GF NeoFlow DN200 User manual

Operating instructions
NeoFlow Pressure Reducing Valve
DN200 –DN300

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Disclaimer
The technical data is not binding. It does not constitute expressly warranted
characteristics. And neither guaranteed properties nor guaranteed durability. It is
subject to modification. Our General Terms of Sales apply.
Observe instruction manual
The instruction manual is part of the product and an important element within the
safety concept.
►Read and observe instruction manual.
►Always have instruction manual available by the product.
►Give instruction manual to all subsequent users of the product

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CONTENTS
1PRODUCT DESCRIPTION .......................................................................................................6
1.1 Intended Use............................................................................................................................6
1.2 EC Manufacturer's declaration..................................................................................................6
1.3 PRESSURE REDUCING VALVE (PRV) CONFIGURATION.................................................................7
1.3.1 METHOD OF OPERATION ...........................................................................................................................7
1.3.2 P&ID ...........................................................................................................................................................7
1.4 PRESSURE RATINGS & PERFORMANCE ......................................................................................8
1.5 FLANGE & SIZING DATA ............................................................................................................8
1.6 NAMEPLATE INFORMATION......................................................................................................9
1.7 BILL OF MATERIALS –PRESSURE REDUCING ASSEMBLY............................................................10
1.8 BILL OF MATERIALS –VALVE BODY..........................................................................................12
1.9 BILL OF MATERIALS –CONTROL BLOCK....................................................................................14
1.10 BILL OF MATERIALS –PRESSURE REDUCING PILOT (PR1)..........................................................15
1.11 BILL OF MATERIALS –SPEED CONTROL....................................................................................16
1.11.1 SEAL KITS..................................................................................................................................................17
1.11.2 PRESSURE SENSE PORTS ..........................................................................................................................17
1.11.3 PRESSURE CONTROLLER COMPATIBILITY.................................................................................................18
1.12 RECOMMENDED TOOLS AND CONSUMABLES..........................................................................18
1.12.1 INSTALLATION/MAINTENANCE TOOLS ....................................................................................................18
1.12.2 LUBRICATION & THREAD SEALANT ..........................................................................................................18
2INSTALLATION ................................................................................................................... 19
2.1 TRANSPORT AND HANDLING ..................................................................................................20
2.2 SITE SELECTION.......................................................................................................................21
2.2.1 BYPASS LINE .............................................................................................................................................21
2.2.2 PERMITTED VALVE ORIENTATIONS..........................................................................................................23
2.2.3 PERMITTED SPATIAL DIMENSIONS...........................................................................................................24
2.3 PILOT SPRING OPTIONS ..........................................................................................................25
2.4 VALVE INSTALLATION .............................................................................................................26
2.5 VALVE BOLT TORQUES............................................................................................................29
2.6 FLANGE ADAPTORS.................................................................................................................29
3COMMISSIONING............................................................................................................... 30
3.1 NeoFlow EXTERNAL COMPONENTS .........................................................................................30
3.2SETTING SPEED CONTROL VALVE.............................................................................................31
3.3 INITIAL PRESSURISING ............................................................................................................32
3.4 SETTING PRV DOWNSTREAM PRESSURE..................................................................................34
3.4.1 WITH HYDRANT........................................................................................................................................34
3.5 ADJUSTING THE SPEED CONTROL............................................................................................36
4MAINTENANCE .................................................................................................................. 37
4.1 DEPRESSURISING CONTROL SYSTEM .......................................................................................38
4.2 LIVE STRAINER & CONTROL SYSTEM FLUSHING........................................................................39
4.3 VALVE REMOVAL....................................................................................................................41
4.4 CONTROL SYSTEM REMOVAL ..................................................................................................43
4.5 CONTROL SYSTEM SERVICING .................................................................................................44
4.5.1 CONTROL BLOCK ......................................................................................................................................44
4.5.2 PRV PILOT.................................................................................................................................................45
4.6 MAIN BODY............................................................................................................................47
4.6.1 SHUT-OFF SEAL SERVICING ......................................................................................................................50
5TROUBLESHOOTING........................................................................................................... 52
5.1 DIAGNOSTICS .........................................................................................................................52

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IMPORTANT INFORMATION PLEASE READ BEFORE PROCEEDING
THIS INFORMATION PROVIDES GUIDANCE FOR THE INSTALLATION AND MAINTENANCE OF THE
NeoFlow Pressure Reducing Valve AND IS INTENDED FOR USE BY COMPETENT PERSONNEL ONLY.
DO NOT WORK ON THE VALVE WHEN PRESSURISED. ONLY A SMALL NUMBER OF MAINTENANCE
ACTIVITIES CAN BE COMPLETED DURING LIVE OPERATION. THESE ARE OUTLINED IN SECION 4.
FAILURE TO FOLLOW THE PROCESSES IN THIS MANUAL MAY INVALIDATE THE PRODUCT
WARRANTY. PLEASE CONTACT GF Piping Systems IF YOU ARE IN ANY DOUBT.
THE INFORMATION PROVIDED IN THIS DOCUMENT IS ACCURATE AT THE TIME OF PUBLICATION.
HOWEVER, IT MAY BE SUBJECT TO CHANGE. THEREFORE, PLEASE CONTACT GF Piping Systems
TO ENSURE YOU HAVE THE LATEST VERSION.
Achilles UVDB registration number 205390

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Abbreviations
EPDM Ethylene Propylene Diene Terpolymer
GCR GCR Tech Pressure Controller
HWN Halma Pressure Controller
P&ID Piping and Instrumentation Diagram
PCS Control Space Pressure
PN Pressure Nominal
PRV Pressure Reducing Valve
SS Stainless Steel
WRAS Water Regulations Advisory Scheme

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1 PRODUCT DESCRIPTION
1.1 INTENDED USE
The pilot controlled NeoFlow pressure reducing valve from GF Piping Systems was conceived for
the automatic pressure and flow control in networks for the supply and distribution of water. The
NeoFlow pressure reducing valve is designed to fit between standard PN10 / PN16 in a wafer-type
arrangement. It is also compatible with ANSI150 class flanges.
Foreseeablemisuse: TheNeoFlow pressurereducing valve may not be used as a pure shut-off valve.
Media other than water as well as water containing an amount of disinfectant may only be used in
consultation with a contact partner from GF Piping Systems. The use of solid matter in the medium
can affect the function of the NeoFlow pressure reducing valve. For this reason, use is only
recommended with an upstream strainer.
1.2 EC MANUFACTURER'S DECLARATION
The manufacturer Georg Fischer Rohrleitungssysteme AG, 8201 Schaffhausen (Switzerland)
explains that the NeoFlow pressure reducing valve fully complies with the standard “EN 1074-5
Valves for water supplies.” If the overall system does not comply with the requirements of an EC
directive, then putting the NeoFlow pressure reducing valve is prohibited until the conformity of the
overall system with the EC directive has been declared. Fittings Involved standards NeoFlow
Pressure reducing valve EN 1074-5 Changes to the fittings that could affect the stated technical data
and the intended use, void this manufacturer's declaration. Additional information can be found in
"GF planning fundamentals.”

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1.3 PRESSURE REDUCING VALVE (PRV) CONFIGURATION
1.3.1 METHOD OF OPERATION
Item
Description
1
Upstream (inlet)
2
Downstream (outlet)
3
Control block
4
Pilot supply
5
Pilot outlet connection
1.3.2 P&ID
Item
Description
1
Pressure reducing
pilot
2
Strainer
3
Restrictor
4
Isolation ball valve
5
Speed Control Valve
6
IP Valve

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1.4 PRESSURE RATINGS & PERFORMANCE
Maximum upstream pressure
16 bar*
Downstream pressure range
0.1-16 bar**
Minimum Pressure Drop
0.1 bar***
*With medium temperature ≤ 20°C; >20°C on request
**Pilot dependent
***Flow rate & size dependent
1.5 FLANGE & SIZING DATA
Dimension
Nominal Pipe
Diameter
Flange compatibility
Kv
(m3/hr)
Cv
(USGal/min)
DN200
DN200 / 8”
PN10 / PN16 / ANSI150
565
653
DN250
DN250 / 10”
PN10 / PN16 / ANSI150
773
894
DN300
DN300 / 12”
PN10 / PN16 / ANSI150
1004
1161

1.6 NAMEPLATE INFORMATION
Manufacturer
Oxford Flow
Manufacturer’s town and country
Oxford, UK
Regulator type
Pilot-operated pressure reducing valve
Standard
EN1074
Body Material
POM-C
Nominal size DN
DN0200-DN300
Allowable pressure PS
16 Bar(g) @ 20°C
Allowable incidental pressure
1.1 x PS
Continuous Operating temperature
range
≤ 20°C; >20°C on request
Flow coefficient Cv
See ‘Pressure Rating & Performance’
Leakage class
EN 12266-1 Rate A
Ports
G1/4 (BSPP)
Nameplate Key
Data
Definition
Example
aaa
Nominal size (DN)
(DN)100
bbbbbbbbb
Serial number
IP2012345
cccc
Year of Manufacture
2020

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1.7 BILL OF MATERIALS –PRESSURE REDUCING ASSEMBLY