Emerson GDU-Incus User manual

Quick Start Guide
00825-0100-3003, Rev AA
August 2021
GDU-Incus
Ultrasonic Gas Leak Detector

Important instructions
Emerson designs, manufactures, and tests products to function within specific conditions. Because
these products are sophisticated technical instruments, it is important that the owner and operation
personnel strictly adhere both to the information printed on the product nameplate and to all
instructions provided in this manual prior to installation, operation, and maintenance.
WARNING
Installing, operating, or maintaining an Emerson product improperly could lead to serious injury or
death from explosion or exposure to dangerous substances.
Comply with all information on the product, in this manual, and in any local and national codes
that apply to the product.
Do not allow untrained personnel to work with this product.
Use Emerson parts and work procedures specified in this manual.
Authorized personnel for installing, operating, servicing, and maintaining the GDU-Incus are instructed
and trained qualified personnel of the operating company and the manufacturer.
It is the operating company's responsibility to:
•Train staff.
•Observe safety regulations.
•Follow the Reference Manual.
Operators must:
•Have been trained.
•Have read and understood all relevant sections of the Reference Manual before commencing
work.
•Know the safety mechanisms and regulations.
To avoid personal injury and loss of property, do not install, operate, maintain, or service this
instrument before reading and understanding this reference manual and receiving appropriate
training.
WARNING
Heavy instrument
The GDU-Incus weighs approximately 40 lb. (18 kg).
Take care when lifting and carrying the unit.
Ensure that all bolts and fixings selected for mounting are suitable for the weight and that the
wall, pole, or mounting surface is solid and stable.
WARNING
Physical access
Unauthorized personnel may potentially cause significant damage to and/or misconfiguration of end
users’ equipment. This could be intentional or unintentional and needs to be protected against.
Physical security is an important part of any security program and fundamental to protecting your
system. Restrict physical access by unauthorized personnel to protect end users’ assets. This is true for
all systems used within the facility.
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NOTICE
The contents of this publication are presented for informational purposes only and while every effort
has been made to ensure their accuracy, they are not to be construed as warranties or guarantees,
expressed or implied, regarding the products or services described herein or their use or applicability.
All sales are governed by Emerson's terms and conditions, which are available upon request. We
reserve the right to modify or improve the designs or specifications of such products at any time.
Emerson does not assume responsibility for the selection, use, or maintenance of any product.
Responsibility for proper selection, use, and maintenance of any Emerson product(s) remains solely
with the purchaser and end user.
To the best of Emerson's knowledge, the information herein is complete and accurate. Emerson makes
no warranties, expressed or implied, including implied warranties of merchantability and fitness for a
particular purpose with respect to this manual and, in no event, shall Emerson be liable for any
incidental, punitive, special, or consequential damages including, but not limited to, loss of
production, loss of profits, loss or revenue, or use and costs incurred including without limitation for
capital, fuel and power, and claims of third parties.
Product names used herein are for manufacturer or supplier identification only and may be trademarks
or registered trademarks of these companies.
All rights reserved. No part of this work may be reproduced or copied in any form or by any means
graphic, electronic, or mechanical without first receiving written permission of Emerson, Shakopee,
Minnesota, United States.
Contents
Introduction.................................................................................................................................5
Installation................................................................................................................................... 7
Operation...................................................................................................................................29
HART® functionality................................................................................................................... 41
Product certifications................................................................................................................. 42
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1 Introduction
1.1 Product overview
The GDU-Incus is an ultrasonic gas leak detector used for detecting airborne
ultrasound generated from pressurized gas leaks. Airborne ultrasound is
generated when gas moves from a high pressure area to a low pressure area
with a ratio in excess of 1.8 to 1 upstream to downstream. However,
Emerson only recommends this detector for pressures above 2 bar (30 psi)
gauge. The intensity of airborne ultrasound generated is dependent on a
number of factors including gas pressure, gas leak size, and gas
temperature.
The detector uses four individual Piezo ceramic sensing heads designed
using a patent-pending floating crystal design. The sensor design makes the
sensing heads virtually indestructible and totally immune to temperature,
moisture, and other contaminants found in hazardous areas. The detector
uses a continuous electronic monitoring test feature to ensure complete
functionality.
The detector has a large dynamic range, which allows use in a wide range of
applications, from offshore platforms to gas transportation systems. The
multi-stage amplifier ensures a linear output across the entire detector
range without drop-off at each end of the range.
The detector is not designed to detect specific gas types, LEL, or ppm. It
responds instantaneously to the ultrasound produced by a wide range of gas
leak sizes and remains unaffected by even the most extreme weather
conditions. The detector is rated to IP66/IP67 and NEMA® Type 4X to
withstand harsh environments.
The detector is supplied with a 4-20 mA analog output, a HART® interface,
and two configured relays.
1.2 Service support
For technical support, contact your Emerson representative or email
[email protected].
The Response Center will ask for product model and serial numbers and will
provide a Return Material Authorization (RMA) number.
The Response Center will also ask for the installation and application details.
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WARNING
Hazardous substances
Individuals who handle products exposed to a hazardous substance can
avoid injury if they are informed of and understand the hazard. If the product
being returned was exposed to a hazardous substance as defined by the
Occupational Safety and Health Administration (OSHA), a copy of the
required Safety Data Sheet (SDS) for each hazardous substance identified
must be included with the returned goods.
1.3 Product recycling/disposal
Consider recycling equipment and packaging. Dispose of the product and
packaging in accordance with local and national legislations and regulations.
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2 Installation
2.1 Safety messages
Instructions in this section may require special precautions to ensure the
safety of personnel performing the operations.
WARNING
Failure to follow these installation guidelines could result in death or serious
injury.
Ensure that only qualified personnel perform the installation.
The area in which the detector is mounted must be in accordance with
the certification of the apparatus and in accordance with local or national
standards.
Do not modify the enclosure or component parts; this will compromise
the Hazardous Area Certification.
Ensure that all wiring and power supply to the detector is within specified
operating parameters.
Except for the terminal cover, the GDU-Incus is a sealed unit. The main
enclosure may be opened only by Emerson or Emerson-authorized
personnel. All warranties and certifications are nullified if the seals are
tampered with or broken.
The GDU-Incus is supplied without cable glands. Ensure that all cable
entry threads are sealed with an appropriate plug to eliminate water
ingress and thread damage. At installation, remove all shipping cable
entry plugs and replace them with approved Ex d cable glands or
blanking plugs to meet hazardous locations requirements. If the
detector is to be installed in a Zone 1 Hazardous Area, an Ex d barrier seal
must be used.
WARNING
Electrical hazard
Electrical shock could cause death or serious injury.
Use extreme caution when making contact with leads and terminals.
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CAUTION
Equipment damage
Identification tags must be firmly secured to the GDU-Incus bracket to
prevent unwanted, locally-generated, ultrasonic noise. Refer to Figure 2-1.
2.2 Unpack and inspect
Procedure
1. Carefully remove all components from the packaging.
2. Verify the components against the enclosed packing list.
3. Inspect all components for obvious damage, such as broken or loose
parts.
4. If any components are missing or damaged, contact your local
Emerson representative or the factory immediately.
2.3 Dimensions
Refer to Figure 2-1 for the dimensions of the GDU-Incus.
Note
Dimensions are in millimeters (top number) and inches (bottom number).
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Figure 2-1: Dimensions
A. Suitable for M10 or equivalent
B. Main body enclosure (housing)
C. Standard mounting bracket shown. U-bolt kits (for pole mounting) and a
"DNV" certified bracket are available.
D. Display
E. Sensor head (four positions)
F. Customer cable entry position available for dual entry/relay output
(ATEX/IECEx units only)
G. Terminal compartment housing
H. Customer cable entry M20 standard. M250.5 in (13 mm) NPT or 0.75 in
(19.0 mm) NPT alternative
I. Identification tag (sold separately) can be mounted on either side of
bracket using holes provided.
J. Top body enclosure (housing)
2.4 Installation procedure
Emerson recommends mounting the GDU-Incus between 10 and 16 ft. (3
and 5 m) above the floor level to eliminate ground reflections and
absorption. You may mount the detector lower than 10 ft. (3 m), but that
may reduce the coverage; contact an Emerson representative for more
details.
Check the area of installation for equipment capable of generating high
levels of spurious airborne noise that would not be classified as "normal
background noise", such as pressure release valves, etc. If any are present in
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the detector range of coverage, contact Emerson or monitor the detector
when activated to ensure immunity.
2.4.1 Mechanical installation
The detector incorporates a dedicated flameproof terminal compartment
certified to Ex d and a flameproof main electronics compartment certified to
Ex d, both sealed to IP66/IP67.
CAUTION
Take care when removing the terminal cover during installation to ensure
that the flamepath surfaces are not scratched or damaged. See Wire the
detector for more information.
The detector has a large detection radius capability; take care when
positioning it to use the maximum coverage while eliminating blind spots
and spurious alarms.
The detector has a variety of mounting options to incorporate installation
into most situations in industrial environments, such as wall/flat surface
mounting (Mount to wall or flat surface), vertical pole mounting (Mount to a
pole), and mounting in an environment where DNV certification is required
(Mount DNV certified detector).
The detector should be mounted so that the four sensor heads are pointing
vertically downwards towards the floor or ground. See Figure 2-2.
Figure 2-2: Three-Dimensional View of Detector Coverage.
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The detector uses four independent sensor heads for full coverage. Figure
2-2 shows a three-dimensional view of the coverage (detector not to scale)
at a 10-ft. (3 m) height above floor level with the detector pointing vertically
downwards. The detector coverage is specified as meters radius at the floor
level, as this is the minimum sensing distance. As shown, the entire area
below the detector is covered, as well as some of the area above and around
the detector. Each sensor overlaps the next, so multiple sensors cover areas
underneath the detector.
2.5 Mounting
2.5.1 Mount to wall or flat surface
When mounting on a vertical flat surface, such as a wall with no significant
vibration, use the standard mounting bracket supplied with the detector. If
you suspect vibration at the fixing point, contact an Emerson representative
for additional options.
Figure 2-3: Wall/Flat Surface Mounting Diagram
Dimensions in mm.
A. Wall mounting bracket
B. Standard bracket
C. Floor
D. Vertical mounting locking fastener, typical both sides
E. Roof
F. See Step 3.
G. See Step 2.
H. See Step 1.
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Note
GDU-Incus assembly weight: approximately 40 lb. (18 kg). Ensure fixings are
capable of supporting assembly weight and local standards for shock
loading.
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Figure 2-4: Wall Mounting Drilling Template
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Figure 2-4 shows the position of the mounting slots on the wall mounting
bracket supplied with the standard GDU-Incus. Drill pairs of Ø 0.4-in. (10
mm) holes on the mounting surface between 1.2 in. (30 mm) and 2.8 in. (70
mm) apart, with a vertical distance of 7.48 in. (190 mm) between the two
pairs of holes.
Procedure
1. Attach wall mounting bracket to wall of flat horizontal support using
four M10 bolts.
2. Position the detector so that the standard bracket is on the studs of
the wall bracket. Secure the brackets together using the two M10
nuts supplied.
3. Permanently fix the brackets together using the socket head bolts
and nuts supplied.
Make sure to use spring washers.
2.5.2 Mount to a pole
In large open areas, Emerson recommends mounting the detector on a pole
to take advantage of the large omni-directional detection coverage.
Mount the detector 10 to 16 ft. (3 to 5 m) high to eliminate reflections and
ground absorption. You may mount the detector lower than 10 ft. (3 m), but
coverage may be reduced; contact an Emerson representative for details.
Make sure the pole complies with local standards and is capable of
supporting the detector weight at the installation height, taking
environmental factors into consideration.
Attach the detector to the pole using two U-bolts fixed to the pole mounting
adapter (you can use the wall bracket for pole mounting if the pole is 1.5 to
2-in. (38.1 to 50.8 mm) diameter. Emerson suggests torquing to 45 Nm, but
use local standards in the first instance.
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Figure 2-5: Pole Mounting Diagram
A. See Step 1.
B. See Step 2.
C. See Step 3.
D. Floor
E. Vertical mounting locking fastener
F. Roof
G. Pole mounting adapter
Note
Specify U-bolt and pole mounting adapter size at time of order. Standard
parts are available for tube sizes from Ø 1.5 in. (38.1 mm) to 4 in. (101.6
mm).
Weight of detector is 40 lb. (18 kg) approximately. Specify free-standing
pole size to support the detector to local standards. Ensure calculations
employ suitable civic factor of safety to support extended weight at
detection height. Ensure nyloc fixing nuts are tightened to 45 Nm or to
applicable local standards.
Procedure
1. Attach pole mounting adapter to pole using two M10 U-bolts. Secure
using nyloc nuts and/or spring washers.
2. Position the detector so that the standard bracket is on the studs of
the pole adapter. Secure the brackets together using the two M10
nuts provided.
3. Permanently fix the brackets together using the socket head bolts
and nuts supplied.
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Use spring washers.
2.5.3 Mount DNV certified detector
When an installation requires equipment to be DNV certified, you must
mount the detector using a DNV mounting bracket.
Figure 2-6: DNV Mounting Diagram
A. Roof
B. Detector permanently locked in vertical position by 4X M10 bolts (one
either side and two on underside of bracket)
C. Floor
D. See Step 3.
E. See Step 2.
F. See Step 1.
G. DNV mounting bracket: GDU-02-412
Figure 2-6 shows the mounting arrangement for DNV installation. Torque all
bolts to 45 Nm and use spring washers in all cases.
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Figure 2-7: DNV Mounting Drilling Template
Figure 2-7 shows the position of the mounting slots on the DNV mounting
bracket supplied with the DNV detector. Drill pairs of Ø 0.4-in. (10 mm)
holes between 2.8 in. (70 mm) and 3.5 in. (90 mm) apart, with a vertical
distance of 3 in. (75 mm) between the two pairs of holes.
Procedure
1. Attach DNV mounting bracket directly to wall or flat horizontal
support using 4 M10 bolts as shown.
Use spring washers.
2. Rest the detector on the flat base plate of the DNV bracket and
secure using M10 bolts either side, making sure to use spring
washers.
3. Secure the detector to the base plate using two M10 bolts, making
sure to use spring washers.
2.6 Terminal compartment wiring
WARNING
Failure to follow these installation guidelines could result in death or serious
injury.
Ensure that only qualified personnel install the detector.
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WARNING
Electrical shock could cause death or serious injury.
Use extreme caution when making contact with the leads and terminals.
Do not open the detector's enclosure in a classified area or where an
explosive atmosphere may be present unless the power to the detector
has been removed.
The detector's terminal cover is certified to flameproof standards; do not
open it while energized.
NOTICE
Connect the detector housing to local ground via the external earth point as
shown in Figure 2-12. Make sure the ground wire is a minimum of 4 mm2 (8
AWG) and as short as possible. Make sure termination at the detector is
suitable for M6 (0.25-in.) fastener. Ensure earth wire is attached using the
supplied spring washer.
The standard GDU-Incus is temperature rated between -40 and +185 °F (-40
and +85 °C), and the heated variant is temperature rated between -67 and
+185 °F (-55 and +85 °C). Ensure that all cable is rated to the appropriate
temperature of installation.
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2.6.1 Wire the detector
NOTICE
Wiring codes and regulations may vary. Wiring must comply with all
applicable regulations relating to the installation of electrical equipment in a
hazardous area and is the installer's responsibility. If in doubt, consult a
qualified official before wiring the system.
In applications where wiring is installed in a conduit, do not use the conduit
for wiring to other equipment.
For full EMC requirements, ensure incoming cables are threaded through the
ferrite beads (provided with the detector). See Figure 2-8.
Figure 2-8: Ferrite Bead Locations
A. Thread cable through ferrite
B. Ferrite
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Procedure
1. To gain access to the terminal compartment, undo the six terminal
cover fixing screws and raise the terminal cover vertically until clear
of the main enclosure.
The terminal cover is held in place with a stainless steel wire. You can
lower the terminal cover to the side of the detector during
installation, but take care to ensure the flame path is not damaged.
Refer to Figure 2-9 for the flamepath details.
Figure 2-9: Flame Path Details
A. Terminal cover
B. Flame path
C. O-ring
2. Seal the terminal compartment with two O-rings to prevent water
ingress.
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