Honeywell COCON 26 DRA-LP/MP User manual

Honeywell
UNDERGROUND GAS REGULATION STATION
TYPE: COCON 26 DRA-LP/MP
Active - Slam
MAINTENANCE AND ASSEMBLY MANUAL
Assembly and maintenance documentation
Cocon 26 Active – Slam configuration
July 12, 2017
Rev 0

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 2
Contents
Page:
1. Technical Data 3
2. Assembly 4
2.1 General 4
2.2 Gas Regulation Station (G.R.S) 6
2.3 Safety Shut-off Valve (S.S.V.) 8
2.4 Cover of Cartridge 10
2.5 Gas Regulation Station Casing 11
2.6 Assembly of Gas Regulation Station and Cover of Cartridge 13
2.7 Assembly of Safety Unit (S.S.V.) 16
2.8 Assembly of Regulator Pilot, Safety Relief Valve and Measuring Units
such as Vent and Pressure Relief Pipes. 18
2.9AssemblyofDustFilter 23
3.Inspection 25
3.1 Inspection of Gas Regulating Station and Safety Unit 25
3.2TestCasing 26
3.3 Assembly of the Gas Regulating Station and Safety Unit
on the Test Casing 27
3.4LeakageTest 27
3.5 Setting of the Gas Regulating Station
and Safety Unit 27
3.6 Removal of the Gas Regulating Station and Safety Unit from the
Test Casing 28
4. Cleaning of Cartridge 28
5. Problems and Possible Solutions 29
6. Spare Parts 30

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 3
1 Technical Data
Technical Data of Type UGPRS : COCON 26.
Medium : all non-aggressive gases
Temperature : -15°C to +50°C
Inlet Pressure (p1) : max. 16 bar or 19 bar
Outlet Pressure (p2) : min. 20 mbar
Differential Pressure Delta P : min. 0.3 mbar
Weight of Cartridge : + 60 kg
Volume of UGPRS (packed) : + 1 m3
Length : ± 1000 mm
Width : ± 1000 mm
Height : ± 1000 mm
Pressure gauge : for inlet and outlet pressure
Control : Gas regulation station with auxiliary power from the inlet pressure
Safety Shut-off Device : Safety Shut-off Valve with monitor control.
Filter Material : Felt
Separation Rate : 98 % at particle size of 3 micron (0.003 mm)
Shut-off Valves : Inlet : Ball Valve DN 50 ANSI300
Outlet : Butterfly valve DN150 PN 16 or PN25
Mounting of Type Plates : on the membrane cover, under the pit cover, on
the regulator pilot, on the monitor control and on the shut-off relay.
Data on the type plate : Name of manufacturer, classification, serial number,
Max. operating pressure, set outlet pressure, year of construction
Regulator Pilot
Gas Regulation Station (G.P.R.S) : Cartridge
Regulator Pilot : RP-LP/MP
Safety Shut-off Valve (S.S.V.) : 050-LP(D)/MP(D)
Safety Relief Blow-off Valve (S.P.R.V.): AV-LP/MP

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 4
2 Assembly
2.1 General
These guidelines provide information on the assembly of the cartridge.
WARNING: Non-compliance of the instructions shown in these maintenance guidelines
could result in the following problems:
- Malfunctioning of the UGPRS
- Damage to individual components
- Personal injury
Disassembly
Chapter 2 describes the assembly of the cartridge. Disassembly takes place in the opposite manner. Please
pay attention to the following instructions when working:
- Always wear protective goggles when assembling the unit.
- Use the right tools to assemble the individual components.
- Keep the parts mentioned in a chapter together and separate them from other parts mentioned in
other chapters. This way you will have sorted all parts for the assembly of a component part as
described in a specific chapter.
- Disassemble the parts of the station carefully. Please ensure that parts like the pressure spring do
not 'shoot off'.
- Replace damaged or worn down parts with new parts.
Numbering
( 3 ) = Pos. 3
( 02.08 ) = Diagram 02.08
( 02.08 Pos. 3 ) = Pos. 3 of diagram 02.08
Article Numbers
The appropriate article numbers as well as the pos. number, number of items and description are stated in
the respective parts list.

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 5
Diagram: 02.01

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 6
2.2 Gas Regulation Station
Assembly
- Place the membrane holder (11) on its raised edge.
- Hold the membrane holder so tightly that the raised edge points to the palm of your hand.
- Slide the membrane (12) over the membrane holder so that the membrane encloses the
membrane holder. The edge of the membrane hole lies on the raised edge of the membrane holder.
The thickened membrane side points to the centre of the membrane holder.
- Slide the membrane disc (44) – with the concave side to the front – against the membrane.
The membrane is now closed between the membrane disc and the membrane holder.
- Secure the membrane disc to the membrane holder with four hex socket head screws (46).
- Put this part aside.
- Slide the guiding holder (47) over the guide valve rod (23).
- Secure the guiding holder to the guide valve rod with a lock ring (52).
The frame on the outer diameter of the control valve (20) separates the control valve into a short and a long
end.
- Slide the largest diameter of the guide valve rod (23) into the long end of the control valve. Press
the guiding holder against the raised edge of the control valve.
- Secure the guiding holder and the guide valve rod in the control valve with a lock ring (51) .
- Put the long end of the control valve through the membrane holder from the convex side.
Ensure that the frame of the control valve lies on the membrane holder. Pay attention not to press
the seal ring in the membrane holder out of the groove when mounting the control valve. .
- Secure the membrane packets to the membrane holder with the disc (65) and four hex socket head
screws (65).

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 7
PARTS LIST: 02.02 No. of Items (belonging to diagram 02.02)
11 (1) Membrane Holder 8104003131980
12 (1) Membrane *8104004106720
20 (1) Control Valve 8104003131970
23 (1) Guide Valve Rod 8104004100520
43 (1) Seal Ring * 8401050502136
44 (1) Membrane Disc 8104003131990
46 (4) Hex Socket Head Screw 8251050060016
47 (1) Guiding Holder 8104004100530
51 (1) Lock Ring 8236050040001
52 (1) Lock Ring 8236000015001
64 (4) Screw 8251110060016
65 (1) Disc 8104004131960
We recommend to have on stock the with * marked parts.
Diagram: 02.02

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 8
2.3 Safety Shut-off Valve
Assembly
- Hold the valve rod (25) so that the screw thread points upwards.
- Slide the two sinus spring rings (27) with the convex side facing downwards over the top of the valve
rod.
- Place the seal ring (31) into the groove of the safety shut-off valve (56).
- Slide the retainer (30) into the safety shut-off valve. The seal ring is pressed between the
safety shut-off valve and retainer.
- Secure the retainer onto the safety shut-off valve with two hex socket head screws (28) and spring
rings (29).
- Slide the retainer over the valve rod and against the sinus spring rings.
- Press the safety shut-off valve against the spring pressure of the sinus springs and place the seal
ring (32) into the groove of the valve rod.
- Screw the guiding (58) onto the valve rod. The seal ring is pressed between the safety shut-off valve
and guiding.
- Take an open lug wrench with a "big jaw" opening (8) in order to tighten the guiding.

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 9
PARTS LIST: 02.03 No. of Items (belonging to diagram 02.03)
25 (1) Valve Rod 8104004100230
27 (2) Sinus Spring Rings 8503210653400
28 (2) Hex Socket Head Screw 8207160040012
29 (2) Spring Ring 8237020040001
30 (1) Retainer 8104004150990
31 (1) Seal Ring * 8404037703222
32 (1) Seal Ring * 8404006002108
56 (1) Safety Shut-off Valve 8104004103880
58 (1) Guiding 8104004100550
We recommend keeping the spare parts marked with * ready for maintenance
purposes.
Diagram: 02.03

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 10
2.4 Cover of Cartridge
The cover of the cartridge (40) closes the top of the gas regulating and safety internal component. The
monitor control is mounted later on the cover of the cartridge. The control valve (02.02 Pos. 20) of the gas
regulation station is located in the interior of the cartridge
Assembly
- Fasten the seal ring (39) into the groove on the interior of the valve guide (10).
- Place a seal ring (41) into the groove on the exterior.
- Place the cover of the cartridge (40) with the concave side facing upwards.
- Slide the valve guide onto the edge in the centre of the cartridge cover.
- Close the valve guide with a lock ring (42) cover of the cartridge.
- Turn over the cover of the cartridge.
- Place the seal ring (3) into the groove on the top of the cover of the cartridge.
Put this part aside.
PARTS LIST 02.04 No. of Items (belonging to diagram 02.04)
3 (1) Seal Ring * 8401047302134
10 (1) Valve Guide 8104004117080
39 (1) Seal Ring * 8401050204329
40 (1) Cover of Cartridge 8104001126260
41 (1) Seal Ring * 8401071102149
42 (1) Lock Ring 8236050075001
We recommend to have on stock the with * marked parts.
Diagram: 02.04

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 11
2.5 Gas Regulation Casing
The safety shut-off valve (02.03) and the dust filter (02.09 Pos.37) are mounted under this casing.
Assembly
- Place the valve seat holder (24) with the smallest diameter facing upwards.
There are three grooves on the top of the valve seat holder. The topmost groove is for a lock ring (55); the
other two grooves are seal ring grooves.
- Place the two seal rings (53) into the seal ring grooves on the top of the valve seat holder.
- Turn over the valve seat holder.
- Place the seal ring (50) into the groove of the top of the valve seat holder.
- Secure the seal ring with a valve cup (60).
- Slide the diameter of the valve seat holder through the hole in the middle of the gas regulation
casing. The valve seat holder frame is located on the gas regulation casing
- Place the gas regulation casing to one side.
- Secure the valve seat holder with a lock ring (55) at the lower end of the gas regulation casing.
- Fasten the seal ring (71) in the groove on the interior of the valve guide (66).
- Place a seal ring (41) into the groove on the exterior.
- Slide the valve guide into the middle of the gas regulation casing.
- Close the valve guide with a lock ring (42).
- Place the gas regulation casing with the largest diameter facing upwards.
- Place the spring pins (13) onto the hole with ø6.
- Place a seal ring (14) into the area around the spring pins.
- Place seal rings (15) into the two grooves in the largest diameter of the
gas regulation casing.

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 12
PARTS LIST 02.05 No. of Items (belonging to diagram 02.05)
13 (1) Spring Pins 8239060060012
14 (1) Seal Ring * 8401006101010
15 (2) Seal Ring * 8401253603274
24 (1) Valve Seat Holder 8104003117480
41 (1) Seal Ring * 8401071102149
42 (1) Lock Ring 8236050075001
50 (1) Seal Ring * 8404047203225
53 (2) Seal Ring * 8401044102132
54 (1) Gas Regulation Casing 8104541126230
55 (1) Lock Ring 8236000050001
60 (1) Valve Cup 8104004117490
66 (1) Valve Guide 8104004134710
71 (1) Seal Ring * 8401049236000
We recommend to have on stock the with * marked parts.
Diagram: 02.05

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 13
2.6 Assembly of Gas Regulation Station and Cover of Cartridge
Assembly
- Bend the membrane (02.02 Pos.12) into the shape as shown in diagram (02.06) on page 14 .
- Slide the short end of the control valve (concave side of the gas regulation station) through the
valve guide (02.04 Pos. 10) in the cover of the cartridge.
Press the thicker membrane edge into the groove in the cover of the cartridge.
- Lower the cover of the cartridge slowly onto the top of the gas regulation casing. Slide the control
valve through the valve guide (02.05 Pos. 66) in the upper flange of the gas regulation casing
(02.06). A spring pin centres the cover of the cartridge to the upper flange of the gas regulation
casing.
- Secure the cover of the cartridge on the top of the gas regulation casing with twelve hex socket
head screws (02.06A Pos. 45).
- Fix the locking screw (73 and 74) as shown in diagram 02.06A to the 1/8” BSP and 1/4“ BSP holes.

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 14
Diagram: 02.06

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 15
PARTS LIST 02.06A No. of Items (belonging to diagram 02.06A)
45 (12) Hex Socket Head Screw 8251050100035
73 (1) Locking Screw 6447200001000
74 (1) Locking Screw 6447210001000
Diagram: 02.06A

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 16
2.7 Assembly of Safety Unit
Assembly
- Place the safety shut-off valve (59) on its cover.
- Slide the pressure spring (57) over the bush.
NOTE: Be careful when removing the pressure pin.
This pressure pin could perhaps be electrified.
- Slide the guide (58) into the bush.
- Slide the valve rod of the safety unit (02.03 Pos. 25) from the end of the gas regulation casing in the
guide valve rod (02.02 Pos. 23). Ensure that the holes in the cover match the holes in the flow
regulator casing (02.05 Pos. 54).
- Secure the cover to the gas regulation station with four hex socket head screws (34) and
spring rings (33).
- Turn this part over.
- Fasten the pressure spring (9) in the valve guide (02.02 Pos. 20)
NOTE: Be careful when removing the pressure pin.
This pressure pin could perhaps be electrified.
- Slide the pressure pin (5) into the guide valve rod (23) against the shut-off valve rod.
- Place the connection piece (6) with the threaded hole facing upwards.
- Place the seal ring (61) on the bottom of the chamber.
- Place the pressure pin guide (8) with the largest hole facing upwards.
- Place the seal ring (4) into the pressure pin guide (8).
- Place the seal rings (68) into the pressure pin guide (8).
- Close everything with lock rings (67).
- Screw the pressure pin guide (8) into the threaded hole of the connection piece.
- Slide the pressure pin guide (8) into the connection piece over the pressure pin
and against the cover of the cartridge.
- Secure the connection piece on the cover of the cartridge with four hex socket head screws (38).
- Slide the monitor control (99) over the pressure pin and against the connection piece. Ensure that
the membrane of the monitor control points in the same direction as the arrow on the cover of the
cartridge (02.04 Pos. 40), which points in the direction of the gas flow.
- Secure the monitor control to the connection piece with four hex socket head screws.
- Secure two handles (2) onto the cover of the cartridge with four hex socket head screws.
- Press a lamella plug (1) into every handle.

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 17
PARTS LIST 02.07 No. of Items (belonging to diagram 02.07)
1 (2) Lamella Plug 8303050000015
2 (2) Handles (for Cartridge) 9304093101370
4 (1) Seal Ring * 8401003701007
5 (1) Pressure Pin Safety Unit 8104004150700
6 (1) Connection Piece 8104003118240
7 (4) Hex Socket Head Screw 8251050120020
8 (1) Pressure Pin Guide 8104004138340
9 (1) Pressure Pin 8501114131660
33 (4) Spring Ring 8237020060001
34 (4) Hex Socket Head Screw 8207160060020
38 (4) Hex Socket Head Screw 8251050080035
57 (1) Pressure Pin 8501134106490
59 (1) Pressure Pin Safety Unit 8104004100060
61 (1) Seal Ring * 8401023501021
67 (1) Lock Ring 8251437012001
68 (1) Ring 8104004138400
99 (1) Monitor Control 050 LP-D 8014030020034
(1) Monitor Control 050 MP-D 8014040020034
99A (3) Hex Socket Head Screw 8251230060012
We recommend to have on stock the with * marked parts.
Diagram: 02.07

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 18
2.8 Assembly of Regulator Pilot, Safety Relief Valve and Measuring
Devices such as Vent and Pressure Relief Pipes.
NOTE: You will need a regulator pilot: RP-LP/MP, shut-off relay 050-LP(D)/MP(D) and safety shut-
off valve AV-LP/MP before starting with the assembly as stated in this chapter. Use the test
casing on assembly.
A measuring sleeve for the inlet pressure (17) is to be secured to the casing with two hex socket head
screws (8). The inlet pressure measuring sleeve is positioned on the high pressure side of the station.
Assembly of the Inlet Pressure Measuring Sleeve (17)
- Attach the ball vales (1) to the end of the inlet pressure measuring sleeve (17) with
a straight pipe fitting with a thread (2).
- Fix the inlet pressure gauge (14) with fittings (16 and 17) to the side of the inlet pressure measuring
sleeve.
- Place the seal ring (9) into the areas underneath the measuring sleeves.
Assembly of the Outlet Pressure Measuring Sleeve (26)
A measuring sleeve for the outlet pressure (26) is to be secured to the casing with two hex socket head
screws (10) after the gas regulating station and safety unit have been installed. The measuring sleeve
secures this cartridge. The outlet pressure measuring sleeve is positioned on the low pressure side of the
station.
- An outlet pressure gauge (20) is mounted to the top side of the outlet pressure measuring sleeve
(26) with a reduction sleeve (26).
- Place the seal rings (27) into the areas underneath the measuring sleeves.
NOTE: Make sure that all connecting pieces are sufficiently greased with a gas-resistant gel suitable
for pneumatic applications.
Assembly of the Pilot and the Outlet Pressure Measuring Sleeve (26)
- Screw the vertical part of the adjustable angle fitting (2) into the connection piece (02.07Pos. 6).
Ensure that the fitting is horizontally mounted.
- Turn this component in such a way that the adjustable angle fitting points to the left.
- Attach connection ‘1’ of the regulator pilot RP-LP/MP to the adjustable angle fitting with the straight
screw-in socket.
There are two arrows on the cover of the cartridge (02.04 Pos. 40). Turn the internal part in such a way that
the arrow, which points in the direction of the gas flow (---->), points to the right. There is a connection on the
cover of the cartridge:
Connection M1 (12.00 hour position): gas pressure regulating connection. (1/4”BSP)
- Secure the pipe (15) to connection ‘3’ of the regulator pilot RP-LP/MP with an angle pipe fitting with
a thread (1, and 52)
- Secure the other end of this pipe to connection ‘M1’ on the cover of the cartridge with an
adjustable angle fitting (52) and valve (51).
- Fix pipes (14) and (25) to the T connector (24).

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 19
- Mount the pipe (25) in the straight connector of the measuring sleeves.
- Secure the pipe (14) to connection ‘2’ of the regulator pilot RP-LP/MP with an adjustable angle
fitting.
- Mount a plug (31) on the vertical part of the T-connector (24).
- Mount the safety relief valve AV-LP/MP with a bracket (38) and two hex socket head screws (37)
under the hex socket head screw (02.07 Pos. 7) of the handle interior (02.07 Pos. 2).
- Secure the pipe (30) to the 15 mm connection of the measuring sleeve.
- Mount the other end of this pipe with an adjustable angle pipe fitting with a thread (5) in the floor
connection of the safety relief valve AV-LP/MP.
- Mount the adjustable angle fitting (12) in the side connection of the safety relief valve
AV-LP/MP and connect the tube (35) with an adjustable angle fitting.
- Secure the pipe to the ½" connection on the cover of the cartridge with a pipe fitting with a
thread (8) and a reduction socket (29).
- Mount the other end of this pipe in the second connection on the measuring sleeves.
- Mount the pipe (22) between the monitor control 050-LP(D)/MP(D) and the remaining connection
on the measuring sleeves with a straight pipe fitting with a thread (8).
NOTE: Please read chapter 3 first before continuing with chapter 2.9.

Maintenance manual
Honeywell
Maintenance and assembly manual underground gas pressure reducing station
Type: COCON26 DRA-LP/MP A/S page 20
PARTS LIST 02.08 No. of Items (belonging to diagram 02.08)
1 (1) Angle Pipe Fitting with a Thread 6450040014001
2 (3) Adjustable Angle Fitting 6414040015001
3 (1) Straight Screw-in Socket 6411040040001
5 (1) Angle Pipe Fitting with a Thread 6450070014001
6 (1) Ball Valves 9202040000004
8 (2) Straight Angle Pipe Fitting w/Thread 6419040014001
12 (1) Adjustable Angle Fitting 6414070015001
14 (1) Pipe Stainless Steel Pipe
15 (1) Pipe Stainless Steel Pipe
20 (1) Pressure gauge 1101061110122
22 (1) Pipe Stainless Steel Pipe
23 (1) Pipe Stainless Steel Pipe
24 (1) T-Connector 6443040011001
25 (1) Pipe Stainless Steel Pipe
28 (1) Pipe Stainless Steel Pipe
29 (1) Reduction Socket 6438232100000
30 (1) Pipe Stainless Steel Pipe
31 (1) Locking Cone 6446040000001
33 (1) Locking Connector 6447200001000
34 (1) Locking Connector 6447210001000
35 (1) Tube 9206010000001
36 (1) Straight Bulkhead Connector 6441070011000
41 (1) Straight Angle Pipe Fitting w/Thread 6419040016321
43 (2) Ring 8250302130018
47 (1) Reduction Connectors 6433070411001
49 (1) Dust Cap 8303050000029
50 (1) Ring 8250301210026
51 (1) Butterfly Valve 931950S133930
52 (2) Angle Pipe Fitting w/Thread 6414040011001
Diagram: 02.08