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

registered design registration.

Contents

Validity and purpose

Target group

Illustration

Safety

General considerations

HON 5020 gas pressure regulator 4

Honeywell Process Solutions

Honeywell Gas Technologies GmbH

Osterholzstraße 45

34123 Kassel

GERMANY

Tel: +49 561 5007-0

Phone number for service: +49 561 5007-180

Fax: +49 561 5007-107

Fax number for service: +49 561 5007-108

E-mail: gas-ks@honeywell.com

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

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

Nameplate

Body part number

Batch number

Foundry code

CE PIN

(only if the unit has been granted a CE type

approval)

Body nominal size

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

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

Model name

Manufacturer

Nominal size

Serial number of the device

Valve seat diameter

Device version

(IS = version with integral overpressure

protection)

Standard (EN 334)

Manufacturing date (month/year)

Connection

Temperature range

Failure function (fail-open)

Maximum allowable pressure

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

Model name

Manufacturer

Nominal size

Nominal pressure / Flange standard

Tightening torque

Manufacturing date (month/year)

Customer reference number

Serial number

Differential pressure

Temperature range (-40° to 175° F)

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

Actuator body

Diaphragm assembly

Flow restrictor

Noise reduction element

Support disc

Inlet pressure

Outlet pressure

Motorization pressure

How it works

Actuator assembly con-

figuration

Description

HON 5020 gas pressure regulator 10

Actuator assembly connection lines:

Figure

No.

Connection

Front:

Inlet pressure

Motorization pressure

Outlet pressure / feedback

Back:

Outlet pressure

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

Optical travel indicator

Optical travel indicator with remote control

Actuator assembly

connection lines

Travel indication option

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