Sensidyne Gilian BDX-II Installation and operating instructions

Use only with specified
BDXII Battery Pack
(Part No. 801862)
Patent Pending
4
3
2
1
Made in USA by
®
Revision A • Document No. 801863M
16333 Bay Vista Dr. • Clearwater, FL 33760 • [phone] • [phone] [FAX]
OPERATION & SERVICE MANUAL

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
4
Document No. 801863M (Rev A)
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 INSTRUC-
TIONS 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’ LIABIL-
ITY HEREUNDER SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF ANY GOODS FOUND DE-
FECTIVE. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, IN-
CLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR USE OR FOR A PARTICULAR PURPOSE WHICH ARE EXPRESSLY DISCLAIMED.
PROPRIETARY NOTICE
This manual was prepared exclusively for the owner of the Gilian BDXII Abatement Air Sam-
pler. The material within this manual is proprietary information and is to be used only to under-
stand, 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 re-
produced 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, Inc.
COPYRIGHT NOTICE
©1997AllRightsReserved.Nopartofthisdocumentmaybereproduced,transmitted,transcribed,
storedinaretrievalsystem,ortranslatedintoanylanguageinanyformbyanymeanswithoutprior
written permission of Sensidyne, Inc.
TRADEMARK NOTICE
Sensidyne, the Sensidyne logo, Gilian and the Gilian logo are registered trademarks. These
trademarks are protected through use and registration in the United States. The trademarks and
service marks used in this document are the property of their respective companies and are used
only for informational and explanatory purposes.

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
Document No. 801863M (Rev A)
5
• PREFACE
• Packing List ...................................................................................................... 3
• Notices .............................................................................................................. 4
• WARNINGS ....................................................................................................... 7
SECTION ONE: INTRODUCTION
1.1 Overview ................................................................................................. 8
1.2 General Description ............................................................................. 8
SECTION TWO: OPERATION
2.1 Introduction ......................................................................................... 11
2.2 Calibration (Flow Adjust) .................................................................. 11
2.3 Operation .............................................................................................. 13
SECTION THREE: MAINTENANCE
3.1 General Maintenance.......................................................................... 14
3.2 Battery Maintenance ........................................................................... 14
3.2.1 Battery Charging ................................................................ 16
3.2.2 Available Battery Chargers ................................................ 16
3.3 Filter Maintenance .............................................................................. 17
TABLE OF
CONTENTS

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
6
Document No. 801863M (Rev A)
SECTION FOUR: APPENDICES
• Appendix A: Parts List .............................................................................. 18
• Appendix B: Specifications ..................................................................... 19
• Appendix C: Troubleshooting Guide .................................................... 20
• Appendix D: Returned Material Authorization
• Returned Material Authorization ............................................................ 21
• Service Options ...................................................................................... 21
LIST OF FIGURES
1.1 BDXII Abatement Air Sampler (Front View) ........................................... 9
1.2 BDXII Abatement Air Sampler (Side View) ........................................... 10
2.1 BDXII Pump Calibration (Flow Adjust) ................................................. 12
3.1 Battery Pack Removal............................................................................. 15
3.2 Internal Filter Maintenance .................................................................... 17
LIST OF TABLES
3.1 Estimated Battery Life ............................................................................. 16
TABLE OF
CONTENTS

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
Document No. 801863M (Rev A)
7
READ AND UNDERSTAND ALL WARNINGS BEFORE USE
Read and understand ALL warnings before using this product. Failure to read, understand, and
comply with ALL warnings could result in property damage, severe personal injury, or death.
Read and understand ALL applicable Federal, State, and Local environmental health and safety
lawsandregulations,includingOSHA.EnsurecompletecompliancewithALLapplicablelawsand
regulations before and during use of this product.
UNDER NO CIRCUMSTANCES should this product be used except by qualified, trained,
technicallycompetentpersonnelandnotuntilthewarnings, OperationandServiceManual ,labels,
and other literature accompanying this product have been read and understood.
The Operation and Service Manual must be read and understood by each user before operating
thisproduct orusing its accessories, inorderto ensure proper andsafeuse and installation ofthis
product and to ensure familiarity with the proper treatment and safety procedures in the event of
an accident.
DO NOT remove, cover, or alter any label or tag on this product, its accessories, or related
products.
DONOToperatethisproductshoulditmalfunctionorrequirerepair.Operationofamalfunctioning
product, or a product requiring repair may result in serious personal injury or death. DO NOT
attempt to repair or modify the instrument, except as specified in the Operation and Service
Manual .Contact theServiceDepartment toarrange for aReturned Material Authorization(RMA).
UseONLY genuineSensidyne replacementpartswhen performinganymaintenance procedures
describedin thismanual. Failureto do somayseriously impair instrumentperformance .Repair or
alteration of the product beyond the scope of these maintenance instructions, or by anyone other
than an authorized service person, could cause the product to fail to perform as designed and
persons who rely on this product for their safety could sustain severe personal injury or death.
DONOT operateinexcessive chemicalor watervaporatmospheres.Failureto followinstructions
may cause permanent damage to the equipment.
The BDX II Abatement Air Sampling Pump employs rechargeable Nickel-Cadmium batteries.
ALWAYS fully charge the battery pack before starting the pump.
DO NOT operate the unit with improperly maintained batteries. This can cause pump failure or
faulting.
DO NOT operatethe unit with a dirtyorblockedinlet filter. This cancausepumpfailure or faulting.
DONOT drop, crush,or roughly handlethe unit,and NEVERsubmergetheunit inwater.This can
cause pump failure or faulting.
DO NOT run the pump beyond its recommended specifications.
WARNINGS

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
8
Document No. 801863M (Rev A)
1.1 OVERVIEW
IMPORTANT
You must read this manual in its entirety to
ensure proper operation of your unit.
This manual contains basic information for
operating and maintaining the Gilian
BDXII Abatement Air Sampler. The BDXII
is capable of delivering up to 3.0 LPM of
sample air for periods exceeding 8 hours,
with a nominal head restriction of up to
20” of water. Primary application for the
Abatement Air Sampler is asbestos sam-
pling, though sampling for emissions,
dusts, fumes, and mists is also possible.
The BDXII is designed for maximum util-
ity, simplicity of operation, long service
life, and extreme ease of maintenance.
Features of the BDXII Abatement Air Sam-
pler include:
• Long life, rechargeable battery pack
• Battery pack rechargeable while at-
tached to unit, or separately
• Belt clip for portability and
convenience
• High impact Lexan plastic case
for durability
• Light weight construction for comfort
when unit is attached to belt
• Built-in, easily readable flowmeter
• Small, long life pump
1.2 GENERAL DESCRIPTION
The BDXII Abatement Air Sampler consists
of a pump contained in a Lexan plastic
case, electronic flow control system, a
pneumatic system, and a rechargeable bat-
tery pack. The BDXII is shown in Figure
1.1 and Figure 1.2.
The BDXII sampler is equipped with a ba-
sic control board, which contains the flow
control circuitry. The board also contains
the On/Off switch, and the flow control
potentiometer.
The pump will normally maintain set flow
within ±5%, with no more than two (2) re-
adjustments needed over an 8-hour pe-
riod. However, heavy filter media loading
may make more frequent readjustments
necessary.
The internal/external vent control is lo-
cated on the top of the sampling pump.
You may select the venting control as de-
sired, using the screwdriver provided with
the pump. Selecting the open circle posi-
tion will vent the pump’s discharge exter-
nal to the sampler’s case (recommended
for moist or corrosive sampling environ-
ments). Selecting the closed circle will
vent the pump’s discharge internally (rec-
ommended for dust laden environments).
SECTION ONE
INTRODUCTION

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
Document No. 801863M (Rev A)
9
Figure 1.1
BDXII Abatement Air Sampler (Front view)
Flow Adj.
On
Off
Use only with specified
BDXII Battery Pack
(Part No. 801862)
Patent Pending
4
3
2
1
INTERNAL/EXTERNAL
VENT CONTROL
OPEN CIRCLE: EXTERNAL
CLOSED CIRCLE: INTERNAL
FLOW ADJUST CONTROL
POWER SWITCH
ANTI-TAMPER DOOR
Made in USA by
®

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
10
Document No. 801863M (Rev A)
Figure 1.2
BDXII Abatement Air Sampler (Side view)
INTERNAL/EXTERNAL
VENT CONTROL
RECHARGEABLE
BATTERY PACK
BATTERY
CHARGING JACK
BELT CLIP
INTERNAL FILTER
ASSEMBLY
FILTER ASSEMBLY
SCREWS (4)

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
Document No. 801863M (Rev A)
11
2.1 INTRODUCTION
Before using the BDXII for sampling, the
unit must be properly prepared. This in-
cludes charging and calibrating the unit for
proper flow rate.
When charging the unit make certain that
the unit is fully charged. This provides the
unit with enough charge to complete a full
period of sampling. Follow the general
instruction provided in Section Three, as
well as the specific instructions provided
with the particular charging device used.
CAUTION
When charging the device, make certain the
AC outlet is nearby and readily accessible.
The BDXII should be calibrated before
and after each day of sampling. Calibration
should be performed using either an elec-
tronic bubble meter (e.g., Gilibrator-2), or
a precision rotameter that has been cali-
brated against an electronic bubble meter.
When a sampling train requires the use of
an unusual combination of sampling me-
dia (such as a glass fiber filter preceding
an impinger), these sampling media
should be installed in-line during calibra-
tion.
2.2 CALIBRATION (FLOW ADJUST)
To ensure proper operation of the BDXII
Abatement Air Sampling Pump, the unit
should be properly calibrated prior to sam-
pling.
The calibration (flow adjust) is recom-
mended using a Gilibrator-2 precision
electronic flowmeter. If you use a preci-
sion bubble meter other than the Gilibra-
tor-2, make certain you follow the instruc-
tions that came with your device.
Refer to Figure 2.1 and calibrate the pump
as follows:
1) Make certain the unit is properly
charged.
2) Using a small Phillips screwdriver,
back out the holding screw just
enough so the anti tamper cover plate
can be rotated 180°. This exposes the
On/Off switch and the flow adjust
screw (See Figure 1.1).
3) Assemble the cassette filter holder for
the sampling media. Use the appropri-
ate filter for the sampling method.
Compress the cassette by using a me-
chanical press or other means of ap-
plying pressure. Use shrink tape
around the cassette to cover joints and
prevent leakage. If a cassette adapter
is used, make certain it does not come
in contact with the backup pad.
SECTION TWO
OPERATION

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
12
Document No. 801863M (Rev A)
Figure 2.1
BDXII Pump Calibration (Flow Adjust)
GILIBRATOR 2
(or equivalent precision flowmeter)
FLOW
(LPM)
READ INSTRUCTIONS
Use only with specified
BDXII Battery Pack
(Part No. 801862)
CAUTION
Patent Pending
Made in USA by
®
4
Flow Adj.
On
Off
3
2
1
Adjust flow
on pump
BDXII ABATEMENT
AIR SAMPLER
ABATEMENT AIR SAMPLER

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
Document No. 801863M (Rev A)
13
2.3 OPERATION
Begin the sample run by switching the
On/Off switch to the On position. Secure
the front anti-tamper cover. The pump will
operate at the flow rate set at the last cali-
bration (flow adjustment). The sampling
run is terminated by moving the On/Off
switch to the Off position.
NOTE
It may be necessary to readjust the flow rate at
least 2 times during the sampling period in
order to maintain flow within ± 5% of the set
flow rate.
After sampling, remove the filter cassette
and prepare the cassette filter for analysis.
Replace the cassette filter with a clean
fresh filter.
Fully charge the battery pack (preferably
overnight) to ensure enough power to
complete the entire next sampling period.
The actual time to achieve a fully charged
battery pack depends on the charging de-
vice used (see Section Three).
4) Move the On/Off switch to the On po-
sition.
5) Set the pump flow rate by turning the
flow adjust screw (clockwise for in-
creased flow and counterclockwise for
decreased flow).
6) Use the built-in rotameter on the
BDXII as a flow indicator only. Accu-
rate flow adjustment settings must be
made by using a Gilibrator-2, or
equivalent flow calibration device, for
calibration measurements.
7) When calibrating the sampler for flow,
the sample collection device (cyclone,
impinger, filter cassette or sorbent
tube) should be in-line.
8) When the desired flow rate has been
attained, move the On/Off switch to
the Off position. The unit is now ready
for sample collection.

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
14
Document No. 801863M (Rev A)
3.1 GENERAL MAINTENANCE
The BDXII Abatement Air Sampling Pump
is relatively maintenance free. Most main-
tenance involves periodic inspection of
the unit, battery maintenance, and filter
maintenance.
General inspection involves checking the
unit for blockage and pump capacity as
follows:
1) Examine the unit for physical damage.
Make certain that all case components
and connections are tight.
2) Turn on the pump and check the
flowmeter.
3) If there is no flow, check all tubing for
blockage.
4) Check for gross contamination with
dust, mud, etc. If contaminated or ex-
cessively dirty, replace the internal fil-
ter.
5) Also, check the Troubleshooting
Guide (Appendix C) and make any
corrective action. If the problem still
exists, return the unit for repair (see
Appendix D for obtaining a Returned
Material Authorization).
3.2 BATTERY MAINTENANCE
The Gilian BDXII Abatement Air Sampler
uses rechargeable Nickel-Cadmium batter-
ies. The battery packs must be fully
charged and maintained properly to
achieve maximum pump run time. The
battery pack has an output of 4.8 Vdc and
a capacity of 1.8 ampere-hours. It is in-
cumbent upon the pump user to ensure
that the battery pack has enough charge to
complete the intended run time.
The BDXII battery pack is charged through
a built-in jack. The jack is located on the
side of the unit, below the internal filter as-
sembly. Note that the charging plug is po-
larized to prevent improper insertion.
CAUTION
Do not short the battery terminals or the charg-
ing jack. Shorting will result in irreversible
damage to the battery pack.
The battery pack may be charged while at-
tached to the unit or charged separately.
Figure 3.1 shows how to remove the bat-
tery pack for battery pack replacement or
for charging the pack separately from the
unit.
SECTION THREE
MAINTENANCE

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
Document No. 801863M (Rev A)
15
Figure 3.1
Battery Pack Removal
RECHARGEABLE
BATTERY PACK
BATTERY
CHARGING JACK
BATTERY PACK
SCREWS (2)

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
16
Document No. 801863M (Rev A)
3.2.2 Available Battery Chargers
• Single-Unit Charger
Single unit chargers provide a constant-
rate charge of 190 mA and can fully charge
a BDXII battery pack in 14 hours.
• Universal Multi-Station Charger
The Multi-Station Charger can charge up to
5 battery packs simultaneously. These
chargers provide a timed, constant-rate
charge of 180 mA and can fully charge a
battery pack in 16 hours. The unit auto-
matically switches to trickle charge
(45␣ mA) as each battery pack becomes
fully charged.
• BMS Multi-Station Charger System
The BMS Multi-Station Charger & Diagnos-
tic System can charge up to 5 battery packs
simultaneously. The BMS offers timed
charging that switches to a pulsed charge
when the battery pack reaches full charge
capacity. Batteries can be charged in un-
der 14 hours. The diagnostic programs
provide accurate test data regarding bat-
tery voltage under load and battery capac-
ity.
3.2.1 Battery Charging
• Battery Life
Battery life is usually measured in charge/
discharge cycles. Gilian battery packs are
capable of providing 300–500 charging
cycles. Since this is very difficult to track
over the life of the battery, Table 3.1 will
help you to anticipate how long the bat-
tery should last. The estimated battery life
is based on proper battery maintenance.
• Memory Effect
Nickel-Cadmium batteries will develop re-
duced capacity when the user does not
maintain the practice of fully discharging
or fully charging the battery after each use.
Memory effect takes time to develop and
usually can be eliminated with two dis-
charge/charge cycles.
• Leakage Current
Nickel-Cadmium batteries always have a
small internal leakage current. If the bat-
tery pack has been removed from the
charger for more than two days without
use, it will require additional charging to
restore it to full capacity. This process can
be repeated 2–3 times without causing
signs of memory effect.
Table 3.1
Estimated Battery Life
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Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
Document No. 801863M (Rev A)
17
Figure 3.2
Internal Filter Maintenance
3.3 FILTER MAINTENANCE
The BDXII internal filter should be
changed whenever it becomes clogged or
dirty. The condition of the internal filter is
visible through the clear window on the
filter assembly.
To change the BDXII filter, refer to Figure
3.2 and follow the steps below.
1) Make certain the pump is turned off.
2) Remove any tubing attached to the
pump.
3) Remove the 4 housing screws on the
filter housing. Remove the filter hous-
ing from the unit.
4) Remove the filter O-ring from the filter
housing. Remove and discard the old
filter.
CENTER O-RING (Orange)
FILTER O-RING (Black)
FILTER
FILTER
HOUSING
HOUSING
SCREWS (4)
5) Insert a new filter in the filter housing.
Make certain the filter is properly cen-
tered and flat.
6) Insert the filter O-ring in the filter
housing. Make certain the O-ring is
properly seated.
7) Reinstall the center O-ring (orange) in
its place on the pump. Make certain it
is properly seated.
8) Reinstall the filter assembly back on
the unit.
9) Insert and tighten the 4 screws.
Repeat this procedure on a periodic basis
or whenever the filter becomes clogged or
dirty.

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
Document No. 801863M (Rev A)
19
APPENDIX B
SPECIFICATIONS
General Specifications
Controls ............................................... Power Switch, Flow Control
Flow Indicator ..................................... Built-in rotameter, range 500–4000 cc/min,
with 500 cc/div @ ±20% Full Scale accu-
racy.
Additional Features ............................. See-through external filter housing, with
filter monitoring lens; built-in belt clip.
Dimensions ......................................... 3.6” (W) x 3.9” (H) x 2.0” (D)
90 mm (W) x 100 mm (H) x 51 mm (D)
Weight ................................................. 21 oz. (595 g)
Power Supply
Battery Pack ........................................ 4.8 volt, 1.8 amp hour
Battery Type ........................................ Rechargeable Nickel-Cadmium
Battery Charge Time ........................... 14–16 hours
Expected Battery Life † ....................... 300–500 charge/recharge cycles
Estimated Battery Life † ....................... 2.5 years (< 20 hours weekly use)
1.5–2.5 years (20–39 hours weekly use)
1–1.5 years (40–60 hours weekly use)
† Inactivity for extended periods may shorten nickel-cadmium battery life.
Battery life estimates are based on proper battery maintenance.
Operating Specifications
Operating Range ................................. 500–3000 cc/min (0.5–3.0 LPM)
Flow Control ....................................... ±5% of set point over an 8-hour period,
with no more than two (2) readjustments
when operating at 2.0 LPM.
Operating Duration (Full Charge) ...... 10 hours at 2.0 LPM, with an inlet pressure
of up to 20” of water at 21°C (70°F)
Operating Temperature ...................... -20°C to 45°C (-4°F to 113°F)
Storage Temperature .......................... -40°C to 45°C (-40°F to 113°F)
Charging Temperature ........................ 5°C to 45°C (41°F to 113°F)

Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
20
Document No. 801863M (Rev A)
APPENDIX C
TROUBLESHOOTING GUIDE
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Gilian®BDXII ABATEMENT AIR SAMPLING PUMP
Document No. 801863M (Rev A)
21
a price quotation is required before au-
thorization of the repair cost, understand-
ing that this invokes extra cost and han-
dling delay. Sensidyne’s repair policy is to
perform all needed repairs to restore the
instrument to its full operating condition.
Repairs are handled on a “first in - first
out” basis. Your order may be expedited if
you authorize an expediting fee. This will
place your order next in line behind or-
ders currently in process.
Pack the instrument and its accessories
(preferably in their original packing) and
enclose your return address, purchase or-
der, shipping and billing information, RMA
number, a description of the problem en-
countered with your instrument and any
special instructions. All prices are subject
to change without notice.
If this is the first time you are dealing di-
rectly with the factory, you will be asked
to prepay or to authorize a COD shipment.
Send the instrument, prepaid, to:
Sensidyne
16333 Bay Vista Drive
Clearwater, FL 33760 USA
Attention: Service Department
RMA #:_______________________
Sensidyne maintains an instrument service
facility at the factory to provide its custom-
ers with both warranty and non-warranty
repair service. Sensidyne assumes no li-
ability for service performed by personnel
other than Sensidyne personnel. To facili-
tate the repair process, please contact the
Sensidyne Service Department in advance
for assistance with a problem which can-
not be remedied and/or requires the re-
turn of the product to the factory. All re-
turned products require a Returned Mate-
rial Authorization (RMA) number.
Sensidyne Service Department personnel
may be reached at:
Sensidyne
16333 Bay Vista Drive
Clearwater, FL 33760 USA
727-530-3602
727-539-0550 [FAX]
All non-warranty repair orders will have a
minimum fee whether the repair is autho-
rized or not. This fee includes handling,
administration and technical expenses for
inspecting the instrument and providing
an estimate. However, the estimate fee is
waived if the repair is authorized.
If you wish to set a limit to the authorized
repair cost, state a “not to exceed” figure
on your purchase order. Please indicate if
APPENDIX D
RETURNED MATERIAL AUTHORIZATION
SERVICE OPTIONS
The Sensidyne Service Department offers you a variety of service options which will
help increase your user confidence while minimizing costly interruptions and
maintenance costs. These options include initial training, on-site technical assistance,
and full factory repairs. Sensidyne has developed several programs which will
allow you to select just the right options best suited to your applications and needs.
For further information, contact the Sensidyne Service Department.