Honeywell HON 5020 User manual

Actuator assembly for
HON 5020
Gas pressure regulator
Component documentation,
Maintenance manual and spare parts

Contents
HON 5020 gas pressure regulator 2
Contents
1General considerations 3
1.1 About this component documentation 3
1.2 About the safety notices 4
2Description 6
2.1 Intended use 6
2.2 Labels/Markings 7
2.3 Identifying the actuator assembly 8
2.4 Layout and operation 9
2.5 Technical specifications 11
3Safety 15
3.1 Basic safety rules 15
3.2 Requirements concerning the workforce, personal protective gear, workplaces 16
4Transport and installation 19
4.1 Transporting the actuator assembly 19
4.2 Mounting the actuator assembly 21
4.3 Checking the system for leaks 22
5Maintenance 24
5.1 Maintenance schedule 24
5.2 Preparing the tools, spare parts and lubricants 24
5.3 Preparing for the maintenance 25
5.4 Maintaining the actuator assembly 26
6Storage, removal, and disposal 29
6.1 Storing the device 29
6.2 Disassembling the device 29
6.3 Disposing of the device 31
7Appendix 32
7.1 Spare parts for the HON 5020 actuator assembly 32
7.2 Spare parts for travel indication option 36
7.3 Lubricants 36

General considerations
HON 5020 gas pressure regulator 3
1General considerations
Topic Page
About this component documentation 3
About the safety notices 4
1.1 About this component documentation
This component documentation applies to the actuator assembly for HON 5020 gas pressure
regulators.
This component documentation provides all individuals with the information required in
order to safely handle the device in connection with the following tasks:
Transport
Installation
Maintenance
Removal, storage, and disposal
This component documentation is intended for everyone working with or on the product:
Transportation personnel
Installation 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 the illustrations in this documentation will match 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 4
© 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 will not be liable for damages and malfunctions arising from failure to
observe this component documentation and other applicable documents.
Changes and additions to the product must be approved by Honeywell Process Solutions in
writing. 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 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
Step-related safety
notices
Safety notices containing specific instructions
relating only to the step
DANGER
WARNING
CAUTION
Copyright
Details about the manu-
facturer’s liability
Constructive changes
Meaning
Types of safety
notices

General considerations
HON 5020 gas pressure regulator 5
Type of safety notice
Description
Sign
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 6
2Description
Topic Page
Intended use 6
Labels/Markings 7
Identifying the actuator assembly 8
Layout and operation 9
Technical specifications 11
2.1 Intended use
The HON 5020 actuator assembly must be used exclusively with a compatible pilot made by
Honeywell. It is intended to be used, in combination with an appropriate pilot, as a gas pres-
sure regulator in a regulating line. Depending on the pilot model used in combination with
the actuator assembly, the latter can be used to maintain the outlet or inlet pressure of a gas
constant within the regulating line, regardless of the influence of disturbance variables such
as pressure changes and/or discharge changes. In addition, when combined with an appro-
priate pilot, the actuator assembly can be used to implement an active-monitor regulator
configuration. As a gas pressure regulator, it can also be used at transfer stations used in gas
transportation networks, as well as in power plants and industrial facilities. The HON 5020
actuator assembly unit can be used 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 component documentation.
Do not use the device against the direction of flow specified on the device and in the
component documentation.
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 7
2.2 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 a detailed list of the information on the nameplate and what it means:
Identifying the device
Small labels must be used to color-code and explicitly name the actuator assembly’s connec-
tion lines based on what the lines are intended for and their minimum nominal size.
Illegible labels
Labels on the HON 5020
actuator assembly
Nameplate
Labels on connection
lines

Description
HON 5020 gas pressure regulator 8
2.3 Identifying the actuator assembly
Make sure you have the right component documentation for your actuator assembly.
To identify your actuator assembly, look at the nameplate.
Make sure that the conditions on site correlate with the information on the type plate and
the technical specifications.
Technical specifications (see page 11)
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 actuator
assembly
Verifying the technical
specifications
Locating the type plate of
the actuator assembly
Interpreting the type
plate of the actuator
assembly

Description
HON 5020 gas pressure regulator 9
For actuator assembly models that use the imperial system, the information on the name-
plate will be as follows:
Figure
No.
Meaning
1
Model name
2
Manufacturer
3
Nominal size
4
Nominal pressure / Flange standard
5
Tightening torque
6
Manufacturing date (month/year)
7
Customer reference number
8
Serial number
9
Differential pressure
10
Temperature range (-40° to 175° F)
11
Maximum allowable inlet pressure
2.4 Layout and operation
In combination with an appropriate Honeywell pilot, the HON 5020 actuator assembly can be
used as a gas pressure regulator in order to maintain the outlet or inlet pressure of a gas
constant within the regulating line, regardless of the influence of disturbance variables such
as pressure changes and/or discharge changes.
The pressure that needs to be regulated is fed to the pilot via the sensing line. The diaphragm
system in the pilot determines the pressure actual value as a force on the measuring dia-
phragm and compares it with the force of the pilot spring, which is used as reference variable.
If control deviations are detected based on the results from this comparison, the opening
position of the actuator assembly’s regulating diaphragm will be changed by adjusting the
motorization pressure so that the pressure being regulated (actual value) will change to
match the setpoint. When there is zero pressure flow, the device seals tightly.
Actuator assembly configuration:
Figure
No.
Meaning
1
Actuator body
2
Diaphragm assembly
3
Flow restrictor
4
Noise reduction element
5
Support disc
6
Inlet pressure
7
Outlet pressure
8
Motorization pressure
How it works
Actuator assembly con-
figuration

Description
HON 5020 gas pressure regulator 10
Actuator assembly connection lines:
Figure
No.
Connection
Front:
1
Inlet pressure
2
Motorization pressure
3
Outlet pressure / feedback
Back:
4
Outlet pressure
5
Inlet pressure
The actuator assembly’s connections have the following dimensions:
M14 x1.5 if the pilot being connected uses the metric system
3/8 NPT if the pilot being connected uses the imperial system
The numbers have the following meaning:
Figure
No.
Description
1
Optical travel indicator
2
Optical travel indicator with remote control
Actuator assembly
connection lines
Travel indication option