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Emerson GDU-Incus Reference Manual

Ultrasonic gas leak detector
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Reference Manual
00809-0100-3003, Rev AA
May 2019
GDU-Incus Ultrasonic Gas Leak Detector

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Summary of Contents for Emerson GDU-Incus

  • Page 1 Reference Manual 00809-0100-3003, Rev AA May 2019 GDU-Incus Ultrasonic Gas Leak Detector...
  • Page 3 HEAVY INSTRUMENT! The GDU-Incus weighs 49 lb. (22 kg) and therefore care must be taken when lifting and carrying the unit. Ensure all bolts and fixings selected for mounting are suitable for the...
  • Page 4 Emerson 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.
  • Page 5 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;...

  • Page 7: Table Of Contents

    Reference Manual Table of Contents 00809-0100-3003, Rev AA May 2019 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 ................
  • Page 8 Reference Manual May 2019 00809-0100-3003, Rev AA 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 ....................

  • Page 9: Section 1: Introduction

    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.

  • Page 10: Service Support

    Reference Manual May 2019 00809-0100-3003, Rev AA Service support Technical support for this product can be provided by contacting your local Emerson sales office or by contacting the Technical Support department at safety.csc@emerson.com Return of material To expedite the repair and return of this product, proper communication between the customer and the factory is important.

  • Page 11: Section 2: General Operation

    May 2019 Section 2: General operation The GDU-Incus is omni-directional and is recommended to be mounted between 10 to 16 ft. (3 to 5 m) 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.

  • Page 12: Section 3: Installation

    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 or Emerson authorized personnel. All warranties and certification are nullified if these seals are broken or tampered with.

  • Page 13: Installation Procedure

    Figure 3-1 Dimensions Installation procedure Mounting height of the GDU-Incus is recommended to be between 10 and 16 ft. (3 to 5 m) above the floor level to eliminate ground reflections and absorption. The GDU-Incus may be used lower than 10 ft.
  • Page 14 (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.
  • Page 15 Reference Manual 00809-0100-3003, Rev AA May 2019 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.

  • Page 16: Mounting

    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 representative for additional options.
  • Page 17 GDU-Incus. Pairs of Ø10 mm holes are to be drilled on the mounting surface between 30 mm and 70 mm apart, with a vertical distance of 190 mm between the two pairs of holes.

  • Page 18: Pole Mounting

    Figure 3-7 Pole Mounting Diagram In large open areas it is recommended that the GDU-Incus is pole mounted to take advantage of the large omni-directional detection coverage. The detector should be mounted 10 to 16 ft. (3 to 5 m) high to eliminate reflections and ground absorption.

  • Page 19: Mounting With Exe Junction Box

    Reference Manual 00809-0100-3003, Rev AA May 2019 3.4.3 Mounting with exe junction box Figure 3-8 Exe-Incus Mounting Diagram The Exe-Incus can either be wall or pole mounted as detailed above in sections 3.4.1and 3.4.2 respectively, however the bracket holding the exe junction box bracket must be located between the ‘wall mounting bracket’...

  • Page 20: Dnv Mounting

    May 2019 00809-0100-3003, Rev AA 3.4.4 DNV mounting Where an installation requires equipment to be DNV certified, the GDU-Incus must be mounted using a ‘DNV Mounting Bracket’ (Part Number GDU-02-412) as shown in Figure 3-9. Figure 3-9 DNV Mounting Diagram Figure 3-9 shows the mounting arrangement for DNV Installation.
  • Page 21 Reference Manual 00809-0100-3003, Rev AA May 2019 Figure 3-10 DNV mounting drilling template Figure 3-4 shows the position of the mounting slots on the DNV mounting bracket supplied with the DNV Incus. Pairs of Ø10 mm holes are to be drilled on the mounting surface between 70 mm and 90 mm apart, with a vertical distance of 75 mm between the two pairs of holes.

  • Page 22: Terminal Compartment Wiring (Non-Exe)

    The standard GDU-Incus is temperature rated between -40 °F and +185 °F (-40 °C and +85°C), and the heated variant is temperature rated between -67 °F and +185 °F (-55 °C and +85 °C). Ensure that all cable is rated to the appropriate temperature of installation.
  • Page 23 Ensure all cable gland and plugging devices are ingress protected to the same standard as the enclosure to maintain certification and are suitable for the size of cable used. If the GDU-Incus is to be installed in an ATEX ‘Zone 1’ Hazardous Area an Exd barrier seal must be used. All FM approved units (US and Canada) must be sealed within 18-in.
  • Page 24 Reference Manual May 2019 00809-0100-3003, Rev AA Figure 3-12 Flame path details Cable shield should be connected to instrument earth in the control room only unless extra RFI protection is required and all local and site grounding regulations are met in which case the shield is to be terminated to local ground via one of the internal earth points shown in Figure 3-13...
  • Page 25 Figure 3-13 GDU-Incus Terminal Compartment Diagram Figure 3-13 shows a view of the GDU-Incus with the terminal cover removed. For single entry enclosures customer cable entry is via position 1 whereas dual entry enclosures will use positions 1 and The terminals are separated into power and communications for terminal row 1 and relay outputs for...

  • Page 26: Wiring Configurations

    Reference Manual May 2019 00809-0100-3003, Rev AA 3.5.2 Wiring configurations Figure 3-14 Electrical Connection Drawing Refer to Figure 3-14 for descriptions of the cable entries for terminal rows 1 & 2. For standard 3-wire connection cables should be connected to Terminal Row 1 in positions +24 V, 0 V and current loop output connected to the mA terminal.

  • Page 27: Exe Junction Box Wiring (Exe-Incus Only)

    Reference Manual 00809-0100-3003, Rev AA May 2019 Exe junction box wiring (exe Incus only) The terminal compartment on the Exe-Incus unit is sealed at the factory and should not be opened on site. Instead, all wiring connections are made via the Exe junction box that is mounted adjacent to the Incus unit.

  • Page 28: External Cables

    Customer cable should be chosen in accordance with Hazardous Area Certification and applicable local regulations. Note: The GDU-Incus has a temperature rating of +85°C (185°F), when used in areas with an ambient temperature above +60°C (140°F) ensure cable has a rating that is equal to or exceeds the proposed maximum working temperature.

  • Page 29: Commissioning

    00809-0100-3003, Rev AA May 2019 Commissioning 3.9.1 Visual inspection Before powering the GDU-Incus, the following should be inspected. Refer to Figure 3-17 for key locations on the GDU-Incus when completing this inspection. • Ensure detector is correctly situated for area of detection.

  • Page 30: Power-Up

    RS485 commands for function setup and all relays will be energized or de-energized as per defaults. Note: If the GDU-Incus has been factory set for specific site requirements it is recommended to carry out the steps outlined in section...

  • Page 31: Section 4: Operation

    00809-0100-3003, Rev AA May 2019 Section 4: Operation Normal operation On power-up the GDU-Incus initializes a diagnostic check and then enters normal operation mode as per factory defaults supplied. Factory Op mode 71 settings; • 4-20 mA = 40-120 dB (Linear scale factor) •...
  • Page 32 If background levels are unknown, typical historical process background levels can be used along with a safety factor. Please contact an Emerson representative for historical values and guidance. Alarm levels can be set in the detector or at the control panel. Most installations set the alarm levels in the control system.

  • Page 33: Delay Time

    Reference Manual 00809-0100-3003, Rev AA May 2019 4.1.2 Delay time To avoid spurious alarms it is recommended that a delay time be used for non-toxic gas applications or when instantaneous detection is not required. The delay timer is activated from the point at which the alarm threshold is first exceeded.
  • Page 34 Reference Manual May 2019 00809-0100-3003, Rev AA Figure 4-3 Graph Showing no Alarm Activation with Spurious Noise Figure 4-3 noise 1 and 2 are spurious noise spikes of approx. 1.5 seconds, typical of man-made ultrasonic noise produced through normal maintenance procedures. Noise 3 is a longer spurious noise of approx.

  • Page 35: Automatic Self-Test

    Aim the transmitter at the sensor face from a known distance, The GDU-Incus display dB level will rise according to the hand held device used and distance. Check all four (4) sensors, if possible, by moving around the detector and repeating.

  • Page 36: Relay Options

    Display The GDU-Incus incorporates a 5 digit x 7 segment, 0.31-in. high x 0.16-in. wide (8 mm high x 4 mm wide) character LED display with red numerals as standard. During operation the real-time dB level is continuously shown while below the programmed alarm level and flashing when above the programmed alarm level.

  • Page 37: 4-20 Ma Output

    Figure 4-6 4-20 mA output values (example shows default Op-Mode 71) Figure 4-6 shows the 4-20 mA output values for GDU-Incus during normal operation and under various fault conditions. The value on the left side shows the mA output tolerance band, internal fault is set for a 1.0 mA output with a tolerance of 0.8 to 1.2 mA for example.

  • Page 38: Fault Outputs

    GDU-Incus should be returned to Emerson for repair. RS485 digital interface The GDU-Incus incorporates an RS485 digital interface which allows access to sensor status and setting information. The RS485 interface allows the device to communicate in a simple point to point configuration or as part of a larger, multi-drop network.

  • Page 39: Section 5 : Hart Functionality

    Variable (PV) measurement of Sound Pressure Level in units of dB. The Secondary Variable (SV) reports the internal case temperature (degrees Celsius) of the GDU-Incus. The Tertiary variable (TV) reports the temperature of the heated section of the Incus, if the Heater option is fitted, otherwise will report the same data as the Secondary Variable.

  • Page 40: Section 6: Maintenance

    106 dB at 1 m (3 ft). Using the GDU-01-TT handheld device makes testing the GDU-Incus and other types of ultrasonic detectors quick and cost effective as it may be undertaken at floor level at distances of up to 8 m (26 ft) (dependent on background noise) provided line of sight with the sensor can be achieved.

  • Page 41: Spare Parts And Accessories

    Reference Manual 00809-0100-3003, Rev AA May 2019 Spare parts and accessories 6.5.1 Spare parts Enclosure Fastener Kits. Terminal cover fastener kit. Consists of six terminal cover fasteners and retaining washers. Terminal Cover O-ring Upper Replacement terminal cover O-ring for upper position, standard. Terminal Cover O-ring Lower Replacement terminal cover O-ring for lower position, standard.

  • Page 42: Accessories

    Consists of two 10-liter nitrogen gas cylinders (150 BAR) and a high pressure gas regulator which are attached to a trolley for portability. Refer to individual accessory datasheets for further information or contact an Emerson representative. Description Part number Test Transmitter. Handheld rechargeable Ultrasonic Sound Emitter...

  • Page 43: Section 7: Specifications

    Reference Manual 00809-0100-3003, Rev AA May 2019 Section 7: Specifications General 7.1.1 Detection method Floating Piezo Ceramic – non consumable, non-ageing 7.1.2 Gases detected All pressurized gases, minimum leak pressure 2 bar (Gauge), leak size dependent 7.1.3 Self-test Continuous electronic check of sensor integrity 7.1.4 Calibration Factory set...

  • Page 44: Performance

    Reference Manual May 2019 00809-0100-3003, Rev AA Performance 7.3.1 Detection frequency range 25 kHz to 100 kHz 7.3.2 Dynamic range 40 dB to 120 dB SPL (In standard operating mode) 7.3.3 Response time Instantaneous (Less than 1 second with HART outputs;...

  • Page 45: Environmental

    Reference Manual 00809-0100-3003, Rev AA May 2019 Environmental 7.5.1 Storage temperature -67 °F to +185 °F (-55 °C to +85 °C) 7.5.2 Operating temperature Standard Unit: -40 °F to +185 °F (-40 °C to +85 °C) Heated Unit: -67 °F to +185 °F (-55 °C to +85 °C) 7.5.3 Relative humidity Humidity (operating): 0 to 100% relative humidity...

  • Page 46: Section 8: Certifications

    00809-0100-3003, Rev AA Section 8: Certifications Marking Figure 8-1 Nameplate locations The GDU-Incus has several areas that contain important information for installation and use which are detailed below. Figure 8-1 shows the position of the nameplate, certification plate, and the terminal cover plate.
  • Page 47 Reference Manual 00809-0100-3003, Rev AA May 2019 Figure 8-3 ATEX/IECEx Certification nameplate (Standard Incus) Figure 8-4 ATEX/IECEx Certification nameplate (Heated Incus Variant) Figure 8-5 FM Certification nameplate...
  • Page 48 Reference Manual May 2019 00809-0100-3003, Rev AA Figure 8-6 ATEX/IECEx terminal cover label Figure 8-7 FM terminal cover label Figure and Figure show the ATEX/IECEx and FM Terminal cover labels respectively. The thread sizes of the enclosure entries situated below the label are shown on the label. If the thread size box is empty the thread position is not machined.

  • Page 49: Atex

    Reference Manual 00809-0100-3003, Rev AA May 2019 ATEX II 2 G Ex d ib IIB+H T4 Gb IP66/IP67 -55°C/-40°C ≤ Ta ≤ +85°C ITS09ATEX16836X IECEx II 2 G Ex d ib IIB+H Gb T4 IP66/IP67 -55°C/-40°C ≤ Ta ≤ +85°C ITS 10.0004X FM (US &...

  • Page 50: Section 9: Ordering Information

    Reference Manual May 2019 00809-0100-3003, Rev AA Section 9: Ordering information Model Option Description GDU-INCUS Ultrasonic Gas Leak Detector Level 1 Conduit / Cable Entry -134 1 x ¾-in. NPT (cFMus approved only) -220 2 x M20 (STANDARD, Not Available for cFMus Certified Units) Level 2 Op.
  • Page 52 SAFETY.CSC@Emerson.com ©2019 Emerson. All rights reserved. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are property of their respective owners. The contents of this publication are presented for information purposes only, and, while effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability.

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