Honeywell HON 5020 Operating instructions

HON 5020
gas pressure regulator
with HON 640a /
HON 642a pilot
User and maintenance manual
Spare parts

Contents
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 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 Layout and operation 12
2.6 Technical specifications 17
3Safety 24
3.1 Basic safety rules 24
3.2 Requirements concerning the workforce, personal protective gear, workplaces 25
4Basics for installing the device in a pipe 28
4.1 Installation examples 28
4.2 Alternative application example: Active monitor regulator 30
4.3 Meter run characteristics 31
4.4 Operating and measuring lines 32
5Transport and installation 34
5.1 Transporting the gas pressure regulator 34
5.2 Installing the gas pressure regulator 36
5.3 Installing the device connections 37
5.4 Checking the system for leaks 39
6Adjusting the settings of the device 41
6.1 Setting the target pressure 41
6.2Adjusting the amplifying valve 43
7Malfunctions 44
7.1 Malfunctions 44
8Maintenance 45
8.1 Maintenance schedule 45
8.2 Preparing for the maintenance 46
8.3 Starting maintenance 47
8.4 Maintaining the actuator assembly 49
8.4.1 Maintaining the actuator assembly 49
8.5 Maintaining the pilot 52
8.5.1 Maintenance for imperial HON 640a / metric HON 640a with diaphragm measuring unit 52
8.5.2 Maintenance for imperial HON 640a with metal bellows measuring unit 60
8.5.3 Maintenance for imperial HON 642a with diaphragm measuring unit 70
8.6 Completing the maintenance 79

Contents
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 3
9Storage, removal, and disposal 80
9.1 Storing the device 80
9.2 Disassembling the device 81
9.3 Disposing of the device 82
10 Appendix 83
10.1 Additional information regarding spare parts 83
10.2 Spare parts drawing for HON 5020 actuator assembly 84
10.3 Maintenance and servicing parts for the actuator assemblies 85
10.4 Spare parts drawing for imperial HON640a pilot with diaphragm measuring unit 89
10.5 Spare parts drawing for imperial HON640a pilot with metal bellow measuring unit 90
10.6 Spare parts drawing for metric HON640a with diaphragm measuring unit 91
10.7 Spare parts drawing for imperial HON642a pilot with diaphragm measuring unit 92
10.8 Bill of materials and spare parts for pilots 93
10.9 Spare parts for travel indication option 95
10.10 Lubricants, threadlockers, and special tools 96

General considerations
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 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 to HON 5020 gas pressure regulators featuring a pilot from the
HON 640a / HON 642a series.
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
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 understood the
following parts of this document before they start with any work involving 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 exploi-
tation 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 5020 gas pressure regulator with HON 640a / HON 642a pilot 5
© Copyright 2020 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 con-
sequences 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 notice
Description
Sign
Basic safety notices
Superordinate safety notices not relating to a
specific task:
They contain a summarized description of
hazards, risks and safety procedures associ-
ated 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 instructions
relating to the entire manual or a group of
manuals
Copyright
Details about the manu-
facturer’s liability
Constructive changes
Meaning
Types of safety
notices

General considerations
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 6
Type of safety notice
Description
Sign
Step-related safety
notices
Safety notices containing specific instructions
relating only to the step
DANGER
WARNING
CAUTION
Additional safety
notice
Instruction to observe certain safety notices
with reference to a location in the document
where safety notices containing 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 bodily
injury.
Warnings about possible material damages are identified with the word Attention in this
document.
Danger levels
Warnings about material
damages

Description
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 7
2Description
Topic Page
Intended use 7
Device models 8
Labels/Markings 9
Identifying the device 10
Layout and operation 12
Technical specifications 17
2.1 Intended use
HON 5020 gas pressure regulators featuring an HON 640a / HON 642a pilot can be used to
maintain the outlet or inlet pressure of a gas constant within a regulating line regardless of
the influence of disturbance variables such as pressure changes and/or discharge changes. In
addition, these gas pressure regulators can be used to implement an active-monitor regulator
configuration. It can be used in transfer stations of gas transportation networks, in power
plants and industrial plants. HON 5020 gas pressure regulators featuring an HON 640a /
HON 642a pilot are 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 attached 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 intended use or
those discussed with and approved by the manufacturer.
Do not use the device in any installation position other than the one documented 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 manufacturer-approved
standard parts.
Do not attempt to modify or remodel the device on your own.
Contents
Intended use
Limitations of use

Description
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 8
2.2 Device models
Gas pressure regulators consisting of an HON 5020 regulator unit combined with a pilot from
the HON 640a or HON 642a series are available in a number of versions. These versions are
derived from the various possible combinations between the various pilot and actuator
assembly versions.
The following table shows which models are available:
Nominal diameters of 1" (DN 25); 2" (DN 50); 3" (DN 80); 4" (DN 100), and 6" (DN 150) with
Flange facing as de-
fined by standard
Pressure rating
Maximum operating
pressure
[bar]
Flange facing
ASME B16.5
Class 150
20
Raised face;
ring joint
Class 300
51
Class 600
102
DIN EN 1759-1
Class 150
20
Bflange;
Jflange
Class 300
51
Class 600
102
DIN EN 1092-1
PN 16
16
Bflange
PN 25
25
PN 40
40
The following table shows which designs and versions are available:
Series
Design
System of
measu-
rement
Setpoint range
[bar]
Standard com-
ponents
Versions /
optional com-
ponents
640a
Diaphragm
measuring unit
Imperial
1-40
Integrated filter
None
Metal bellows
measuring unit
Imperial
20 -90
Integrated filter
None
Diaphragm
measuring unit
Metric
1-40
Integrated
filter
Inlet pressure
gauge
Outlet pres-
sure gauge
Protection
against over-
pressure
642a
Diaphragm
measuring unit
Imperial
1-40
Integrated filter
None
The designs that use the imperial system of measurement feature ports that conform to
Anglo-American thread standards and use inches as a unit.
The designs that use the metric system of measurement feature ports that conform to Euro-
pean thread standards and use metric units.
Gas pressure regulator
versions
HON 5020 actuator
assembly models
Designs and versions in
the HON 640a and
HON 642a pilot series

Description
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 9
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 device type. Special-purpose versions are
identified with “SO” in the inspection certificate, which is included with the gas pressure
regulator.
The remaining sections in this user manual mostly use the version with the HON 640a impe-
rial pilot with a diaphragm assembly as a reference. 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 manu-
facturer 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 erroneous opera-
tion, use, or installation.
Labels, as well as inscriptions and stamping on the device, can eventually become 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 instructions. 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 following labels/markings can be found on the actuator assembly’s casing:
Figure
No.
Meaning
1
Nameplate
2
Body part number
3
Batch number
Foundry code
4
CE PIN
(only if the unit has been granted a CE type
approval)
5
Body nominal size
6
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 regulator’s
connection lines (measuring impulse 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
Labels on the HON 5020
actuator assembly
Nameplates
Labels on connection
lines

Description
HON 5020 gas pressure regulator with HON 640a / HON 642a pilot 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 (see page 17)
The type plate of the actuator assembly can be found here:
Figure
No.
Meaning
1
Front of the actuator assembly
For actuator assembly models that use the metric system, the information on the name-
plate will be as follows:
Figure
No.
Meaning
1
Model name
2
Manufacturer
3
Nominal size
4
Serial number of the device
5
Valve seat diameter
6
Device version
(IS = version with integral overpressure
protection)
7
Standard (EN 334)
8
Manufacturing date (month/year)
9
Connection
10
Temperature range
11
Failure function (fail-open)
12
Maximum allowable pressure
13
Maximum allowable inlet pressure
Identifying the gas pres-
sure regulator
Verifying the technical
specifications
Locating the type plate of
the actuator assembly
Interpreting the type
plate of the actuator
assembly