Honeywell HON 380 Instruction Manual

HON 380 gas pressure
regulator with
HON 673/674 controller
User and maintenance instructions
Spare parts

Contents
HON 380 gas pressure regulator with HON 673/674 controller 2
Contents
1General considerations 4
1.1 About this user manual 4
1.2 About the safety notices 5
2Description 7
2.1 Intended use 7
2.2 Device models 8
2.3 Labels/Markings 9
2.4 Identifying the device 10
2.5 Physical design and operation 11
2.6 Technical specifications 15
3Safety 19
3.1 Basic safety rules 19
3.2 Requirements concerning the workforce, personal protective gear, workplaces 20
4Basics for installing the device in a pipe 23
4.1 Installation example 23
4.2 Meter run characteristics 24
4.3 Operating and measuring lines 26
5Transport and installation 27
5.1 Transporting the gas pressure regulator 27
5.2 Installing the gas pressure regulator 28
5.3 Installing the device connections 30
5.4 Checking the system for leaks 31
6Adjusting the settings of the device 33
6.1 Adjusting the regulator unit setpoint 33
6.2 Adjusting the throttle valve on the measuring line of the regulator unit 36
7Malfunctions 37
7.1 Malfunctions 37
8Maintenance 39
8.1 Maintenance schedule 39
8.2 Preparing for the maintenance 40
8.3 Starting maintenance 41
8.4 Removing the regulator unit 43
8.5 Dismounting the controller 45
8.6 Performing maintenance on regulator unit 47
8.6.1 Performing maintenance on regulator unit RE1 47
8.6.2 Performing maintenance on regulator unit RE2 52
8.6.3 Performing maintenance on regulator unit RE0 57
8.7 Installing the regulator unit 61
8.8 Maintaining the monitoring device 62
8.9Installing the controller 62
8.10 Completing the maintenance 63

Contents
HON 380 gas pressure regulator with HON 673/674 controller 3
9Storage, removal, and disposal 64
9.1 Storing the device 64
9.2 Disassembling the device 65
9.3 Disposing of the device 66
10 Appendix 67
10.1 Additional information regarding spare parts 67
10.2 Spare parts kit for HON 380 with RE1 69
10.3 Spare parts kit for HON 380 with RE2 71
10.4 Spare parts kit for HON 380 with RE0 75
10.5 Lubricants 78

General considerations
HON 380 gas pressure regulator with HON 673/674 controller 4
1General considerations
Topic Page
About this user manual 4
About the safety notices 5
1.1 About this user manual
This user manual applies for gas pressure regulator HON 380 in combination with
controller HON 673/674.
This user manual provides all individuals with the information required for the safe
handling in connection with the following tasks:
Transport
Installation
Start-up
Set-up
Maintenance
Decommissioning, disassembly, renewed start-up, storage and disposal
Note: Detailed information on the HON 673/674 controller can be found in the
component documentation included in delivery.
This user manual is intended for anyone working with the product:
Transportation personnel
Installation personnel
Set-up and operating personnel
Maintenance and service personnel
Honeywell offers products with identical functions in a number of different sizes.
For this reason, we are unable to guarantee that illustrations in this user manual
coincide with the dimensions of your product. In these cases, the illustrations
should be viewed as a concept sketch.
Failing to observe the information provided in this document may lead to injuries,
including death and material damages.
To ensure the safety, any persons handling the product must have read and un-
derstood the following parts of this document before they start with any work in-
volving it:
the chapter entitled Safety
the chapters that describe the work to be done
Unless explicitly permitted, the disclosure as well as duplication of this document,
the exploitation and communication of its contents are prohibited. Any breach or
infringement will result in liability for damages. All rights reserved in the event of
patent, utility model or registered design registration.
Contents
Validity and purpose
Target group
Illustration
Safety
Copyright notice

General considerations
HON 380 gas pressure regulator with HON 673/674 controller 5
© Copyright 2022 by
Honeywell Process Solutions
Honeywell Gas Technologies GmbH
Osterholzstraße 45
34123 Kassel
GERMANY
Tel: [phone]
Phone number for service: [phone]
Fax: [phone]
Fax number for service: [phone]
E-mail: [e-mail]
Website:
www.honeywellprocess.com
www.hongastec.de
Printed in Germany
The manufacturer is not liable for damages and malfunctions arising from non-
observance of this user manual and the other applicable documents.
The written approval from Honeywell Gas Technologies GmbH, Kassel, is required
for any modifications and additions to the product. Any violation will void the legal
liability for consequences arising thereof.
1.2 About the safety notices
The information contained in the safety notices is intended to prevent personal
injury. Safety notices contain the following information:
Nature and source of the danger
Possible consequences associated with the non-observance of the notice
Procedures for the prevention of personal injury
This document contains the following types of safety notices:
Type of safety no-
tice
Description Sign
Basic safety notices Superordinate safety notices not relating
to a specific task:
They contain a summarized descrip-
tion of hazards, risks and safety proce-
dures associated with the handling of
the device.
Their purpose is to inform and educate
the user about an existing danger and
about practicing behavioral safety.
They are suitable as safety instruction
for all employees handling the device.
Recognizable by the
heading of the chapter
Instruction-related
safety notices
Safety notices containing specific in-
structions relating to the entire manual
or a group of manuals
Copyright
Details about the
manufacturer’s
liability
Constructive changes
Meaning
Types of safety
notices

General considerations
HON 380 gas pressure regulator with HON 673/674 controller 6
Type of safety no-
tice
Description Sign
Step-related safety
notices
Safety notices containing specific in-
structions relating only to the step
DANGER
WARNING
CAUTION
Additional safety
notice
Instruction to observe certain safety no-
tices with reference to a location in the
document where safety notices contain-
ing specific information about dangers,
risks and specific instructions for safety
procedures can be found
The safety notices containing specific instructions are identified with a signal
word. The signal word represents a certain danger level:
Danger level If you fail to follow the instruction, then
…
And the consequence is
…
DANGER an accident will happen serious bodily injury or
death.
WARNING an accident may happen possible serious bodily
injury or death.
CAUTION an accident may or will happen. minor or moderate bod-
ily injury.
Warnings about possible material damages are identified with the word Attention
in this document.
Danger levels
Warnings about
material damages

Description
HON 380 gas pressure regulator with HON 673/674 controller 7
2Description
Topic Page
Intended use 7
Device models 8
Labels/Markings 9
Identifying the device 10
Physical design and operation 11
Technical specifications 15
2.1 Intended use
The HON 380 direct-acting gas pressure regulator must be used and operated
exclusively with a compatible controller made by Honeywell. The gas pressure reg-
ulator is to be used in combination with a controller to provide a safety-shut off
function in a regulating line.
Depending on the type, the gas pressure regulator can be used to maintain the
outlet pressure of a gas constant within the regulating line, regardless of the influ-
ence of disturbance variables such as pressure changes and/or changes in con-
sumption.
As a gas pressure regulator, it can be used in transfer stations used in gas trans-
portation networks, as well as in power plants and industrial facilities. Gas pres-
sure regulator HON 380 with controller HON 673/HON674 is suitable for use
with natural gas or dry, non-aggressive industrial gases.
Note: The utilization limits of the device with regard to the medium, operating
pressure and operating temperature can be gathered from the type plate at-
tached on the device or the technical specifications.
The use under different operating conditions must be coordinated in consultation
with the manufacturer.
Please observe the following limitations of use:
Do not use the device for any media other than those mentioned in the in-
tended use or those discussed with and approved by the manufacturer.
Do not use the device in any installation position other than the one docu-
mented in this user manual.
Do not use the device against the direction of flow specified on the device
and in the user manual.
When replacing defective parts, only use original spare parts or manufac-
turer-approved standard parts.
Do not attempt to modify or remodel the device on your own.
Contents
Intended use
Limitations of use

Description
HON 380 gas pressure regulator with HON 673/674 controller 8
2.2 Device models
The gas pressure regulator HON 380 in combination with a HON 673/HON 674
controller is available in a number of versions. There are different versions of the
controller and of the regulator.
The following table shows which models are available:
Nominal diameters of 1" (DN25), 2" (DN50), 3" (DN80), and 4" (DN100)
each with
Flange facing as
defined by standard
Pressure rating Maximum opera-
ting pressure
[bar]
Flange facing
ASME B16.5 Class 150 20 Raised face
DIN EN 1092-1 PN 16 16 B flange
The following table shows which models are available:
Regulator unit (RE): Setpoint range
Body
DN 25 DN 50 DN 80 DN 100
RE1 20 mbar to
1000 mbar
X X
RE2 20 mbar to
1000 mbar
X X X
RE0 1000 mbar to
2000 mbar
X X X X
The comparator stage as an individual component is executed in four models with
different designs in dependence on the control range (Wd) of the controller:
Control range Wdso Design for upper response pressure
25 to 2300 mbar K1a: Diaphragm measuring unit
400 to 5200 mbar K2b: Diaphragm measuring unit
Control range Wdsu Design for lower response pressure
10 to 300 mbar K1a: Diaphragm measuring unit
60 to 400 mbar K2b: Diaphragm measuring unit
The comparator stage as an individual component is executed in three models
with different designs in dependence on the control range (Wd) of the controller:
Control range Wdso Design for upper response pressure
40 to 500 mbar K4: Diaphragm measuring unit
200 to 1500 mbar K5: Diaphragm measuring unit
600 to 4500 mbar K6: Diaphragm measuring unit
Gas pressure regula-
tor versions
HON 380 gas pres-
sure regulator
versions
Regulator unit
versions
HON 673 controller
models
HON 674 controller
models

Description
HON 380 gas pressure regulator with HON 673/674 controller 9
Control range Wdsu Design for lower response pressure
5 to 60 mbar K4: Diaphragm measuring unit
15 to 120 mbar K5: Diaphragm measuring unit
40 to 300 mbar K6: Diaphragm measuring unit
The technical specifications and the Maintenance section, as well as the spare
parts lists and spare parts drawings in the appendix, describe all the gas pressure
regulator versions and all the models corresponding to the standard for this de-
vice type. Special-purpose versions are identified with “SO” in the inspection cer-
tificate, which is included with the gas pressure regulator.
However, other versions and models will be covered specifically as well when there
are important differences that need to be pointed out.
If you have trouble understanding the information in this documentation, contact
the manufacturer without fail before starting any work on the device.
2.3 Labels/Markings
Illegible information on the device poses a risk of injury due to resulting erro-
neous operation, use, or installation.
Labels, as well as inscriptions and stamping on the device, can eventually be-
come soiled or otherwise unrecognizable to such an extent that users will not be
warned effectively of hazards and may be unable to follow required operating in-
structions. This will pose a risk of injury.
Make sure to always keep all relevant labels in good condition so that they will
be easily legible.
Immediately replace damaged and missing labels.
The labels and markings of the gas pressure regulator can be found here:
Figure No. Description
1 Regulator type plate
2 Gas pressure regulator type plate
3 Arrow indicating direction of flow on
controller type plate
4 Body nominal size
5 Arrow indicating the direction of flow
For the location of the nameplates, as well as a detailed list of the information on
them and what it means, please refer to:
Identifying the device (see page 10)
Small labels must be used to color-code and explicitly name the gas pressure reg-
ulator’s connection lines (measuring lines and operating lines) based on what the
lines are intended for and their minimum nominal size.
Versions and designs
in this user manual
Illegible labels
Gas pressure regula-
tor HON 380 labels
and markings
Nameplates
Labels on connection
lines

Description
HON 380 gas pressure regulator with HON 673/674 controller 10
2.4 Identifying the device
Make sure you have the right manual for your gas pressure regulator.
Use the nameplates to identify the gas pressure regulator.
Make sure that the on-site conditions match the information on the nameplates
and the technical specifications.
Technical specifications
The gas pressure regulator HON 380 type plate locations are as follows:
Figure No. Meaning
1 Front of the body
2 On the side of the regulator unit
3 On the side of the controller
The details on the type plate have the following meaning:
Figure No. Meaning
1 Manufacturer
2 Model name
3 CE - PIN
4 Device version
5 Nominal size
6 PS = Maximum allowable pressure
7 Serial number of the device
8 Year built
9 Temperature range
10 Connection
11 Standard (EN 334)
Identifying the gas
pressure regulator
Verifying the tech-
nical specifications
Locating the gas pres-
sure regulator’s
nameplates
Interpreting the type
plate of the gas pres-
sure regulator

Description
HON 380 gas pressure regulator with HON 673/674 controller 11
The details on the type plate have the following meaning:
Figure No. Meaning
1 Manufacturer
2 Model name
3 maximum inlet pressure
4 Serial number of the device
5 Failure function (fail-open)
6 Wds = specific setpoint range
7 Serial number of the device
8 PSD = maximum permissible outlet
pressure
9 Pds = nominal value of the controlled
variable
10 Valve seat diameter
The type plates are described in the HON 673 / HON 674 component documen-
tation.
2.5 Physical design and operation
The gas pressure regulator is made up of the following assemblies:
Figure No. Description
1 Regulator unit (RE):
2 Body
3 Controller - safety shut-off valve
(SAV)
Interpreting the type
plate on the regulator
unit
Interpreting the type
plate and additional
type plate of the con-
troller
Figure

Description
HON 380 gas pressure regulator with HON 673/674 controller 12
Design of the regulator unit:
Figure No. Meaning
1 Spring adjuster
2 Pilot spring
3 GPR vent line connection
4 GPR comparator diaphragm
5 GPR measuring line connection
6 Compensating diaphragm
7 Valve spindle
8 Valve plate
Design of the regulator unit:
Figure No. Meaning
1 Spring adjuster
2 Pilot spring
3 GPR vent line connection
4 GPR measuring line connection
5 GPR comparator diaphragm
6 Compensating diaphragm
7 Valve spindle
8 Valve plate
Design of the regula-
tor unit RE1 DN 50
Design of regulator
unit RE2

Description
HON 380 gas pressure regulator with HON 673/674 controller 13
Design of the regulator unit:
Figure No. Meaning
1 Spring adjuster
2 Pilot spring
3 GPR vent line connection
4 GPR comparator diaphragm
5 GPR measuring line connection
6 Compensating diaphragm
7 Valve spindle
8 Valve plate
The design of the controller is described in the component documentation in-
cluded in delivery.
Connections of the gas pressure regulator:
Figure No. Connection
1 Vent line connection, regulator unit
2 Measuring line connection, regulator
unit
3 Measuring line connection, SAV
4 Vent line connection, SAV
Design of regulator
unit RE0
Design of the
controller
Connection lines of
the HON 380 gas
pressure regulator

Description
HON 380 gas pressure regulator with HON 673/674 controller 14
Figure Color Meaning
Outlet pres-
sure
Atmo-
spheric
pressure
Inlet pres-
sure
The comparator diaphragm of the regulator unit captures the actual value of
the outlet pressure and compares it with the reference variable specified by
the pilot spring.
A regulation deviation directly influences the closing member posi-
tion via the valve spindle. The flow rate change this causes results in
an adjustment of the outlet pressure actual value so that it matches
the setpoint. When there is zero pressure flow, the device seals
tightly.
If the actual value of the outlet pressure in the regulating line exceeds or falls
below a certain response pressure, the closing member of the safety shut-off
valve located on the input side shuts off the flow of gas.
The SAV measuring diaphragm with the switching sleeve moves into
the corresponding disengaged position, the ball engagement
mechanism enables the SAV valve spindle and the control element
of the safety shut-off closes.
The SAV can only be engaged in the open position manually when the outlet
pressure at the sensing point is at least within the specified re-engage differ-
ential range for overpressure or underpressure relative to the response pres-
sure setpoint.
The SAV can also be equipped with a manual or a remote release feature, as
desired. It is also possible for it to be executed in functional class A (with dia-
phragm rupture protection) or B (without diaphragm rupture protection).
Functional diagram of
the HON 380 gas
pressure regulator
How the HON 380 gas
pressure regulator
works

Description
HON 380 gas pressure regulator with HON 673/674 controller 15
2.6 Technical specifications
Components Material
Valve body Cast steel
SAV Aluminum cast alloy and aluminum
wrought alloy
Casing of actuator Steel plate / aluminum alloy
Diaphragms; gaskets NBR
Internal parts Aluminum alloy, steel, brass
Criterion Value
Max. inlet pressure pumax 20 bar
Temperature range -20 to +60 °C
(-4 to +140 °F)
There are various flange facings for the nominal diameters of 1" (DN 25),
2" (DN 50), 3" (DN 80), and 4”(DN 100) as specified in the following standards:
ASME B16.5
Pressure rating as per Class 150 =20 bar
Flange facing: Raised face
DIN EN 1092-1
Pressure rating as per PN 16 =16 bar
Flange facing: B flange
Materials
Environmental condi-
tions
Pressure rating and
flange facing stand-
ards

Description
HON 380 gas pressure regulator with HON 673/674 controller 16
The figures show schematic representations of the device’s structure. The dimen-
sions for the different types can be taken from the table.
Type DN 25 and DN 50
HON 380 dimensions

Description
HON 380 gas pressure regulator with HON 673/674 controller 17
Type DN 80 and DN 100
Valve body Safety shut-off valve
Size
A
mm
(in.)
B
mm
(in.)
C
mm
(in.)
X
mm
(in.)
Y
mm
(in.)
D
mm
(in.)
E
mm
(in.)
ØF
mm
(in.)
DN 25 (1″) 184
(7.24)
64
(2.52)
72
(2.83)
75
(2.95)
255
(10.04)
105
(4.13)
DN 50 (2″) 254
(10.00)
87
(3.43)
87
(3.43)
80
(3.15)
255
(10.04)
105
(4.13)
DN 80 (3″) 298
(11.73)
149
(5.87)
149
(5.87)
190
(7.48)
95
(3.74)
250
(9.84)
300
(11.81)
max. 180
(7.09)
DN 100 (4″) 352
(13.86)
185
(7.28)
164
(6.46)
225
(8.86)
110
(4.33)
300
(11.81)
310
(12.20)
max. 180
(7.09)
Gas pressure regulator with regulator unit
RE1 RE2 RE0
Size G
mm
(in.)
ØH
mm
(in.)
J
mm
(in.)
G
mm
(in.)
ØH
mm
(in.)
J
mm
(in.)
G
mm
(in.)
ØH
mm
(in.)
J
mm
(in.)
DN 25 (1″) 405
(15.94) 297
(11.69)
105
(4.13) - 525 (20.67) 250
(9.84)
105
(4.13)
DN 50 (2″) 410
(16.14)
110
(4.33)
550
(21.65)
395
(15.55)
110
(4.33)
525
(20.67)
110
(4.33)

Description
HON 380 gas pressure regulator with HON 673/674 controller 18
Gas pressure regulator with regulator unit
RE1 RE2 RE0
Size G
mm
(in.)
ØH
mm
(in.)
J
mm
(in.)
G
mm
(in.)
ØH
mm
(in.)
J
mm
(in.)
G
mm
(in.)
ØH
mm
(in.)
J
mm
(in.)
DN 80 (3″)
-
640
(25.20)
200
(7.87)
620
(24.41)
200
(7.87)
DN 100 (4″) 630
(24.80)
205
(8.07)
610
(24.02)
205
(8.07)
HON 380 weights
Gas pressure regulator with regulator unit
RE1 RE2 RE0
with SAV without SAV with SAV without SAV with SAV without SAV
Size kg (lb) kg (lb) kg (lb) kg (lb) kg (lb) kg (lb)
DN 25 (1″) 18 (40) 16 (35) 34 (75) 32 (71)
DN 50 (2″) 24 (53) 22 (49) 35 (77) 33 (73) 41 (90) 38 (84)
DN 80 (3″) 73 (161) 65 (143) 79 (174) 71 (157)
DN 100 (4″) 89 (196) 80 (176) 95 (209) 85 (187)
Connections of the lines
Controller SAV
Measuring line Vent line Measuring and breather lines
Connection for
RE1 Pipe 12 x 1.5
(pipe 12 x 1.5 on the device)
Pipe 12 x 1.5
(thread G 1/2)
RE2 Pipe 16 x 2
(pipe 16 x 2 on the device)
Pipe 12 x 1.5
(thread G 1/2)
Pipe 12 x 1.5
(thread G 3/8)
RE0 Pipe 16 x 2
(thread G 1/2)
Pipe 12 x 1.5
(thread G 3/8)
Criterion Value
Nominal diameter DN 25 (1″), DN 50 (2″), DN 80 (3″), DN 100
(4
″
)
Maximum operating pressure 20 bar (285 psi)
Criterion Value
Nominal diameter DN 25 (1″), DN 50 (2″), DN 80 (3″), DN 100
(4
″
)
Maximum operating pressure 16 bar (232 psi)
The device’s mechanical components do not contain any potential sources of ig-
nition, and accordingly do not fall under the scope of ATEX 95 (94/9/EC). The
electrical components used on the device meet all applicable ATEX requirements.
Operating pressure,
Class 150
Operating pressure,
PN 16
ATEX specifications

Safety
HON 380 gas pressure regulator with HON 673/674 controller 19
3Safety
Topic Page
Basic safety rules 19
Requirements concerning the workforce, personal protective gear, workplaces20
3.1 Basic safety rules
These rules are intended for any individuals handling the device.
These rules are designed to make sure that any individuals handling the device
obtain detailed information about the dangers and safety procedures and ob-
serve the safety notices contained in the user manual and on the device. If you do
not follow these rules, there is a risk of injury including death and material dam-
ages.
Observe the following rules:
Read the chapter entitled Safety and the chapters relating to your responsi-
bilities in their entirety. It is vital that you have understood these contents.
Always keep the user manual close by the device so that you can refer to it
again.
Include the user manual if you are giving the device away.
Observe the following rules:
Only individuals who meet the requirements set forth in this user manual
have permission to handle the device.
The device’s intended use includes its use in hazardous locations. All work
with and on the device must be carried out only after the presence of an ex-
plosive atmosphere has been fully ruled out.
Only use the device for the intended purpose. Never use the device for any
other, potentially logical purposes.
Follow all safety procedures outlined in this user manual and on the device.
In particular, wear the mandatory personal protective gear.
Only stay at the specified work places.
Do not modify the device in any way, e. g. by removing parts or adding unap-
proved parts. In particular, you have no permission to modify or disable any
safety contrivances.
Adhere to the device maintenance intervals specified in this user manual.
When replacing defective parts, only use original spare parts or manufac-
turer-approved standard parts.
Contents
Target group of these
rules
Purpose of these rules
Handling the user
manual
Handling the device

Safety
HON 380 gas pressure regulator with HON 673/674 controller 20
In your capacity as the company operating the device, you must ensure the fol-
lowing:
All personnel must meet the requirements corresponding to their duties.
All personnel must read and understand this user manual before working
with/on the device.
All occupational health and safety regulations that apply in your country
must be complied with.
Hazards resulting from specific working conditions at the location where the
device is being used must be determined by means of a risk assessment and
rendered avoidable by means of appropriate operating instructions.
All personnel must be provided with the personal protective equipment re-
quired for their work. This personal protective equipment must be in good
condition at all times.
All personnel must wear the personal protective equipment required for their
work.
The device is designed and built such that the employees can work with it without
being at risk. In spite of all the precautions, accidents can happen under unfavor-
able circumstances. Always consult the directives of your company concerning
the protection of the workforce.
3.2 Requirements concerning the workforce, personal protective gear,
workplaces
Individuals tasked with handling the device must meet the following require-
ments:
Personnel Responsibilities Required qualification
Skilled person or ex-
pert
Any work on and with the de-
vice
 Professional training and expe-
rience operating pressure
equipment and systems
Knowledge of the relevant
standards and regulations
Ability to identify and avoid
dangers autonomously
Certified, indepen-
dent competent per-
son
Safety checks Professional training
Knowledge of the relevant
standards and regulations
Ability to identify and avoid
dangers autonomously
Carrier Company-to-company trans-
port
 Professional training and expe-
rience transporting pressure
equipment and systems
Knowledge of the relevant
standards and regulations
Ability to identify and avoid
dangers autonomously
Knowledge with securing hau-
ling distances
Knowledge with the use of
hoisting equipment
Transportation per-
sonnel
Intra-company transport Professional training and experi-
ence with the transport using
stackers, etc.
Operator’s duties op-
posite the employees
Conduct in the event
of accidents
Requirements con-
cerning the workforce