Sensidyne Gilian 800i User manual

Gilian 800i
Air Sampling Pump
Operation Manual
1000 112TH Circle N, Suite 100 • St. Petersburg, Florida 33716 USA
[phone] • [phone] • [phone] [FAX] • www.sensidyne.com
REF 360-0166-01 (Rev D)

1
Gilian 800i
Air Sampling Pump
Operation Manual
REF 360-0166-01 (Rev D)
Software Version L.4.22

Gilian 800i Air Sampling Pump
360-0166-01 - (Rev D) 2
PROPRIETARY NOTICE
This manual was prepared exclusively for the owner of the Gilian 800i Live Flow Air Sampling Pump. The material
within this manual is proprietary information and is to be used only to understand, operate, and service the
instrument. By receiving this document, the recipient agrees that neither this document nor the information disclosed
within nor any part thereof shall be reproduced or transferred, physically, electronically or in any other form, or used
or disclosed to others for manufacturing or for any other purpose except as specifically authorized in writing by
Sensidyne, LP.
COPYRIGHT NOTICE
© 2013 Sensidyne, LP All Rights Reserved. No part of this document may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any language in any form by any means without the prior written
permission of Sensidyne, LP.
TRADEMARK NOTICE
Sensidyne, the Sensidyne logo, Gilian, and the Gilian logo are registered trademarks of Sensidyne, LP. Gilian 800i
and the Gilian 800i logo are trademarks of Sensidyne, LP. These trademarks are protected through use and
registration in the United States. Other trademarks and servicemarks used in this document are the property of their
respective companies and are used only for informational and explanatory purposes.
SOFTWARE LICENSE
The software installed in the Gilian 800i pump is the property of Sensidyne, LP and shall remain the property of
Sensidyne, LP in perpetuity. The software is protected by U.S. and international copyright laws and is licensed for
specific use with the Gilian 800i pump. The user may NOT reverse-engineer, disassemble, decompile, or make any
attempt to discover the source code of the software. The software may NOT be translated, copied, merged or
modified in any way. The user may NOT sublicense, rent, or lease any portion of the software. The right to use the
software terminates automatically if any part of this license is violated.
DISCLAIMER
THE SELLER ASSUMES NO RESPONSIBILITY WHATSOEVER, TO ANY PARTY WHOSOEVER, FOR ANY
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH RECEIVED BY OR RESULTING FROM, IN WHOLE, OR
IN PART, THE IMPROPER USE, INSTALLATION, OR STORAGE OF THIS PRODUCT BY THE USER, PERSON,
FIRM, ENTITY, CORPORATION OR PARTY NOT ADHERING TO THE INSTRUCTIONS AND WARNINGS IN THIS
MANUAL, OR OTHERWISE PROVIDED BY THE SELLER OR FROM NOT ADHERING TO ALL FEDERAL, STATE,
AND LOCAL ENVIRONMENTAL AND OCCUPATIONAL HEALTH AND SAFETY LAWS AND REGULATIONS.
THE SELLER SHALL NOT BE LIABLE FOR DIRECT, INDIRECT, CONSEQUENTIAL, INCIDENTAL OR OTHER
DAMAGES RESULTING FROM THE SALE AND USE OF ANY GOODS AND SELLERS’ LIABILITY HEREUNDER
SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF ANY GOODS FOUND DEFECTIVE. THIS WARRANTY
IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE OR FOR A PARTICULAR PURPOSE
WHICH ARE EXPRESSLY DISCLAIMED.

Gilian 800i Air Sampling Pump
3360-0166-01 - (Rev D)
TABLE OF CONTENTS
Preface
• Notices ............................................................................................................2
• Warnings .........................................................................................................4
• Certifications and Approvals ............................................................................5
SECTION ONE: Introduction
•Components...............................................................................................6
SECTION TWO: Set-Up
2.1 Preparation ................................................................................................9
2.2 Pump Start-Up .........................................................................................10
2.3 Setting the Flow Rate ..............................................................................11
2.4 Calibration ................................................................................................13
2.4.1 Sample Media Method Set-Up ......................................................13
2.4.2 Display Calibration Procedure.......................................................14
SECTION THREE: Program Setup
3.1 Programming ...........................................................................................16
3.2 Program enable/disable............................................................................17
3.3 Program Edit.............................................................................................17
SECTION FOUR: Options
4.1 Option List ................................................................................................18
4.2 Option Settings.........................................................................................19
SECTION FIVE: Operation
5.1 Starting the Sample Run ..........................................................................21
5.2 Stopping the Sample Run ........................................................................23
5.3 Locking the Keypad..................................................................................24
5.4 Unlocking the Keypad...............................................................................24
5.5 Clearing the Run Data .............................................................................25
5.6 Flow Calculation .......................................................................................25
SECTION SIX: Maintenance
6.1 Battery Maintenance.................................................................................26
6.2 Pump Filter Maintenance..........................................................................27
SECTION SEVEN: Appendices
Appendix A: Troubleshooting Guide ................................................................28
Appendix B: Parts List .....................................................................................30
Appendix C: Specifications ..............................................................................31
Appendix D: Fast Charger................................................................................33
Appendix E: Factory Calibration and Service....................................................34

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WARNINGS
READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE
Failure to read, understand, and comply with ALL accompanying literature, product labels, and warnings could
result in property damage, severe personal injury, or death.
Read and understand ALL applicable environmental health and safety laws and regulations. Ensure complete
compliance with ALL applicable laws and regulations before and during use of this product.
DO NOT remove, cover, or alter any label or tag on this product, its accessories, or related products.
UNDER NO CIRCUMSTANCES should this product be used except by qualified, trained, technically competent
personnel.
The Gilian 800i portable Air Sampling Pump is intended for both indoor and outdoor use when protected from
splashed or windblown liquids. The unit is not waterproof so NEVER submerge the unit in water. Pump failure
or faulting may result.
Pump is Intrinsically Safe when used with specified battery pack 783-0007-01. Refer to Certifications and Approvals
section for approval ratings.
DO NOT operate this product should it malfunction, require repair, or have a cracked or broken case.
DO NOT repair or modify, except as specified in Operation Manual. All user controls and adjustments are
made by sealed keypad on front of pump. The only user-replaceable parts are the Battery pack and Pump
Filter (See Section Six).
Use ONLY specified Sensidyne parts when performing maintenance procedures described in this manual.
Intrinsic safety certifications become void by substitution of components, unauthorized repair or alteration. All
other Service to be performed by Sensidyne Authorized Service Departments only. (See Appendix B for Parts
List. See Appendix E for Service Contact Information).
This product uses rechargeable Nickel-Metal-Hydride batteries. Always fully charge before use. DO NOT open
case, charge or replace batteries in an explosive atmosphere. Use only battery pack and chargers specified in
Parts List. Do not insert any foreign objects into the battery charging jack. Do not insert any foreign objects into
the battery connection. Shorting the contacts will blow the protective fuse. DO NOT operate pump while
charging. Caution: Both charger and battery become warm during charging.
If the equipment can come into contact with aggressive substances, it is the responsibility of the user to take
suitable precautions that prevent it from being adversely affected, thus ensuring that the Intrinsic Safety
protection is not compromised. Aggressive substances are acidic liquids or gases that may attack metals, or
solvents that may affect polymeric materials or other solvents or corrosives. Suitable precautions are regular
checks as part of routine inspections and establishing from material data sheets that chemicals known to be
present do not affect material of the pump (polycarbonate, polyphenylene, epoxy).
DO NOT operate with a dirty or blocked inlet filter or kinked tubing. Pump failure or faulting may result.
If further translation is required, please contact the Sensidyne EU Authorized Representative (see Back Cover
for contact information).

Gilian 800i Air Sampling Pump
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Certification and Approvals

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SECTION ONE
Introduction
The Gilian 800i is a low flow rate sampling pump with extremely high back pressure capabilities. It offers user
programmability for easy, flexible preprogrammed sampling schedules, long battery life, Hazardous Area
certification for ATEX and US in all zones and gases, and fast charge capability.
This manual assumes that the pump is in the factory default state, with program and all options disabled.
Enabling the program or options can cause the pump to operate in a manner different than described in the
operation section of this manual. Operation with the program or options enabled is described in the applicable
section.
The features that can vary the behavior of the system are the user program capability.
An option of disable restart retry
An option to enter keyboard lock when a sample starts
An option to start a sample immediately when power is applied
An option to disable periodic flow adjust.
An option to disable periodic SCAL adjustments while sampling.
To reset pump to factory initialization state:
With the pump power on, hold down the Power/Enter Key, when “OFF” appears in
display press and hold “Clr” key. Clr will appear and flash. Continue holding key until
the display blanks. This procedure will disable all options, disable the program and
return the display calibration to the default setup.
Components
(1) Filter Housing Assembly (Inlet Port)
(2) Belt Clip
(3) Battery Charging Jack (with cover)
No Function

Gilian 800i Air Sampling Pump
7360-0166-01 - (Rev D)
(4) 4-button Keypad
(5) Indicator LED:
Green - Indicates Normal
Operation (Flow rate in
regulation)
Red –On at startup (PCA
indication)
(6) Liquid Crystal Display (LCD)

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360-0166-01 - (Rev D) 8
LCD Details
(6.1) Four 7-Segment Characters, indicating
Flow Rate, Time, Volume Sampled and
Messages.
(6.2) VOL & L. Indicates number in display is
sample volume in liters.
(6.3) MIN. Indicates number in display is
sample time in minutes.
(6.4) CC/MIN. Indicates number in display is a
flow rate in cc/minute
(6.5) SET. Indicates the Set/Cal button is active
to select the value shown in the numeric
display.
(6.6)FAULT. Indicates a Fault Condition
FAULT appears when pump is not able
to maintain set flow rate.
(6.6)HOLD. If pump is in fault for 30 seconds
continuously, pump enters HOLD and the
indicator appears.
(6.7) HRS. Indicates number in display is
duration in hours
(6.8)Battery Indicator.
3 bars = High charge
2 bars = Medium charge
1 bar = Low charge
no box = imminent shut down
(6.9) NOT USED
(6.10) The program has been enabled
(6.11) Indicates a program has been enabled
and will begin as soon as the pump is
started. The program controls the pump to
be off or on, depending on the program
setup and progress, even if the motor is
not running.
CC / MIN
L / MIN
VOL
.. .
6.1
6.2
6.3
6.4
6.8
6.7 6.5
6.6
6.11
6.10
6.9
HOLD
HRS
FAULT
SET PROG
IN MM

Gilian 800i Air Sampling Pump
9360-0166-01 - (Rev D)
SECTION TWO
Setup
2.1 Preparation
The battery pack must be fully charged before using pump. It takes about three hours to
charge the battery from complete discharge. Refer to Section Six for full battery
maintenance.
Attach Sensidyne Charger PN 298-0013-01 to power source or Five-Unit Power station.
Plug charger into battery charging jack. Charging cycle will begin immediately and will
complete as indicated by charger LED. Refer to charger labeling or Appendix D for full
details of LED functions.
Battery pack may be charged through built-in jack while attached to pump or separately.
The pump should not be used during charging.
Battery pack may be charged detached or while attached to pump, through built-in jack.
The pump should not be used during charging.
Caution
Both charger and battery pack become warm during charging.
DO NOT operate pump while charger is attached.
Do not short battery terminals. Shorting will blow internal fuse.
Charging and Battery removal should not be done in a hazardous location.

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2.2 Pump Start-Up
Power Up
Press and release POWER button
Display will illuminate and run a Start-up
Sequence, then enter Ready Mode
Start-Up Sequence (approx. 10 seconds):
Screen Test
This is a functional test of the entire display
HOLD
HRS FAULT SET PROG
IN MM
CC / MIN
L MIN
VOL
.. .
Version No.
Indicates the Version of Software installed in
pump (Current version may vary from picture.
Should show version from page 1.)
..
Last Cal screen
Shows number of run hours since last
calibration. If more that 200 hours have passed
since last calibration, the value is displayed for
twice as long and blinks.
HRS
If the AutoStart option is enabled, the pump will
start a sample immediately. If “dCLr” is
displayed, AutoStart was selected, but unable
to start because data must be cleared.
Ready Mode
In Ready Mode, display cycles through following
screens:
Flow Rate Set Point or, if AutoStart was
selected, the live flow rate.
CC / MIN
Total Sample Time of the current or last event.
MIN
Total Volume Sampled of the current or last
event.
LVOL
.
If no buttons are pushed, Ready Mode continues cycling through screens for 75 minutes
then pump turns off.

Gilian 800i Air Sampling Pump
11 360-0166-01 - (Rev D)
Power Down
Press and hold Power button until display
shows “OFF” (3-4 seconds), then release.
Pump will show “OFF” for a few seconds until it
powers down.
Holding Clr while “OFF” is displayed will reset all
calibrations and data to factory settings.
2.3 Setting The Flow Rate
NOTE
This section is required only if you are changing pump flow rate. If you’re using previously
set flow rate, simply verify it using a Reference Meter (see Section 2.4.2).
At Ready Mode, press SET/CAL button once.
“FLO” is displayed.
SET
Press ENTER button to begin setting the flow
rate.
CC / MIN

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Press ▲ button to increase flow rate set point
or ▼ button to decrease flow rate set point, in
1 cc/min increments.
Pressing and holding ▲ or ▼ button will change
setting rapidly after a short delay.
CC / MIN
Elapsed Time and Total Volume will be cleared.
When desired flow rate set point is reached
press ENTER button. Pump will return to Ready
Mode.
CC / MIN
MIN
LVOL
.

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2.4 Calibration
The pump should be calibrated every 200 run hours or 30 days, for optimum accuracy of
the displayed flow. Longer calibration intervals are allowable with different accuracy
specifications. See Appendix C. Calibration is also recommended when a new flow is
chosen. Entering calibration will reset the hours since last calibration.
2.4.1 Set-Up
Set up a flow reference instrument to measure the pump flow rate, such as a Gilibrator-2,
Gilibrator-3 or Go-Cal. The Gilibrator-2 is illustrated in this manual.
Choose a sample media of similar back pressure to that used in the field.
Attach 1/4” ID tubing from pump to media and from media to the reference meter.
To Reference Meter

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360-0166-01 - (Rev D) 14
2.4.2 Display Calibration
At Ready Mode, press SET/CAL button twice.
“CAL” is displayed
Press ENTER button to enter Calibration Mode.
“SCAL” (Self-Calibration) is displayed for 10
seconds, allowing the pump to establish a zero
reference for the flow control system. Pump will
then start running, and display the set flow rate.
CC / MIN
NOTE
To exit Calibration Mode without changing flow calibration, simply press ENTER. This
action will also reset the hours since last calibration, sample time and total volume
sampled.
Measure flow rate using reference meter.
FLO
AVERAG
SAMPLE#
cc
cc
Gilibrator 2
2
Charge

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15 360-0166-01 - (Rev D)
Adjust pump display to match actual
flow rate on reference meter. Press
▲ button to increase. Press and ▼
button to decrease.
SET
CC / MIN
When pump display matches
reference meter press SET button.
Pump motor continues running and
adjusts speed to deliver adjusted
flow rate. Pump display returns to
the originally selected flow set point.
CC / MIN
Continue to measure flow rate on
reference meter. If reference does
not match intended flow rate, you
may repeat Previous 2 Steps until
the actual flow rate is correct. When
the flow rate is correct, Proceed to
Next Step.
FLO
AVERAG
SAMPLE#
cc
cc
Gilibrator 2
2
Charge
CC / MIN
Press ENTER button to complete
calibration.
The pump stops and returns to
Ready Mode
Note On Field Calibration
The above display calibration procedure serves to make internal pump adjustments and
improve the accuracy of the flow display. It does not replace field calibration as described
by OSHA and NIOSH. A flow verification using the Gilibrator and the exact field sampling
train should be conducted before and after each field sample. Procedures for field
calibration may be referenced in the NIOSH Manual of Analytical Methods at
www.cdc.gov/niosh or in the OSHA Technical Manual at www.osha.gov.
=
?

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360-0166-01 - (Rev D) 16
SECTION THREE
Program
The program capability allows a time based sampling program to be set and executed.
From the time it is initiated until it completes the program or is canceled, the pump will use
the programmed time sequence to turn the pump on and off at specified intervals. All
programs specify the flow rate, run duration and an “OFF” between interval steps. Only the
first step has a delay time. If option 4 is enabled, the program will consist of a single run
interval. If option 4 is disabled (the default setting) the program consists of four sequential
program segments each specifying an on-period and off-period, ending with a cycle count
that will repeat the four on/off intervals the designated number of times.
Each on/off interval is set to a number of minutes. If any interval, other than the delay, is
specified as zero it terminates that cycle of the program, even if there are non-zero intervals
at later points in the program. After each cycle ends, the cycle count is evaluated and the
program terminates or the next cycle starts. Setting a cycle count of zero is not significant
and one cycle will be executed, exactly as if the cycle count were set to one.
At each interval there is an SCAL (Self-calibration), which takes ten seconds to establish a
zero reference for the flow control system. The pump does not run during the SCAL and
this time is not counted as part of the program or the sample.
If a flow fault occurs and the pump enters “HOLD”, the time that elapses while the pump is
halted is not counted in the sample runtime, but is counted by the program timer. During
this Fault Activated HOLD time, the unit will attempt to restart every 3 minutes. If the “on”
interval for a segment has not expired, Hold restarts are enabled, and the fault condition
has been corrected, the pump will restart and continue and complete the on-interval. If the
on-interval expires before the three minutes elapses, the pump will not restart as it has
entered the next off-interval. The pump will restart at the next on interval if one occurs. Up
to 10 restarts will be attempted before the program is terminated.
3.1 Programming
At Ready Mode, press SET/CAL button three
times. “Pro0”, program disabled or “Pro1”,
program enabled, is displayed.
PROG

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3.2 Program enable/disable
Press the ▲ button to enable Program Mode,
“Pro1” and “PROG” are displayed.
Press ▼ button to disable Program Mode.
“Pro0” is displayed.
NOTE: If program is not to be edited, press the
enter button repeatedly to advance through the
programming options and return pump to ready
mode.
PROG
3.3 Program Editing
The program capability is controlled by the Option 4 setting. If the option is disabled
(default) there are eleven program parameters. If Option 4 is enabled ("single run"), there
are three parameters. Program editing proceeds through each separate numeric
parameters. Press ENTER button to begin setting of parameters.
Press the ▲button to increase each parameter or ▼button to decrease each parameter.
Press the ENTER button to accept each setting and move to next parameter.
The parameters are as follows:
Note: If any interval is set to 0.000, the program will skip to the cycle count.
Parameter Name Display Parameter Range
Flow rate 0000 4.00-10.00 L/min
Delay Time before start d.000 0-999 minutes
Seg 1 On Time, Segment 1 1.000 0-999 minutes
Seg 1 Off Time, Segment 1 .000 0-999 minutes
Seg 2 On Time, Segment 2 2.000 0-999 minutes
Seg 2 Off Time, Segment 2 .000 0-999 minutes
Seg 3 On Time, Segment 3 3.000 0-999 minutes
Seg 3 Off Time, Segment 3 .000 0-999 minutes
Seg 4 On Time, Segment 4 4.000 0-999 minutes
Seg 4 Off Time, Segment 4 .000 0-999 minutes
Cycle count C.000 0-999 number of cycles to run
If a parameter is modified, the program is saved to non-volatile memory and preserved.
After the last parameter, the pump returns to Ready mode.
Disabled
Enabled

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SECTION FOUR
Options
Options allow the functionality of the pump to be modified. Each option can be set to
On (1) or Off (0). The option settings are stored in nonvolatile memory and preserved over
power down and battery changes.
The options are listed below, i.e. o.0.01 (Off) or o.1.01 (On).
Note: All options are set to the default (Off) at the factory.
4.1 Options List
Option
Option Title
Option Description
Default
01
Fault Hold Lock
If set to On, and the pump
goes into Fault for any reason,
the pump will be locked in
Fault Hold and will not try to
restart. If set to Off, the pump
will try to restart 3 minutes after
entering Fault Hold.
Off (0)
o.0.01
02
Auto Lock
If set to On, the program will
enter Keyboard Lock when a
manual or programmed
sample is started, The
keyboard can be unlocked as
described in section 5.4.
Off (0)
o.0.02
03
Auto Start
If set to On, the pump will start
a sample when turned on. If
sample data has not been
cleared, the pump will display
“dCLr” and enter idle mode.
Off (0)
o.0.03
04
Single Event Program
If set to On, the program will
specify flow rate, delay time
and a single on time ("Single
Event"). If set to off, the
program will be full length with
4 on/off segments and a cycle
counter.
Off (0)
o.0.04
05
SCAL disable
If set to On, there will be an
SCAL at run start, but not
during the run.
Off (0)
o.0.05