Emerson GDU-Incus User manual

Reference Manual
00809-0100-3003, Rev AD
December 2020
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.
In-depth specialist knowledge is required to work with and on the GDU-Incus.
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 49 lb. (22 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.
The Emerson logo is a trademark and service mark of the Emerson Electric Company.
Copyright © 2020 by Emerson, Shakopee, Minnesota, United States
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.
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Contents
Chapter 1 Introduction.............................................................................................................. 7
1.1 Product overview.........................................................................................................................7
1.2 Service support............................................................................................................................7
1.3 Product recycling/disposal...........................................................................................................8
Chapter 2 Installation.................................................................................................................9
2.1 Safety messages.......................................................................................................................... 9
2.2 Unpack and inspect..................................................................................................................... 9
2.3 Dimensions................................................................................................................................10
2.4 Installation procedure................................................................................................................11
2.5 Mounting...................................................................................................................................13
2.6 Terminal compartment wiring...................................................................................................18
2.7 External cables...........................................................................................................................25
2.8 External ground......................................................................................................................... 26
2.9 Commissioning..........................................................................................................................27
Chapter 3 Operate....................................................................................................................29
3.1 Normal operation...................................................................................................................... 29
3.2 Check sensor functionality.........................................................................................................34
3.3 Output options..........................................................................................................................34
3.4 Display.......................................................................................................................................35
3.5 4-20 mA output......................................................................................................................... 36
3.6 Fault outputs............................................................................................................................. 37
Chapter 4 HART® functionality.................................................................................................39
Chapter 5 Maintenance............................................................................................................41
5.1 Hand-held test...........................................................................................................................41
5.2 Troubleshooting........................................................................................................................41
5.3 Storage......................................................................................................................................41
5.4 Spare parts and accessories....................................................................................................... 41
Chapter 6 Certifications........................................................................................................... 43
6.1 Marking..................................................................................................................................... 43
6.2 ATEX..........................................................................................................................................44
6.3 IECEx..........................................................................................................................................44
6.4 FM (US & Canada)...................................................................................................................... 44
6.5 INMETRO................................................................................................................................... 45
6.6 EAC............................................................................................................................................45
6.7 KTL............................................................................................................................................ 45
6.8 DNV...........................................................................................................................................45
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6.9 ABS............................................................................................................................................ 45
6.10 Declaration of Conformity....................................................................................................... 46
6.11 China RoHS tables....................................................................................................................48
Appendix A Theory of operation................................................................................................. 49
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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 and a HART® interface.
1.2 Service support
To expedite the return process outside of North America, contact your Emerson
representative.
Within the United States, call the Emerson Response Center toll-free number
1-800-654-7768. This center is available 24 hours a day to assist with any needed
information or materials.
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.
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 Material Safety Data Sheet (MSDS) for each hazardous
substance identified must be included with the returned goods.
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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 shock could cause death or serious injury.
Use extreme caution when making contact with leads and terminals.
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.
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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
All dimensions are provided in millimeters.
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. M25 ½-in. national pipe thread (NPT) or ¾-in. NPT
alternative
I. Identification tag (sold separately) can be mounted on either side of bracket using holes
provided.
J. Top body enclosure (housing)
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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 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.
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Figure 2-2: Three-Dimensional View of Detector Coverage.
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.
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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
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.
Note
GDU-Incus assembly weight: 39.7 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 3.5
in. (90 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 39.7 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.
Use spring washers.
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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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