GF NeoFlow DN200 User manual

Operating instructions
NeoFlow Pressure Reducing Valve
DN200 –DN300

2
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

3
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

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Item No.
(PRV)
Description
Quantity
1
Main body
1
2
Oxford Flow PR1 pilot
1
3
Control block assembly
1
4
120 Mesh (125 Micron) Control space
circular strainer
1
5
Control system restrictor block
1
6
Leengate G1/4 SS Ball
2
7
Tameson R1/4 to G1/4 Unequal tee
2
8
Nero R3/8 –R1/4 Reducing nipple
1
9
Nero R1/4 barrel nipple
2
10
Vee-Lok R1/4 to 10mm tube straight
3
11
Vee-Lok R1/4 to 10mm tube elbow
1
12
Accu G1/4” Plug
5
13
Accu R1/4” Plug
1
14
SS Bonded seal
5
15
BS119 Control space seal
2
16
BS110 Control space strainer seal
1
17
M6 x 70 Socket head bolt –A2-70 SS
4
18
PRV Upstream 10mm SS tubing
1
19
PRV Downstream 10mm SS tubing
1

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1.8 BILL OF MATERIALS –VALVE BODY

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Item
No.
Description
Quantity
101
Core
1
102
Cap
1
103
Strainer
1
104
Casing
1
105
Inlet
1
106
Shut off seal
1
107
Nameplate Sticker
1
108
Isolation valve handle
1
109
M20 x 1.5 to G1/4 Bulkhead
4
110
Spring
1
111
Geann –G3/8 quarter turn ceramic
cartridge valve
1
112
Core seal
1
113
Primary shaft seal
1
114
Inlet
1
115
BS110 Control space seal
1
116
BS017 Bulkhead seal
4
117
Socket head bolt –A2-70 SS
x
118
∅4 x 18mm ISO8750 Roll pin –A1 SS
1
119
Bossard Delta PT Self Tapping Screw –
A2 SS
x

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1.9 BILL OF MATERIALS –CONTROL BLOCK
Item No.
Description
Quantity
201
Control Block
1
203
60 Mesh Strainer
1
204
Control block strainer plug
1
205
BS119 Strainer
1

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1.10 BILL OF MATERIALS –PRESSURE REDUCING PILOT (PR1)
Item
No.
Description
Quantity
301
PR1 Pilot Base
1
302
Diaphragm Housing
1
303
Spring Case
1
304
Diaphragm Support
1
305
Actuator
1
306
Upper Spring Guide
1
307
Diaphragm
1
308
G1/4 Pilot base plug
1
309
Pilot setpoint bolt (60mm)
1
310
PR1 Pilot Nameplate Sticker
1
311
Pilot Primary Spring
1
312
Pilot Actuator Spring
1
313
Pilot Diaphragm Bolt
1
314
Pilot base seal
1
315
Pilot base plug seal
1
316
M6 Flanged torque nut
1
317
M6 x 40 Socket head bolt –A2-70
SS
8
318
M10 Thin Hex Nut –A2-70 SS
1
319
M10 Spring colour indication
washer –Plastic/A2 SS
1
320
Actuator Pin
1
321
∅3 x 10mm ISO8750 Roll pin –A1
SS
2

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1.11 BILL OF MATERIALS –SPEED CONTROL
Item No.
Description
Quantity
501
Control block mount
1
502
CAM Restrictor
1
503
Speed control schematic plate
1
504
CAM Damper seal
1
505
Bossard pan head Torx screw 2.2 x 5mm
2
506
∅3 x 24mm ISO2338 Parallel dowel pin –
A1 SS
2
507
Eagle Plastic Devices: Dial selector
1

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1.11.1 SEAL KITS
Valve Size
Seal Kits (inc. all O-
Rings)
DN200
173021008
DN250
173021009
DN300
173021010
1.11.2 PRESSURE SENSE PORTS
Logging equipment and pressure gauges can be attached on the upstream, downstream and PCS
(Control Space Pressure) control loop ports.
Pressure Logging Ports
A
Upstream
B
Downstream
C
Control Space (optional)

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1.11.3 PRESSURE CONTROLLER COMPATIBILITY
Controller
Compatible
Comments
I20
YES
Replace pilot and control block with i20 system. Addition
connection ports provided on request to connect to i20
controller
GCR
YES
Replace pilot set bolt with an M10 controller bolt
HWM
YES
1.12 RECOMMENDED TOOLS AND CONSUMABLES
1.12.1 INSTALLATION/MAINTENANCE TOOLS
•Spanners/sockets (full set)
•Flat head screwdrivers
•Torque wrenches
•Allen/hex keys (full set, ball-ended)
1.12.2 LUBRICATION & THREAD SEALANT
Lubrication
The manufacturer approved lubricant for all static seals is any generic WRAS approved silicone
grease, for instance SGM494.
The manufacturer approved grease for all dynamic seals is Molykote 111 (WRAS approved).
Thread Sealants
The manufacturer approved thread sealant for all metal thread inserts on the valve body is Loctite
5331 (WRAS approved).
The manufacturer approved thread sealant for all metal-on-metal threads is Loctite 5400 (WRAS
Approved).

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2 INSTALLATION
Meaning of the Signal Words
In this instruction manual, warnings are used, which shall warn the user of death, injuries or
material damage. Always read and observe these warnings!
DANGER! Imminent danger! Non-observance may result in major injuries or death.
►Measures to avoid the danger.
WARNING! Possible danger! Non-observance may result in serious injuries.
►Measures to avoid the danger.
CAUTION! Dangerous situation! Non-observance may result in minor injuries.
►Measures to avoid the danger.
ATTENTION! Dangerous situation! Non-observance may result in material losses.
Safety Information
2.1 Observe instruction manual!
The instruction manual is part of the product and an important component within the safety concept.
Non-observance may lead to severe injuries.
• Read and observe instruction manual.
• Always have instruction manual available by the product. • Give instruction manual to all
subsequent users of the product.
2.2 Commissioning and use by qualified personnel only
• Product and accessories should exclusively put into operation by persons who have the
necessary training, knowledge, or experience.
• Regularly instruct personnel on all questions regarding the local regulations applying to
occupational safety and environmental protection, especially for pressurized pipes. The following
target groups are addressed in these operating instructions:
• Operators: Operators are instructed in the operation of the product and observe the safety
guidelines

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2.1 TRANSPORT AND HANDLING
Transport via the packaging provided. Do not rest regulator on control system.
►Transport and store the product in its unopened original packing.
►Protect the product from harmful physical influences such as dust, heat, humidity and UV radiation.
► The product and its components must not be damaged either by mechanical or thermal influences.
► Store the product with the lever in the open position (delivery state).
►Check the product for general damage prior to installation.
ATTENTION
All NeoFlow valves MUST be stored indoors, at room temperature and out of direct sunlight at all times.
WARNING
DO NOT LIFT via the external control system (i.e., the pilot, pilot bracket or feed tubes). Damage to these
components through improper lifting processes can lead to a loss of system integrity.
Note: Consideration should be given to sites where flooding, freezing, snow, or freezing rain may be
experienced. Additional overhead protection ofthepilot regulator from weather and/orflooding should
be used where necessary.
Prior to installation, all pipes should be flushed to remove chips, scale, and debris. The regulator
should be thoroughly checked for internal or external damage.
Note: Whilst installing, ensure disinfection procedures are used on all connections to
prevent contamination.