Sensidyne Gilian BDX-II User manual

Gilian BDX-II
Air Sampling Pump
Operation Manual
1000 112TH Circle N, Suite 100 • St. Petersburg, Florida 33716 USA
[phone] • [phone] • [phone] [FAX] • www.sensidyne.com
REF 360-0136-01 (Rev E)

Gilian® BDXII ABATEMENT AIR SAMPLING PUMP
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PACKINGLIST
The items listed below are shipped with the Gilian BDXII Abatement Air Sampler:
•BDXII Abatement Air Sampler
•Tool Kit
•Tubing
•Operation and Service Manual
ALWAYS check to make certain
You have received all of the items listed above.
If you have any questions or need assistance, contact your
Sales Representative, or call
[phone]
OR
[phone]

Gilian® BDXII ABATEMENT AIR SAMPLING PUMP
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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
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
© 2005, © 2008 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 prior written permission of Sensidyne, LP.
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.
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’ LIABIL- ITY 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.

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TABLE OF CONTENTS
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

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TABLE OF CONTENTS
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................................................................................................................. 22
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

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WARNINGS
READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE
This product is intended for use in abatement air sampling for asbestos or lead removal projects. It is not
designed for use with low flow modules, and it is not recommended for use with cyclones or impactors that
require constant flow control.
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 laws and
regulations, including OSHA. Ensure complete compliance with ALL applicable laws and regulations before and
during use of this product.
UNDER NO CIRCUMSTANCES should this product be used except by qualified, trained, technicallycompetent
personneland notuntilthewarnings, Operation and Service Manual ,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 this product or
using its accessories, in order to ensure proper and safe use and installation of this 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.
DO NOT operate this product should it malfunction or require repair. Operation of a malfunctioning 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 the ServiceDepartmenttoarrange
for a Returned Material Authorization(RMA).
Use ONLY genuine Sensidyne replacement parts when performing anymaintenance procedures described in this
manual. Failure to do so may seriously impair instrument performance. 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.
DO NOT operate in excessive chemical or water vapor atmospheres. Failure to follow instructions may cause
permanent damage to the equipment.
The BDXII Abatement Air Sampling Pump employs rechargeable Nickel-Cadmium or
Nickel-Metal-Hydride 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 operate the unit with a dirtyor blocked inlet filter. This can cause pump failure or faulting.
DO NOT drop, crush, or roughly handle the unit, and NEVER submerge the unit in water. This can cause pump
failure or faulting.
DO NOT run the pump beyond its recommended specifications.

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SECTION ONE
Introduction
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 sampling, though sampling for
emissions, dusts, fumes, and mists is also possible.
The BDXII is designed for maximum utility, simplicity of operation, long service life, and
extreme ease of maintenance. Features of the BDXII Abatement Air Sampler include:
•Long life, rechargeable battery pack
•Battery pack rechargeable while attached 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 battery pack. The
BDXII is shown in Figure 1.1 and Figure 1.2.
The BDXII sampler is equipped with a basic 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) readjustments
needed over an 8-hour period. However, heavy filter media loading may make more frequent
readjustments necessary.
The internal/external vent control is located on the top of the sampling pump. You may select
the venting control as desired, using the screwdriver provided with the pump. Selecting the
open circle position will vent the pump’s discharge external to the sampler’s case
(recommended for moist or corrosive sampling environments). Selecting the closed circle will
vent the pump’s discharge internally (recommended for dust laden environments).

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Figure 1.1
BDXII Abatement Air Sampler (Front view)

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Figure 1.2
BDXII Abatement Air Sampler (Side view)

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SECTION TWO
Operation
2.1 INTRODUCTION
Before using the BDXII for sampling, the unit must be properly prepared. This includes
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 electronic bubble meter (e.g., Gilibrator-2), or a precision rotameter
that has been calibrated against an electronic bubble meter.
When a sampling train requires the use of an unusual combination of sampling media (such
as a glass fiber filter preceding an impinger), these sampling media should be installed in-line
during calibration.
2.2 CALIBRATION (FLOW ADJUST)
To ensure proper operation of the BDXII Abatement Air Sampling Pump, the unit should be
properly calibrated prior to sampling.
The calibration (flow adjust) is recommended using a Gilibrator-2 precision electronic
flowmeter. If you use a precision bubble meter other than the Gilibrator-2, make certain you
follow the instructions 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 appropriate filter for
the sampling method. Compress the cassette by using a mechanical press or other means
of applying 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.

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Figure 2 .1
BDXII Pump Calibration (Flow Adjust )

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4) Move the On/Off switch to the On position.
5) Set the pump flow rate by turning the flow adjust screw (clockwise for increased flow and
counterclockwise for decreased flow).
6) Use the built-in rotameter on the BDXII as a flow indicator only. Accurate 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 (i.e. a filter cassette) 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.
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 calibration (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 device used (see Section Three).

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3.1 GENERAL MAINTENANCE
The BDXII Abatement Air Sampling Pump is relatively maintenance free. Most maintenance
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 excessively dirty,
replace the internal filter.
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-Metal-Hydride batteries.
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
incumbent 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 assembly. Note that the
charging plug is polarized to prevent improper insertion.
CAUTION
Do not short the battery terminals or the charging jack. Shorting will result in
irreversible damage to the battery pack.
The battery pack may be charged while attached to the unit or charged separately. Figure 3.1
shows how to remove the battery pack for battery pack replacement or for charging the pack
separately from the unit.
NOTE
The BMS Multi-Station Charger has a single and double discharge mode (Single
Evaluation and Double Evaluation) designed to enhance the performance of Nickel-
Cadmium batteries. Excessive use of these discharge/charge features will needlessly
shorten battery life. We recommend use of the Double Evaluation mode for
maintenance only (maximum once monthly) for use with Nickel-Cadmium batteries.
These modes offer no advantage with Nickel-Metal-Hydride batteries.

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Figure 3 .1
Battery Pack Removal

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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 battery should last. The estimated
battery life is based on proper battery maintenance.
• Leakage Current
Nickel-Metal-Hydride batteries always have a small internal leakage current. If the battery
pack has been removed from the charger for more than two days with-out 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.
3.2.2 Available Battery Chargers
• Single-Unit Charger
Single unit chargers provide a constant-rate charge of 194 mA and can fully charge a BDXII
battery pack in 16 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 15
hours. The unit automatically switches to trickle charge (41mA) as each battery pack
becomes fully charged.
• BMS Multi-Station Charger System
The BMS Multi-Station Charger & Diagnostic 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 under 14 hours. The
diagnostic programs provide accurate test data regarding battery voltage under load and
battery capacity.
WARNING
DO NOT use the BMS-200 charger to charge Ni-MH battery version pumps.
Use ONLY the BMS II-100CE model with
Ni-MH battery models to prevent permanent damage to the batteries
Pump Usage
Weekly Use
Es. Battery Life†
High Medium
40-60 hours
1-1.5 years
Low
20-39 hours
1.5-2.5 years
< 20 hours
over 2.5 years
† Inactivity for extended periods may shorten battery lif e .
Table 3.1
Estimated Battery Life

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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 housing from the
unit.
4) Remove the filter O-ring from the filter housing. Remove and discard the old filter.
5) Insert a new filter in the filter housing. Make certain the filter is properly centered 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.
Table 3.2
Internal Filter Maintenance

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APPENDIX A
PARTS LIST
Part No.
Description
801863-7
Abatement Air Sampler (pump only) with Ni-MH Battery Pack **
783-0008-04
Rechargeable Battery Pack (Ni-MH) **
911-0601-US-R
Single Unit Charger (120V @ 50/60 Hz), Output: 194 mA
911-0601-EU-R
Single Unit Charger (230V @ 50/60 Hz), Output: 194 mA
811-9919-US
Universal Multi-Station Charger (115V 50/60 Hz), Output: 180 mA
811-9919-EU
Universal Multi-Station Charger (230 V 50/60 Hz), Output: 180 mA
380-0015-01
Tool Kit
201050-100
Replacement Filters (pkg of 100)
800556
Filter Kit
800142
Clip Assembly (3/8”)
200484
Tubing, 36”, ¼” ID
360-0136-01
Operation & Service Manual
* For further information onspare parts, please contact your
Customer Service Representative.
** See Section 3.2.2 regarding use ofBMS Chargerswith Ni-MH Batteries

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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 accuracy.
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-Metal-Hydride
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)
Certifications
Intrinsic Safety - UL 17G9
Class 1, Div 1, Groups A,B,C,D
Temp Code T3C

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APPENDIX C
TROUBLESHOOTING GUIDE
Cause
Remedy
• Pump is running but no flow (or reduced flow).
Internal filter may be clogged
Remove obstruction or replace filter.
• Unable to adjust flow rate to desired setting.
Sampling filter cassette is clogged.
Remove cassette. If flow is now adjustable,
replace filter cassette.
System may have leaks.
Check for leaks in tubing, assemblies, and
internal filter. Repair leaks or replace
assemblies, as necessary.
Improperly seated or damaged valves or
diaphragm
Return unit to factory for repair.
Pump motor is worn or damaged
Return unit to factory for repair.
• Flowmeter float appears to be “stuck”.
System may have leaks.
If float is stuck at bottom of flowmeter,
identify other symptoms (low or no flow with
pump running, etc.) and follow direction
accordingly.
Float is stuck.
Return unit to factory for repair.
• Pump will not run for the specified battery charge life.
Battery pack not properly installed.
Disconnect battery pack and re-install it
properly.
Battery pack may be damaged or
discharged
Charge or replace battery pack, as needed.
Batteries may be exhibiting “memory.”
Allow battery pack to fully discharge.
FULLY recharge battery pack.
Pump motor is worn.
Return unit to factory for repair.