Apollo Valve Installation Best Practices
Proper installation is the difference between a valve that lasts 20 years and a callback in 6 months. These best practices apply to Apollo ball valves, backflow preventers, PRVs, relief valves, and press fittings on commercial and industrial jobs.
Ball Valve Installation
- Use two wrenches on threaded connections. Apply one wrench on the valve body hex nearest the pipe being tightened. Never use a single wrench — it stresses the valve body and can crack the joint.
- Do not over-tighten. NPT threads are tapered — 2-3 turns past hand-tight is typically sufficient. Over-tightening cracks bronze bodies, particularly in smaller sizes.
- Install in the open position when making soldered or press connections on copper press valves to prevent seat and seal damage from heat or over-crimping.
- Use appropriate thread sealant. PTFE tape or paste sealant for water and steam. Check sealant compatibility for chemical service — some solvents attack PTFE.
- Provide access. All valves require operator access for maintenance and testing. Do not install in inaccessible locations without a valve box or access panel.
- Support large valves independently. Valves 2" and larger should be supported independently of the piping — do not rely on pipe connections to support valve weight.
ApolloPress / Press-Fit Installation
- Verify press tool jaw size. Use the correct jaw or head for the pipe size and fitting type. Wrong jaw size produces an incomplete crimp and a leak.
- Inspect the pipe end. Cut pipe square. Deburr inside and outside. Remove all burrs — they cut the O-ring seat and cause immediate or early leaks.
- Mark insertion depth. Mark the pipe at the fitting insertion depth before assembly. Confirm pipe is fully inserted before pressing — visible marks confirm correct insertion.
- Do not re-press. A properly pressed fitting is permanent. Do not attempt to re-press the same joint — cut out and replace with a new fitting.
- Inspect the green or yellow indicator ring (PowerPress). On Apollo 89FV PowerPress valves, the colored ring provides visual confirmation the connection is not yet pressed. Ring remains visible until crimp is complete.
Backflow Preventer Installation
- RP assemblies must be installed horizontally with the relief port facing downward. Vertical installation prevents proper relief valve operation.
- Maintain minimum clearance below the relief port. Code typically requires 12" minimum between the relief port and the floor or drain to allow free discharge.
- Install a full-size drain below the relief port. The relief valve will discharge water during a backpressure event — the floor drain must be sized to handle full flow.
- Test before final connection. Have the assembly tested by a certified tester after installation and before the water authority issues final acceptance.
- Protect from freezing. Backflow assemblies must be protected from freeze damage. Insulate or locate in a heated space.
Relief Valve Installation
- Install upright or per manufacturer orientation. T&P relief valves must be installed with the sensing element in the water — typically in the top 6" of the water heater tank or in the hot water outlet piping.
- Do not install a shut-off valve between the relief valve and the appliance. This is a code violation and a safety hazard.
- Run discharge piping to a safe point of termination. Full-size discharge pipe, no reduction, no upward turns, terminated 6" above floor drain or as required by local code.
- Never test by lifting the lever on an old valve. Manual test on a valve that has been in service risks the valve not re-seating. Replace valves on a defined schedule rather than testing in the field.
PRV Installation
- Install with flow arrow in correct direction. PRVs are directional — verify the flow direction arrow aligns with the downstream direction.
- Install isolation valves on both sides. Upstream and downstream isolation allows servicing or replacement without draining the entire system.
- Install a pressure gauge downstream. Allows field verification of the setpoint and monitoring of downstream pressure.
- Install a thermal expansion tank on closed systems. A PRV on a closed system without a thermal expansion tank will cycle continuously as pressure builds from water heater thermal expansion.