PACKING/HANDLE NUT
PARTS ILLUSTRATION
HANDLE
STEM
BODY
O-RING
BALL
PACKING GLAND
PACKING/BEARING STEM
RETAINER
SEAT
Page 4 I893900. Rev D
A Division of Conbraco Industries, Inc. Matthews, NC Pageland, SC Conway, SC
APOLLOXPRESS™ Valve System
INSTALLATION, OPERATION, & MAINTENANCE GUIDE
Page 1
INSTALLATION
SYMPTOM
POSSIBLE REASONS
SOLUTION
Valve Size
Stem Thread
Packing Nut Torque (in
-
lbs.)
APOLLOXPRESS™ valves are bi-directional. They may be installed in vertical or
horizontal pipe runs without regard to flow direction and without regard to stem
orientation.
Note: Valves must be installed in piping systems that comply with the applicable
portions the ASME B31 standards. Special considerations must be taken with respect
to pipe line expansions and contractions and the media expansion and contractions
within the piping system.
Preparing the Tube
Cut the desired length of tubing using a tubing cutter. De-burr the inside and outside
diameter of the tube with a rounded file or de-burring tool. Clean the tube of all dirt, oil,
grease or foreign matter.
Caution: Tubing that has burrs or out-of-round could make tube insertion difficult. Burrs must be
removed and tubing ends should not be damaged. Tubing should also be squarely cut.
Inserting the Tube
Make sure that the o-rings seals are in place and free of dirt, oil, grease or other foreign
matter. Insert the tube into the valve using a twisting motion. Make sure that the tube is
fully inserted into the retainer stops or shoulders. Mark the tube with a permanent
marker to indicated the proper depth.
Caution: Make sure tubing is inserted to the proper depth. Failure to do so could result in an
improper seal that could lead to extensive property damage or bodily harm.
Warning: Do not lubricate the seal in the valve with anything other than water. Hydrocarbon based
lubricants will cause the seal to soften and swell.
Pressing the Valve
(1)
Place open jaws around valve connection. Make sure the contour of the jaw set is
properly aligned with the seal bead of the valve connection.
(2)
Actuate press tool. The
pressing cycle takes 4 – 8 seconds, depending on the press tool. Once a press cycle
begins, and the rollers contact the jaw arms, the tool will lock-on and automatically
complete the press cycle.
refer to specific tool operator’s manual.
Caution: Jaw set must be square to the tube and properly aligned with the contour of the valve.
Inspect the press tool to verify it is in good working condition. Inspect the ring/jaw sets and verify
that they are clean and do not display excessive wear. For battery operated units verify that the
battery has an adequate charge. (A tone is normally emitted when a low battery condition occurs.)
Most quality press tools require re-calibration after 20,000 cycles. See tool manufacture’s IOM.
Warning: To avoid pinch point injury, keep hands and fingers away from jaws. Avoid sharp edges
that may have formed on the valve during the pressing operation
(3)
Press jaw arms to open jaw set. If tool malfunctions, please
(4)
Remove the press tool and jaw connection.
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Warning: (Required by California) This product contains a chemical known to the state
of California to cause Cancer and Birth Defects or other Reproductive Harm.
Inspecting the Connection
(1)
Check the valve and confirm the presence of the press mark.
connection for the following: Misaligned tubes, tubes not fully inserted, check depth
marks, loose connection, incorrect jaw alignment with the fitting.
these problems are found, then a new section of tubing and a new valve will have to be
prepared, inserted and pressed.
and local codes.
Troubleshooting
Wrong jaw set or press ring for the
tube size or material.
The jaw set or ring was not square to
Press cycles
produced are not
complete.
Excessively
large or sharp
fins present at
press joint
parting line
where jaw or ring
tips come
together.
Jaws stick to
valve
excessively after
completing joint.
the tube.
Jaw contour was not aligned with the
valve contour.
The jaw set or ring has exceeded life
expectations and may have failed.
Copper material build-up on jaws or
rings in the contoured profile area
near jaw or ring tips.
Excessively worn or damaged jaw
sets or rings.
Copper material build-up on jaws or
ring in the contoured profile area
near jaw or ring tips.
(4)
Test the system in accordance with normal practice
Install correct jaw set.
Redo the joint with new tube and
valve and make sure that the jaw set
or ring is square to the valve.
Redo the joint with new tube and
valve and make sure that the jaw set
or ring is square to the valve.
If cracked, replace old jaw set with a
new jaw set and redo the joint using
a new tube and valve.
Clean jaw sets or rings in the
contoured area using metal polishing
pads such as Scotch-Brite®. Refer to
the press tool’s maintenance section
for proper instructions.
Discard jaws or press ring and
replace with a new jaw set.
Clean jaw sets or rings in the
contoured area using metal polishing
pads such as Scotch-Brite®. Refer to
press tool’s maintenance section for
proper instructions.
(2)
Inspect the press
(3)
If one or more of
OPERATION
The valve handle is marked showing proper rotation direction for “ON” and “OFF”
positions. Rotation is clockwise for “OFF” (closed) and counterclockwise for “ON”
(open).
MAINTENANCE
Normal stem packing wear can be compensated for by tightening the packing gland
nut. There are two nuts on the stem. The top nut retains the lever. The top nut and the
lever may need to be removed for easy access to the packing nut. The packing nut is
the lower nut on the stem. (Wrench part number H371400 is available to ease this
operation.) Tighten the packing nut clockwise in 1/8 turn increments until observed
leakage stops. Do not exceed the values shown in the table below. Reinstall the handle
and handle nut.
¼” – ½” 5/16 – 24 UNF 35
¾” - 1” 3/8 – 24 UNF 50
1 ¼” - 2” 5/8 – 18 UNF 150
CAUTION: Do not disassemble valve while under pressure nor with trapped hazardous fluids
therein.
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