Honeywell HON 985B Manual

Gas Mixer HON 985B 985.29-1
Serving the Gas Industry
Worldwide
OPERATING AND MAINTENANCE INSTRUCTIONS/
SPARE PARTS EDITION 01/2017

Table of contents Page
1. General information 3
1.1 General information 3
1.2 Safety information 3
1.3 Applications and features 4
1.4 Structure and mode of operation 4
2. Specific operating instructions 5
2.1 High frequency radiation exposure 5
2.2 Stepper motor control card 5
3. Technical data 5
3.1 Technical features of the mixer 5
3.2 Dimensions and technical features of the stepper motor 5
3.3 Technical features of the proximity sensor (limit switch) 6
3.4 Dimensional drawing 7
4. Specific maintenance instructions 8
4.1 Intervals for maintenance instructions 8
4.2 Tightening torques MA8
4.3 Lubricants 8
4.4 Adhesives 8
5. Maintenance 9
5.1 Dismantling the proximity sensors 9
5.2 Dismantling the drive unit 9
5.3 Dismantling the Venturi insert 10
5.4 Replacing the guide belts 10
5.5 Installing the Venturi insert 10
5.6 Mounting the induction elbow 10
5.7 Mounting the drive unit 11
5.8 Adjusting the proximity sensors 11
6. Spare parts
6.1 Spare parts drawing 12
6.2 Spare parts list 13
6.3 Parts for maintenance purposes 14
985.29-1 p.02

985.29-1 p.03
1. General information
1.1 General information
All persons involved with the assembly, operation and / or maintenance of the gas mixer
HON 985B -140/65-ZW-N-NI must attentively read and understand these operating and
maintenance instructions in their entirety.
Inspection and maintenance intervals depend mostly on the operating conditions at the respective
system. Amongst other factors, the device used and the corresponding gas composition, and the
existing gas contamination as well as any accumulating condensates must be taken into account.
There are no general rules or recommendations for intervals. Therefore, it is advisable to include the
devices in the gas engine maintenance intervals.
If operational irregularities are discovered during the operation or during a functional
test, unplanned maintenance work on the mixer is required. This must be performed
as soon as possible after the discovery of the deviation in operating behaviour.
During maintenance, components must be cleaned and then checked thoroughly. This is necessary
even if there have not been any unusual observations during operation and / or functional testing.
The check must include in particular seals, all moving parts such as the transmission thread and
Venturi insert. Any and all defective parts must be replaced with new ones. The same applies to
O rings removed during disassembly.
Do not use any spare / wear parts and/or oils & lubricants not specifically recommended in the Honeywell
operating and maintenance instructions. In the event spare / wear parts and/or lubricants & oils other
than those specifically recommended are used, Honeywell shall not be held liable for any defects and / or
consecutive damages attributable to such use of illegal parts, lubricants, oils etc.
Some parts in the lists and drawings are marked with a letter “W”. We recommend to always have
a reserve of those parts in stock for maintenance purposes.
Those spare parts are put together in another separate list at the end of the spare parts list.
Danger of damage to property and /
or the environment
Important additional information
Eye catcher Used for:
Danger to life and limb
Note
Caution
!
Danger
!
Note
1.2 Safety information
In this manual, safety information is highlighted by means of the following
signal words and eye catchers

985.29-1 p.04
1.3 Applications and features
•Applications
– Variable mixing of air and fuel gas for gas engines (e.g. for λ-control, electronic spark control,
combustion-chamber temperature control)
– Mixing gases for operating gas motors with multiple types of fuel gas (e.g. sewage gas,
secondary operation with natural gas)
– In general, mixing all sorts of gases (e.g. boosting low calorific-value gases like waste dump gas)
– Applicable for natural gas, sewage gas, dump gas, mine gas, propane, butane and neutral gases
•Features
–Simple construction
–
–Adjustable fuel-gas mixing gap provides for flexible mixing ratios
–Fine adjustment of mixing ratios possible
–Sensitive stepper motors provide for precise adjustment of mixing gap
–Turbulent mixing (homogenization)
Mixture of air
/ fuel gas
not rich enough too rich
increase mixing gap reduce mixing gap
1.4 Structure and mode of operation
gas 2 (fuel gas) flowing in through an upstream gas pressure control section to the same pressure as gas 1 (air). With the
reduction of the cross-section, there is an acceleration of gas 1 (air) flowing in. Acceleration means the pressure of the gas
The downstream flow edges of the torpedo support the turbulent mixing of the two types of gases (homogenization).
For a more precise adjustment of the mixing ratio λ-control, for instance), there are sensitive electronic control loops
and motors that can adjust the gap according to operational requirements.
Gas 2
(Fuel gas)
Gas 1
(Air)
Air
/ fuel
gas mixture
Constriction
device
(torpedo)
Venturi
nozzle
Adjustable
mixing gap
Mixing zone
HON 985B - 140/65-ZW-N-NI
Stepper motor
with control*
*) Stepper motor control, e.g. for
– λ-control
– Control of cylinder temperature
– Electronic spark control
Fig 1: Functional principle

ø5,5
56
47
ø38
20
ø6
76 max.
985.29-1 p.05
2. Specific operating instructions
2.1 High frequency radiation exposure (comment on application at gas engine)
Possible high frequency radiation exposure (e.g. from the coil and its cable) must be observed
with regard to the proper response from the proximity sensors and stepper motor. Cables must
be laid separately.
2.2 Stepper motor control card
A stepper motor control card is not included in the scope of delivery. When choosing a stepper motor control card,
the following data on the stepper motor and the limit sensors should be taken into account.
3. Technical data
3.1 Technical features of the mixer
3.2 Dimensions and technical features of the stepper motor
Max. permissible pressure load PS 0.5 bar
Mixing ratio Qn air/ Qn fuel gas 3.5 : 1 to 25 : 1
yollamuinimulA:ydoBlairetaM
yollalA:straplanretnI
/ steel
RBN:slaeS
Max. operating and environmental temperature –10 °C to +80 °C
SEP design in accordance with PED
rotomreppetsdirbyhngiseD
gnihctiwslellarap,ralopibepytlioC
²mcg084aitrenifotnemomrotoR
mN7.1euqrotgnidloH
Full steps per shaft rotation 200
°8.1)petslluf(elgnapetS
W4.4liocrepecnatsiseR
A4.1esahpreptnerruc.xaM
V42egatlovlortnoc.niM
Hm91liocrepytivitcudnI
Length of the electrical supply line approx. 0.3 m
tekcosdnagulpdnuornip-5noitcennoclacirtcelE
Table 1: Technical features of the mixer
Fig 2: Dimensional drawing of the stepper motor
Table 2: Technical features of the stepper motor
Note
Connection plug
Caution
!
Cable and connection plug must be
fastened properly so that a cable break
does not occur.
Note A socket compatible with the stepper motor is included in the delivery.

3
24
51
a b c d
e
f
g
h
25
40
M8
+
-
985.29-1 p.06
Fig 3: Connection diagram of the stepper motor
3.3 Technical features of the proximity sensor (limit switch) for Venturi position
gulpecived1VnoitcennoC
01egatlovgnitarepO
– 60 VDC
%01≤elppiR
zH005ycneuqerfgnihctiwS
Am001tnerrucgnitarepO
Am51noitpmusnocrewopgnildI
)dehctiwsevitisop(reneponppgnikramtuptuO
)Am001taV3.xam(–egatlovgnitarepoeerfecafrusevitcA
V3.0≤derevocecafrusevitcA
Interference voltage (permissible voltage peaks) max. 1000 V
/ 10 ms
mhOk01ecnatsiserlanretnI
eerfsiecafrusevitcanehwthgilwolleyDELsutatsgnihctiwS
31WStunretnuocdnag
nitsujdA
Table 3: Technical features of the proximity sensor
Note A socket compatible with the proximity sensor is included in the delivery.
Fig 5: Proximity sensor connection diagram
Fig 4: Proximity sensor
Colours of the wires
a - blue/white
b - blue
c - red
d - red/white
e - green
f - green/white
g - black/white
h - black
Straight socket
LED
Inductive sensor
Counter nut
Adjusting nut
1 / brown
2 / white
3 / blue

X
X
ø140
23
483.5
350.5
18
ø83
(273)
75 75
ø150
ø152
122
ø133.6
4xø9
45°
ø I
34
ca. 300
76
76
ø62
8.5
94
46.5
11.5 76
76
97
1)
985.29-1 p.07
3.4 Dimensional drawing HON 985B-140/65-ZW-N-NI
Flow direction
ø I Variable torpedo diameter (see spare parts list)
1) Induction elbow can be installed at any angle position
in relation to the fastening level
2) Pressure measurement M10 x 1 connection possibility
Fig 6: Dimensional drawing
Fuel gas connection level
Fastening level
Air connection (hose)
Mixture connection
Stepper motor connection
Proximity sensor “lean”
(second “rich”
proximity sensor optional)
4 x M 8 - 12 deep
HELICOIL
Locking screw 2)
4 x M 8 - 12 deep
HELICOIL
Fastening clamp

985.29-1 p.08
812712412.on.metI
Tightening torque in Nm 8 12 20
4. Specific maintenance instructions
Do not carry out maintenance unless the system is safely de-energised and depressurised.
Danger
!
4.2 Tightening torques MA
Screws and nuts without a specification of the tightening torques are normally tightened according to the commonly
available tables for screw dimensions and qualities using an appropriate tool. Parts with a specified tightening torque
(see spare parts drawing) are to be tightened to the specified value with a torque wrench (see table).
Table 4: Tightening torques MA
4.3 Lubricants
.ontrapHONstnacirbuLstnenopmoC
18072esaergenociliSsgnir-OllA
19072etsapylbmessAswercsgninetsafllA
40772tnegapilSeldnipsrotomehtnodaerhtnoissimsnarT
Observe the notes regarding lubricants in chapter 1.1 General information.
Caution
!
4.4 Adhesives
The parts to be glued must be completely clean, dry and free of grease. Specifications for adhesive connections
can be found in the spare parts drawing and the following maintenance instructions.
Table 5: Lubricants
No. Adhesive connections HON part no.
69382odeproT1
09662niP2
Table 6: Adhesives
4.1 Intervals for maintenance purposes
The intervals between maintenance tasks depend largely on the operating conditions of the device.
Please observe chapter 1.1. General Information.
If operational irregularities are discovered during the operation or during a functional test,
unplanned maintenance work on the mixer is required. This must be performed as soon
as possible after the discovery of the deviation in operating behaviour.
Note
All O-rings which are replaced (1.1 General information) must be lubricated with silicone grease before installation
after the device maintenance.

985.29-1 p.09
5. Maintenance
With the description of the individual maintenance steps, the same position numbers are used here for the identification
of the component as can be found in the spare parts drawing (page 12) and the spare parts list (page 13).
In order to enable simple, easy maintenance work, we recommend following the sequence of the individual steps.
The device must be dismantled from the plant prior to maintenance work.
5.1 Dismantling the proximity sensors
Before dismantling the drive unit of the mixer and beginning with the maintenance work,
the proximity sensors (208) should be removed from the device in order to prevent damage.
Prior to the dismantling, the sensors should be disconnected from the power source.
Unscrew the cable sockets (209) from the initiators. Loosen the counter nuts of the proximity
sensors and unscrew the sensors from the adapter.
5.2 Dismantling the drive unit
Remove the plug (206) and loosen the connection between the adjustable coupling (207) and pin (204) by partially
unscrewing the threaded pin (Figure 7).
Then remove the plug (211), loosen the cylinder screw (212) and remove it with the bush (213). Then the four
cylinder screws (214) can be loosened and the stepper motor (215) with adjustable coupling unit (207) can be
removed from the induction elbow (223) (Fig. 8)
Fig 7: Position of the threaded pin
Fig 8: Stepper motor with adjustable coupling
The adjustable coupling (207) is screwed onto the motor spindle; it can be removed by rotating the spindle.
Clean the parts and check the condition of the transmission thread (inside and outside thread). Let the cleaned parts
connection is firmly seated.
Caution
!
Threaded pin Adjustable coupling
Stepper motor
Adjustable coupling
Disc
Motor spindle

985.29-1 p.10
5.3 Dismantling the Venturi insert
Loosen the cylinder screw on the profile clip (217) and remove it. Disconnect the body (201) together
with the Venturi insert and pin (204) from the induction elbow.
The parts should be carefully separated from one another in order to prevent damage
to the pin by bending, etc.
Now the Venturi insert/pin/torpedo unit (Figure 9) can be pulled out of the mixer body.
All parts of this unit are adhered to one another and may not be separated from one another. If the parts can
Fig 9: Venturi insert/pin/torpedo unit
5.4 Replacing the guide belts
Remove and dispose of the old guide belts (221 and 222). Clean the sliding surfaces on the Venturi insert
and groove for the belts with adjacent surfaces and allow to dry.
Fit new guide belts.
The guide belts and sliding surfaces may not be lubricated. Lubrication of the parts can
negatively influence the operating behaviour of the devices.
Caution
!
5.5 Installing the Venturi insert
Move the body up to the vertical position with the connection side facing the induction elbow. Slide the Venturi insert with
the small diameter forward into the body and check the ease of movement of the insert. The resistance may be too great
when sliding the insert due to production tolerances. In this case, the guide belts must be adjusted by removing a thin layer.
In the process, it must be ensured that the Venturi insert does not slip through under its own weight. If this should occur,
the play between the insert and the belts is too great.
5.6 Mounting the induction elbow
After the adaptation of the guide belts the body is mounted together with the induction elbow (223). The body remains
vertically aligned. Prior to mounting the induction elbow, make sure that the O-ring (203) is not twisted out of the centring
collar. Carefully place the elbow on the mixer body so that the pin goes in through the hole in the induction elbow (Figure 7)
provided for this purpose. Place the profile clip on the angles of the two flanges (on the housing and the induction elbow)
and connect the two parts in the correct spatial arrangement by tightening the cylinder screw.
Rod
Venturi insert
Torpedo
Caution
!

985.29-1 p.11
5.7 Mounting the drive unit
Before fitting the stepper motor and adjustable coupling, spray the threaded spindle on the stepper motor with slip agent
(Table 5). Then rotate the coupling onto the spindle and adjust the distance to the motor flange (see Figure 10).
Fig 10: Adjustable coupling – stepper motor flange adjustment measurement
Slide the Venturi insert into the upright body until its mechanical stop and fit the adapter (210). Then mount the
stepper motor with the adjustable coupling. In the process, make sure that the cylinder pin (205) goes through the
hole in the disc (Fig. 8) and the pin runs in the coupling. Fasten the stepper motor with adapter by tightening the
four cylinder screws (214) on the induction elbow. Tighten the threaded pin (Figure 7) and insert the plug (206).
5.8 Adjusting the proximity sensors (limit switches)
Before adjusting the sensors, first screw in the cylinder screw (212) hand-tight into the threaded hole in the adjustable
coupling (spare parts drawing) with the sleeve (213) fitted in the threaded hole provided for this purpose.
Adjust a mixing gap of 0.5 + 0.1 mm by moving the stepper motor. An adjustment of 0.5 mm takes place with
a control frequency of 20 Hz in full step operation in 5 seconds.
With a change to the control frequency by a factor K, the adjusting time changes
by the factor 1/K.
With a change to the step precision by a factor 1/F, the adjusting time changes
by the factor F.
With an adjustment of both parameters, factors F and 1/K are multiplied.
Adjust the switching point of the “lean” position by screwing in the proximity sensor (208). Screw in the proximity
sensor until the LED on the sensor goes out. Then lock the sensor in its position by tightening the counter nut.
Observe the tightening torque according to the spare parts drawing.
If the device is equipped with two sensors, the switching point for the “rich” position is adjusted first (max. mixing
gap width). For this purpose, increase the mixing gap an additional 4 mm from the "lean" switching point by moving
the stepper motor (total gap width 4.5 + 0.1 mm). In full step operation the additional adjustment at a 40 Hz step
frequency takes place in 20 seconds. Observe the notice above.
The adjustment of the screw-in position of the proximity sensor, "rich" switching point, takes place analogously to
the adjustment of the "lean" switching point. Then lock the sensor in place here as well by tightening the counter nut.
Note
Caution
!
Observe the adjustment measurement!
Adjustable coupling
Stepper motor

MA= 10 Nm
218 219 220 221 222 223
W W W
W 201 202 203 204 205 206 207 208, 209 210 211 212 213 214 215, 216 217
224 226 227 228 229 W W W W
MA
MA
MA
*2
*1
225
W
X
X
6.1 Spare parts drawing HON 985B -140/ 65-ZW-N-NI
985.29-1 p.12
pictured rotated through 90°
pictured rotated through 90°
6 Spare parts
MABe sure to comply with torque figures in table on page 7!
WParts should be held in stock for maintenance purposes
*Adhesive connection (in accordance with table 6)

Item
no. Denomination Number W Material Part no.
985.29-1 p.13
6.2 Spare parts list HON 985B - 140/65-ZW-N-NI
91403001MLG1ydoB102
11403001MLG1tresniirutneV202
50212GKW1gniR-O302
96332001tSN1noitcesertnectfahS402
77271tS1niprednilyC502
86062K1gulP602
79213001tS/tSN1gnilpuocelbatsujdA702
22142tSN)2(1rosnesytimixorP802
32142K1tekcoS902
39213001ML1retpadA012
012101K1gulP112
02101tS1wercsrednilyC212
69213001tSN1hsuB312
122101tS4wercsr
ednilyC412
64313001zB/ML1rotomreppetS512
70142K1tekcoS612
72282tSN1pilcelfiorP712
218 Torpedo, optional:
17513001K152ØodeproT812
07513001K123ØodeproT812
98903001K183ØodeproT812
96513001K124ØodeproT812
74501tS1wercsgnikcoL912
27581MLW1gnirgnilaeS022
51403001KW1tlebediuG122
41403001KW1tlebediuG222
71403001MLG1woblenoitcudnI322
24312GKW1gni
R-O422
225 Complete guide, comprised of Pos. 226 to 228 1 LM/Bz ... 10030011
90003001zB/MLW1ediuG622
01003001ML1redlohediuG722
12302GKW1gniR-O822
20291tSFW1gnirgnikcoL922
WParts should be held in stock for maintenance purposes
German abbreviations stand for the following materials:
ssarbtsaC...sMGlatemthgiL...MLleetS...tS
cniztsaC...nZGssarB...sMleetssselniatS...tSN
eznorbmuinimulA...zBlAleetstsaC...SGleetsgnirpS...tSF
citsalP...KnoritsacetihpargladiorehpS...GGGleetsgnirpssselniatS...tSFN
slairetamcitehtnyssuommuG...GKeznorbtsaC...zBGeznorB...zB
slairetamdemaoF...tSSlatemthgiltsaC...MLGreppoC...uC

Item
.ontraPrebmuNnoitanimoneD.on
985.29-1 p.14
6.3 Parts for maintenance purposes
502121gniR-O302
275811gnirgnilaeS022
514030011tlebediuG122
414030011tlebediuG222
243121gniR-O422
225 Complete guide, comprised of Pos. 226 to 228 1 10030011
900030011ediuG622
123021gniR-O822
202911gnirgnikcoL922
180721esaergenociliS–
190721etsapylbmessA–
407721tnegapilS–
6938211evisehdA–
0966212evisehdA–

For More Information
To learn more about Honeywell’s
Advanced Gas Solutions, visit
www.honeywellprocess.com or contact
your Honeywell account manager
GERMANY
Honeywell Process Solutions
Honeywell Gas Technologies GmbH
Osterholzstrasse 45
34123 Kassel, Germany
Tel: [phone]
Fax: [phone]
HON 985.29_1
2017-01
© 2017 Honeywell International Inc.