Honeywell HON 5020 Operating instructions

HON 5020
gas pressure regulator
with HON 630 pilot
User and maintenance manual
Spare parts

Contents
HON 5020 gas pressure regulator with HON 630 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 16
3Safety 23
3.1 Basic safety rules 23
3.2 Requirements concerning the workforce, personal protective gear, workplaces 24
4Basics for installing the device in a pipe 27
4.1 Installation examples 27
4.2 Alternative application example: Active monitor regulator 29
4.3 Meter run characteristics 30
4.4 Operating and measuring lines 31
5Transport and installation 33
5.1 Transporting the gas pressure regulator 33
5.2 Installing the gas pressure regulator 35
5.3 Installing the device connections 36
5.4 Checking the system for leaks 37
6Adjusting the settings of the device 39
6.1 Adjusting the loading pressure 39
6.2 Adjusting the control stage setpoint 40
6.3 Adjusting the amplifying valve 41
7Malfunctions 43
7.1 Malfunctions 43
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 50
8.4.1 Maintaining the actuator assembly 50
8.5 Maintaining the pilot 53
8.5.1 Disassembling the pilot and maintaining the base plate 53
8.5.2 Maintaining the control stage with a diaphragm assembly 56
8.5.3 Maintaining the control stage with a metal bellows assembly 63
8.5.4 Maintaining the control stage with a larger diaphragm assembly 72
8.5.5 Maintaining the load limiting stage 82

Contents
HON 5020 gas pressure regulator with HON 630 pilot 3
8.5.6 Maintaining the fine mesh filter 85
8.5.7 Reassembling the pilot 87
8.6 Completing the maintenance 88
9Storage, removal, and disposal 89
9.1 Storing the device 89
9.2 Disassembling the device 89
9.3 Disposing of the device 91
10 Appendix 92
10.1 Additional information regarding spare parts 92
10.2 Spare parts for the HON 5020 actuator assembly 94
10.3 Spare parts for two-stage HON 630 pilot 98
10.4 Spare parts for load limiting stage 103
10.5 Spare parts for control stage 105
10.6 Spare parts for fine mesh filter 111
10.7 Spare parts for travel indication option 112
10.8 Lubricants, threadlockers, and special tools 113

General considerations
HON 5020 gas pressure regulator with HON 630 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 an HON 630 pilot.
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 630 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 630 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 630 pilot 7
2Description
Topic Page
Intended use 7
Device models 8
Labels/Markings 9
Identifying the device 10
Layout and operation 12
Technical specifications 16
2.1 Intended use
HON 5020 gas pressure regulators featuring an HON 630 pilot can be used to maintain the
outlet pressure of a gas constant within a regulating line regardless of the influence of dis-
turbance variables such as inlet pressure changes and/or discharge changes. These devices
are also characterized by high accuracy even in the event of large inlet pressure changes. 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 630 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 630 pilot 8
2.2 Device models
Gas pressure regulators consisting of an HON 5020 regulator unit combined with an HON 630
pilot 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 HON 630 pilot features a number of individual expansion options.
The following individual components are always part of the device:
HON 905 fine mesh filter
Inlet pressure gauge
Amplifying valve
Control stage, including spring adjuster and base plate
The following individual components are optional expansions:
Load limiting stage, including spring adjuster and loading pressure gauge
Outlet pressure gauge
With HON 925 protection against overpressure for setpoint ranges Wdof 0.3
to 20 bar
Without protection against overpressure for setpoint ranges Wdof 10 to 40
bar
HON 915 vent valve
Electrical remote setpoint adjustment for control stage and/or load limiting stage
The standard HON 630 pilot version features two stages, i.e., it includes both a load limiting
stage and a control stage.
The manufacturer uses designation HON 630-1 for the single-stage pilot version featuring a
control stage but no load limiting stage.
Gas pressure regulator
versions
HON 5020 actuator
assembly models
HON 630 pilot models

Description
HON 5020 gas pressure regulator with HON 630 pilot 9
There are three different versions of the individual control stage component installed in the
HON 630 pilot, with the specific version used depending on the control stage’s setpoint range
(Wd):
Setpoint range Wd
Design
0.3 to 1 bar
With larger diaphragm assembly
0.5 to 40 bar
With diaphragm assembly
10 to 90 bar
With metal bellows assembly
The optional load limiting stage for the HON 630 pilot always features a diaphragm assembly
regardless of the control stage’s setpoint range (Wd).
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 two-stage 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
Control stage models
Models for the optional
load limiting stage
Versions and designs in
this user manual
Illegible labels
Labels on the HON 5020
actuator assembly

Description
HON 5020 gas pressure regulator with HON 630 pilot 10
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.
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 16)
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
Nameplates
Labels on connection
lines
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