Emerson GDU-Incus Reference 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.

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.

Reference Manual	Contents
00809-0100-3003	December 2020

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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December 2020			00809-0100-3003
	6.9 ABS............................................................................................................................................		45
	6.10	Declaration of Conformity.......................................................................................................	46
	6.11	China RoHS tables....................................................................................................................	48
Appendix A	Theory of operation.................................................................................................		49

GDU-Incus

Reference Manual	Introduction
00809-0100-3003	December 2020

1 Introduction

1.1Product 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 patentpending 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.

1.2Service 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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1.3Product recycling/disposal

Consider recycling equipment and packaging. Dispose of the product and packaging in accordance with local and national legislations and regulations.

GDU-Incus

Reference Manual	Installation
00809-0100-3003	December 2020

2 Installation

2.1Safety 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.

2.2Unpack and inspect

Procedure

1.Carefully remove all components from the packaging.

2.Verify the components against the enclosed packing list.

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December 2020	00809-0100-3003

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.

2.3Dimensions

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)

GDU-Incus

Reference Manual	Installation
00809-0100-3003	December 2020

2.4Installation 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.

2.4.1Mechanical 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.

GDU-Incus

Reference Manual	Installation
00809-0100-3003	December 2020

2.5Mounting

2.5.1Mount 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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December 2020	00809-0100-3003

Figure 2-4: Wall Mounting Drilling Template

GDU-Incus

Reference Manual	Installation
00809-0100-3003	December 2020

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.

2.5.2Mount 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.

GDU-Incus

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