm 60 sec
1,3-Butadiene 0.1-200 ppm 0.1 ppm 75 sec
Methylene Chloride 0.2-200 ppm 0.2 ppm 30 sec
PID Detector: easy access to lamp and sensor for
cleaning and replacement
Filter: porous metal, for dust and particle
filtering, field replaceable
Inlet probe: Teflontube with ferrule fitting.
Keypad: 1 operation key and 2 program keys
Analog output: 0 to 2.5 volt linear output

GENERAL INFORMATION
1 - 4
Intrinsic Safety: UL & cUL Class 1, Division I,
Groups A, B, C, D (US & Canada)
0575 II 1G
DEMKO 03 ATEX 0204759X
Eex ia IIC T4 (Europe)
EM Interference: no effect when exposed to 0.43 mW/cm2
RFI (5 watt transmitter at 12 inches)
Alarm Setting: preset alarm limits for two action levels
Audible Alarm: 90 dB buzzer @ 10 cm
Visual Alarm: flashing red LED
External Alarm: optional plug in pen size vibration alarm
or remote alarm
Real-time Clock: automatic date and time stamps data
logged information
Data logging: 4000 data points, includes serial number,
user ID and site ID, date and time
Communication: down load data to PC and upload
instrument setup from PC through RS-232
link to serial port on PC
Calibration: two-point field calibration of zero and
standard reference gas for compound
specific vapor
Sampling Pump: internal integrated flow rate, 400 cc per
minute minimum (VOC tube), low flow
alarm
Temperature: -20oto 45oC (-4oto 113oF)
Humidity: 0 % to 95 % relative humidity
(Non-condensing)
Housing: ABS + PC, conductive coating, splash and
dust proof, will withstand 10’ drop test
Attachment: wrist strap

OPERATION
2 - 1
2. OPERATION OF ULTRARAE
The UltraRAE PID Monitor gives the real time measurements
and activates alarm signals whenever the exposure exceeds
preset limits. Prior to factory shipment the UltraRAE is preset
with default alarm limits and the sensors are pre-calibrated with
standard calibration gas. However, the user should calibrate the
instrument before the first use. After the monitor is fully
charged and calibrated, it is ready for immediate operation.
2.1 Figure 2-1 UltraRAE Features
Three keys
Buzze
r
LCD display
Gas exit port
Red LEDs
Gas entry
Wrist strap
Charger connector
Communication
p
ort
Tube holder and reader

OPERATION
2 - 2
2.1 Physical Description
The main components of the UltraRAE Compound Specific
PID monitor include:
•Three keys for user to interact with the monitor: 1 operation
key and 2 programming keys for normal operation or
programming of the monitor
•LCD display for direct readout and calculated
measurements. The display is a one-line, eight-digit,
alphanumeric, 5x7 dot matrix type and has a back light for
readings under low light conditions
•Buzzer and red LED for alarm signal whenever the
exposures exceed preset limits
•Wrist strap
•Charge contact for plugging directly to the charging station
•Gas entry and exit ports with 5-in. Teflon inlet probe
•RAE-SEP tube holder and electronic tube type reader
•Serial communication port for PC interface

OPERATION
2 - 3
2.2 Keys and Display
Figure 2-2 shows the LCD display and the keypad on the front
panel of the monitor. The function of the 3 keys during normal
operation are summarized below:
Figure 2-2. UltraRAE Key Pad & Display
Key Function in Normal Operation
[MODE] -Turn on/off the power* and step through menu
[N/-] -Toggle on/off the back light, negative
acknowledgement /decrement value
[Y/+] -Start measurement, positive acknowledgement
/increment value
•* Pressing and holding the [MODE] key for 5 seconds turns
off the power to the monitor. Press the [MODE] key
momentarily to step through menu items. To save time,
press any key during message scrolling to skip to the end of
the message.
0.0
pp
m
Light sensor
Alarm LED’s
Charge LED

OPERATION
2 - 4
2.3 Power On/Off
To turn on the UltraRAE Compound Specific PID monitor,
press [MODE] key for one second and release. The audio
buzzer will beep once and the display will show “ON!..” and
then “Ver #.##” to indicate the unit’s current firmware version
number. The model number, current date and time, unit internal
temperature, last calibration date and time, battery voltage, and
shut off voltage are displayed.
To turn off the UltraRAE Compound Specific PID monitor,
press and hold the [MODE] key for 5 seconds. The monitor
will beep once per second during the power-down sequence
with a count down timer showing the number of remaining
seconds. The message “Off!..” flashes on the LCD display and
the display will go blank indicating that the monitor is turned
off.
Data protection during power off
When the monitor is turned off, all the current real time data
including last measured value are erased. However, the datalog
data is preserved in non-volatile memory. Even if the battery is
disconnected, the datalog data will not be lost. During power
off period, the real time clock will continue to operate until the
battery is completely drained (usually in 5-7 days without any
charging). If the battery is completely drained or is
disconnected from the monitor for more than 30 minutes, the
real time clock will be lost. In this case, the user needs to enter
the real time clock information again, as described in Section 4,
or send the PC clock during configuration.

OPERATION
2 - 5
2.4 Operation
After the monitor is turned on and cycles through the start up
menu, the message “Ready..” will be displayed even if no tube
is presently inserted.
At this point, the user has two options: 1) step through the idle
operation menu, or 2) take a measurement.
2.4.1 Idle Operation
Press the [MODE] key to cycle through the idle operation
menu. The PID sensor and pump are turned off during this idle
operation. Idle operation menu displays include:
•Ready…
•Last tube name and reading
•Tube type selection (when barcode reader is turned off)
•Battery voltage
•Date, time and temperature
•PC communication
The displays are arranged in a “round robin” order:
Bat=4.8V
10/01/97
08:20
T=25°C
Last=Benzene
0.0 ppm
PC comm?
Change current
tube type
(
barcode disabled
)
Ready…

OPERATION
2 - 6
To choose a specific display, press the [MODE] key one or
more times until the desired display appears.
Note: To get back to “Ready” mode from any of the above
display, press the [MODE] key repeatedly until the
“Ready” message appears.
Figure 2-3 The UltraRAE is Ready
READY: The monitor is ready for a measurement to be taken.
Press the [MODE] key to advance to the next menu. If a tube is
inserted at this point, the “Tube in!” message is displayed,
followed by the alternate display of the gas name and “Start?”
The [Y/+] key can be pressed to start a measurement if the
monitor does not detect the presence of the tube. In either case,
the monitor will go to the second phase of the measurement
cycle (see Section 2.4.2).
LAST TUBE MEASUREMENT: This menu displays
“Last=”, followed by the name of the last tube and the
measurement value in ppm. For example: Last = Benzene 0.0
ppm. Press the [MODE] key to advance to the next menu.
Ready…

OPERATION
2 - 7
CHANGE CURRENT TUBE TYPE [Only in the default
condition where the barcode reader is turned “Off”]: The
present tube type is displayed e.g., “Benzene?” and can be
altered by pressing [N/-] until the desired tube type is displayed.
Press [Y/+] to accept the displayed tube. With the barcode
reader “Off,” the instrument assumes that the same type of tube
will be used until a different tube type is programmed. It is
important to select the tube type correctly because this
determines the lamp required and the measure wait time.
!! CAUTION !!
If the incorrect tube type is programmed or the Measure
Wait Time is otherwise set too short, it is possible to
underestimate the VOC concentration and thereby cause
overexposure.
This menu item is not displayed when the barcode reader is
enabled (to enable see Section 4.7.9).
BATTERY: The menu displays the present battery voltage.
Note: A fully charged battery pack should show 4.8 volts or
higher. When the battery voltage falls below 4.4 volts, a
flashing “Bat” will appear as a warning message. When the
battery voltage falls below 4.2 volts, there are about 20-30
minutes of run time left before the monitor turns off
automatically.
DATE, TIME, TEMP: This menu displays the current date
(month/day/year), time (24-hour format), and internal unit
temperature in degrees Celsius. For example:
7/16/97 … 9:00 (24 hr format) … 25°C ... 77°F