Rosemount Incus Operating Manual

Part Number: MAN-GDU-INCUS, rev. 7

GDU-Incus Ultrasonic Gas Leak Detector

Reference Manual

Release: July 2015

Important Instructions

Emerson Process Management 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 must 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.

Installing, operating or maintaining an Emerson Process Management 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 Process
Management parts and work procedures specified in this manual.

In-depth specialist knowledge is an absolutely necessary condition for working with and on the GDU­Incus.

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 responsibility of the operating company to;

• train staff,

• observe safety regulations

• follow the instruction manual

Operators must;

• have been trained

• have read and understood all relevant sections of the instruction 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 instruction manual and receiving appropriate training

HEAVY INSTRUMENT! The GDU-Incus weighs 22 kg (49 lb) and therefore care must be taken when
lifting and carrying the unit. Ensure all bolts and fixings selected for mounting are suitable for the
weight and that the wall, pole, or mounting surface is solid and stable.

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 Process Management’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 Process Management does not assume responsibility for the selection, use or maintenance of
any product. Responsibility for proper selection, use and maintenance of any Emerson Process
Management product(s) remains solely with the purchaser and end-user.

To the best of Emerson Process Management’s knowledge the information herein is complete and
accurate. Emerson Process Management 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 Process Management be liable for any incidental, punitive, special or
consequential damages including, but not limited to, loss of production, loss of profits, loss of 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/registered trademarks of these companies.

The Emerson logo is a trademark and service mark of the Emerson Electric Company.

Copyright © 2015 by Emerson Process Management, Slough, Berkshire, United Kingdom

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 Process
Management,

Slough, Berkshire, United Kingdom.

Warranty

1. Limited Warranty. Subject to the limitations contained in Section 10 (Limitation of Remedy

and Liability) herein, Seller warrants that (a) the licensed firmware embodied in the Goods will
execute the programming instructions provided by Seller; (b) that the Goods manufactured by
Seller will be free from defects in materials or workmanship under normal use and care; and (c)
Services will be performed by trained personnel using proper equipment and instrumentation
for the particular Service provided. The foregoing warranties will apply until the expiration of
the applicable warranty period. Sensors and detectors are warranted against defective parts
and workmanship as outlined in section 7.6. Products purchased by Seller from a third party for
resale to Buyer (Resale Products) shall carry only the warranty extended by the original
manufacturer. Buyer agrees that Seller has no liability for Resale Products beyond making a
reasonable commercial effort to arrange for procurement and shipping of the Resale Products.
If Buyer discovers any warranty defects and notifies Seller thereof in writing during the
applicable warranty period, Seller shall, at its option, (i) correct any errors that are found by
Seller in the firmware or Services; (ii) repair or replace FOB point of manufacture that portion of
the Goods found by Seller to be defective; or (iii) refund the purchase price of the defective
portion of the Goods/Services. All replacements or repairs necessitated by inadequate
maintenance; normal wear and usage; unsuitable power sources or environmental conditions;
accident; misuse; improper installation; modification; repair; use of unauthorized replacement
parts; storage or handling; or any other cause not the fault of Seller, are not covered by this
limited warranty and shall be replaced or repaired at Buyer’s sole expense and Seller shall not
be obligated to pay any costs or charges incurred by Buyer or any other party except as may be
agreed upon in writing in advance by Seller. All costs of dismantling, reinstallation, freight and
the time and expenses of Seller’s personnel and representatives for site travel and diagnosis
under this limited warranty clause shall be borne by Buyer unless accepted in writing by Seller.
Goods repaired and parts replaced by Seller during the warranty period shall be in warranty for
the remainder of the original warranty period or 90 days, whichever is longer. This limited
warranty is the only warranty made by Seller and can be amended only in a writing signed by an
authorized representative of Seller. The limited warranty herein ceases to be effective if Buyer
fails to operate and use the Goods sold hereunder in a safe and reasonable manner and in
accordance with any written instructions from the manufacturers. THE WARRANTIES AND
REMEDIES SET FORTH ABOVE ARE EXCLUSIVE. THERE ARE NO REPRESENTATIONS OR
WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, AS TO MERCHANTABILITY, FITNESS FOR
PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR
SERVICES.

2. Limitation of Remedy and Liability. SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY

DELAY IN PERFORMANCE. THE REMEDIES OF BUYER SET FORTH IN THE AGREEMENT ARE
EXCLUSIVE. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION
(WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER
TORT OR OTHERWISE), SHALL SELLER’S LIABILITY TO BUYER AND/OR BUYER’S CUSTOMERS
EXCEED THE PRICE TO BUYER OF THE SPECIFIC GOODS MANUFACTURED OR SERVICES
PROVIDED BY SELLER GIVING RISE TO THE CLAIM OR CAUSE OF ACTION. BUYER AGREES THAT
IN NO EVENT SHALL SELLER’S LIABILITY TO BUYER AND/OR BUYER’S CUSTOMERS EXTEND TO
INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. THE TERM
“CONSEQUENTIAL DAMAGES” SHALL INCLUDE, BUT NOT BE LIMITED TO, LOSS OF
ANTICIPATED PROFITS, REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT
LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF BUYER’S CUSTOMERS.

Reference Manual Table of Contents

MAN-GDU-INCUS Revision 7 July 2015

Contents

Section 1 : Introduction ............................................................................ 1

1.1 Product overview ................................................................................................................ 1

1.2 Service support ................................................................................................................... 2

1.3 Return of material ............................................................................................................... 2

1.4 Product recycling/disposal .................................................................................................. 2

Section 2 : General operation .................................................................... 3

Section 3 : Installation .............................................................................. 4

3.1 Unpacking and inspection .................................................................................................. 4

3.2 Dimensions ........................................................................................................................ 4

3.3 Installation procedure ......................................................................................................... 5

3.3.1 Mechanical installation ...................................................................................... 5

3.4 Mounting ........................................................................................................................... 8

3.4.1 Wall / Flat surface mounting ............................................................................... 8

3.4.2 Pole mounting ................................................................................................. 10

3.4.3 Mounting with Exe Junction Box ....................................................................... 11

3.4.4 DNV mounting ................................................................................................. 12

3.5 Terminal Compartment Wiring (Non-Exe) ......................................................................... 14

3.5.1 General ............................................................................................................ 14

3.5.2 Wiring configurations ...................................................................................... 18

3.6 Exe Junction Box Wiring (Exe-Incus Only) .......................................................................... 19

3.7 External cables .................................................................................................................. 20

3.8 External ground ................................................................................................................ 20

3.9 Commissioning ................................................................................................................ 21

3.9.1 Visual inspection .............................................................................................. 21

3.9.2 Power-up ......................................................................................................... 22

Section 4 : Operation .............................................................................. 23

4.1 Normal operation ............................................................................................................. 23

4.1.1 Alarm level ....................................................................................................... 23

4.1.2 Delay time ....................................................................................................... 25

4.1.3 Automatic self-test .......................................................................................... 27

4.2 Sensor functionality check ................................................................................................ 27

4.3 Output options ................................................................................................................. 27

4.3.1 Relay Options ................................................................................................... 28

4.4 Display ............................................................................................................................. 28

4.5 4-20 mA output ................................................................................................................ 29

4.6 Fault outputs .................................................................................................................... 30

4.6.1 2.0 mA Sensor test fault ................................................................................... 30

4.6.2 1.0 mA Internal process fault ............................................................................ 30

4.6.3 0.5 mA ‘All Sensors dead’ fault ......................................................................... 30

4.6.4 0 mA Major fault .............................................................................................. 30

4.7 RS485 digital interface ...................................................................................................... 30

Section 5 : HART functionality ................................................................. 31

Section 6 : Maintenance ......................................................................... 32

6.1 Handheld test ................................................................................................................... 32

6.2 Verification test ................................................................................................................ 32

6.3 Troubleshooting ............................................................................................................... 32

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6.4 Storage ............................................................................................................................ 32

6.5 Spare parts and accessories .............................................................................................. 33

6.5.1 Spare parts ....................................................................................................... 33

6.5.2 Accessories ...................................................................................................... 34

Section 7 : Specifications ........................................................................ 35

7.1 General............................................................................................................................. 35

7.1.1 Detection method ........................................................................................... 35

7.1.2 Gases detected ................................................................................................ 35

7.1.3 Self-test ........................................................................................................... 35

7.1.4 Calibration ....................................................................................................... 35

7.2 Output signal .................................................................................................................... 35

7.2.1 4 — 20 mA ........................................................................................................ 35

7.2.2 Digital .............................................................................................................. 35

7.2.3 Relay 1 ............................................................................................................. 35

7.2.4 Relay 2 ............................................................................................................. 35

7.2.5 HART® .............................................................................................................. 35

7.3 Performance ..................................................................................................................... 36

7.3.1 Detection frequency range .............................................................................. 36

7.3.2 Dynamic range ................................................................................................. 36

7.3.3 Response time ................................................................................................. 36

7.3.4 Detection coverage.......................................................................................... 36

7.3.5 Start-up time ................................................................................................... 36

7.4 Electrical ........................................................................................................................... 36

7.4.1 Operating voltage range .................................................................................. 36

7.4.2 Power consumption ......................................................................................... 36

7.4.3 Cable entry ...................................................................................................... 36

7.5 Environmental .................................................................................................................. 37

7.5.1 Storage temperature ....................................................................................... 37

7.5.2 Operating temperature .................................................................................... 37

7.5.3 Relative humidity ............................................................................................. 37

7.5.4 Metallurgy ....................................................................................................... 37

7.5.5 Ingress protection ............................................................................................ 37

7.5.6 Weight ............................................................................................................. 37

7.5.7 Dimensions ...................................................................................................... 37

7.6 Warranty .......................................................................................................................... 37

Section 8 : Certifications ......................................................................... 38

8.1 Marking ............................................................................................................................ 38

8.2 ATEX................................................................................................................................. 41

8.3 IECEx ................................................................................................................................ 41

8.4 FM (US & Canada) ............................................................................................................. 41

8.5 EAC .................................................................................................................................. 41

8.6 INMETRO .......................................................................................................................... 41

8.7 KCs ................................................................................................................................... 41

Section 9 : Ordering information ............................................................. 42

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Section 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 1.8:1 upstream to downstream, however, the GDU-Incus is only recommended
for pressures above 2 bar (30 psi) Gauge. The intensity of airborne ultrasound generated is dependent
on a number of factors including but not limited to gas pressure, leak size and gas temperature.

The GDU-Incus uses 4 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 industry. The GDU-Incus uses a
continuous electronic monitoring test feature to ensure complete functionality.

The GDU-Incus 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 GDU-Incus is not designed to detect specific gas types, LEL or ppm, but instead responds
instantaneously to the ultrasound produced by a wide range of leak sizes while being unaffected by
even the most extreme weather conditions. The GDU-Incus is rated to IP66/IP67, NEMA Type 4X to
withstand harsh environments.

The GDU-Incus is supplied with a 4-20 mA analog output, ‘multi-drop’ RS485 digital interface and a

®

interface.

HART

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1.2 Service support

Technical support for this product can be provided by contacting your local Emerson Process
Management sales office or by contacting the Technical Support department at

[e-mail]

1.3 Return of material

To expedite the repair and return of this product, proper communication between the customer and
the factory is important. Before returning a product for repair, e-mail [e-mail] for a
Return Material Authorization (RMA) number.

On the return of the equipment, include the following information:

1. RMA number provided to you by Emerson Process Management

2. Company name and contact information

3. Purchase order, from your company, authorizing repairs or request for quote

4. Ship all equipment, prepaid to:

Emerson Process Management
158 Edinburgh Avenue
Slough
Berkshire
SL1 4UE, UK

5. Mark all packages with Return for Repair and include RMA number

Pack items to protect them from damage and use anti-static bags or aluminum-backed cardboard as
protection from electrostatic damage.

All equipment must be shipped prepaid. Collect shipments will not be accepted.

1.4 Product recycling/disposal

Recycling of equipment and packaging should be taken into consideration and disposed of in
accordance with local and national legislations/regulations.

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Section 2: General operation

The GDU-Incus is omni-directional and is recommended to be mounted between 3 to 5 meters (10 to
16 feet) above the area of interest to eliminate ground absorption and reflections.

It is recommended that the area where the GDU-Incus is to be situated is ultrasonically mapped prior to
installation or at commissioning while all processes are running to establish a background noise level
for alarm purposes. The alarm level should be set above the background noise level. Please contact an
Emerson Process Management representative to request a mapping survey or mapping tools.

The GDU-Incus responds instantaneously to pressurized gas leaks or other sources of ultrasonic noise
between 25 kHz and 100 kHz. It is, therefore, recommended that a delay time is built in to the control
system or alternatively, programmed in the GDU-Incus when using it in standalone mode to prevent
spurious alarms. The delay time is recommended to be set at a minimum of fifteen (15) seconds but
this should be increased in response to the process located near to the detector as shown in the graph
in section 4.1.2.

The maximum area which can be monitored by a single GDU-Incus is affected by several factors such as
background (ambient) ultrasound level, gas pressure, leak size, temperature of the gas, and
environmental conditions. Emerson Process Management has formulated a series of calculations that
take all of these external factors into account and are able to determine accurate coverage information
for most installations. Please contact an Emerson Process Management representative to advise on
appropriate coverage for each installation.

The GDU-Incus detection coverage can be verified at installation or as part of a maintenance schedule
using the GDU-PTV Performance Target Verification Kit to simulate an actual gas release of known size
and pressure at the perimeter of the GDU-Incus detection radius. See section 6.5 for a listing of spare
parts and accessories or contact an Emerson Process Management representative for further details.

Compared to other Ultrasonic and traditional forms of detection, the GDU-Incus has the following
advantages:

 Gas does not need to reach the sensor for detection to occur
 Unaffected by weather conditions
 Sensors are unaffected by temperature, pressure, moisture, and contaminant build-up
 Multiple sensor redundancy in each unit
 Continuous self-test function
 No calibration required results in cost saving over detector lifecycle
 Can be remotely tested from up to 8 meter distance saving on maintenance scaffold costs
 4-20 mA Current Loop with HART communication as standard, plus relay outputs for ‘Fault’ and

‘Alarm’ conditions.

 Can operate standalone or as part of an interfaced control system.

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Section 3: Installation

The area in which the detector may be mounted must be in accordance with the certification of the
apparatus and in accordance with the standards of the appropriate authority in the country concerned.

Do not modify the enclosure or component parts as this will compromise the Hazardous Area
Certification.

Ensure all wiring and power supply to the detector is within specified operating parameters.

The GDU-Incus is a sealed unit with the exception of the terminal cover; the main enclosure is not to be
opened by anybody other than Emerson Process Management or Emerson Process Management
authorized personnel. All warranties and certification are nullified if these seals are broken or tampered
with.

The GDU-Incus is supplied without cable glands. Ensure all cable entry threads are sealed with an
appropriate plug to eliminate water ingress and thread damage. At installation, all shipping cable entry
plugs are to be removed and replaced with suitably approved Ex d cable glands or blanking plugs to
meet hazardous locations requirements. If the GDU-Incus is to be installed in a ‘Zone 1’ Hazardous Area
an Exd barrier seal must be used.

Identification tags must be firmly secured to the GDU-Incus bracket in the position shown on Figure 3-1
to prevent unwanted locally generated ultrasonic noise.

3.1 Unpacking and inspection

Carefully remove all of the components from the packaging and verify them against the enclosed
packing list. Inspect all components for obvious damage such as broken or loose parts. If you find any
components missing or damaged, notify your local Emerson Process Management representative or
the factory immediately.

3.2 Dimensions

Refer to Figure 3-1 for the dimensions of the GDU-Incus. Note: all dimensions are provided in
millimeters.

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Figure 3-1 Dimensions

3.3 Installation procedure

Mounting height of the GDU-Incus is recommended to be between 3 and 5 meters (10 to 16 feet)
above the floor level to eliminate ground reflections and absorption. The GDU-Incus may be used lower
than 3 meters (10 feet) but coverage may be reduced, please contact an Emerson Process
Management representative for more details.

Observe 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, please contact Emerson Process Management or
monitor the detector when activated to ensure immunity.

3.3.1 Mechanical installation

The GDU-Incus 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. Care should be
taken when removing the terminal cover during installation to ensure that the flamepath surfaces are
not scratched or damaged.

The GDU-Incus has a large detection radius capability and care should be taken when positioning to
utilise the maximum coverage while eliminating blind spots and spurious alarms.

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The GDU-Incus has a variety of mounting options to incorporate installation into most situations found
in industrial environments such as wall / flat surface mounting (refer to section 3.4.1), vertical pole
mounting (refer to section 3.4.2), and mounting in an environment where DNV certification is required
(refer to section 3.4.4).

The GDU-Incus can be mounted in any orientation (unless a DNV bracket is used which fixes the
detector in vertical orientation) but care should be taken to position the display facing an area where
the information can be easily viewed.

Figure 3-2 3D view of detector coverage

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The GDU-Incus utilizes 4 independent sensor heads for full coverage. Figure 3-2 shows a 3D view of the
coverage (detector not to scale) at a 3m (10 foot) height above floor level with the detector pointing
vertically downwards. The GDU-Incus 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 areas underneath the
detector are covered by multiple sensors.

Figure 3-3 shows a 2D view of coverage when the detector is mounted vertically downwards and

highlights that the radius coverage stated is the minimum area covered.

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Figure 3-3 2D view of detector coverage

Figure 3-4 Coverage when mounted at an angle

Figure 3-4 shows coverage when the detector is mounted at an angle. This method is recommended

when the detector is mounted close to a wall or in an enclosed space to increase the coverage area.

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3.4 Mounting

3.4.1 Wall / Flat surface mounting

Figure 3-5 Wall/Flat surface mounting diagram

When mounting on a vertical flat surface such as a wall with no significant vibration it is sufficient to use
the standard mounting bracket supplied with the GDU-Incus. If vibration at fixing point is suspected,
please contact an Emerson Process Management representative for additional options.

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