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ALH System-One
Gas-Free Tapping System for ¾" to 2½" NPT tapped holes
(60psig Maximum Allowable Operating Pressure)
Operating Manual
February 11
th
, 2019
PLCS, LLC 102 Gaither Drive Unit 1, Mt Laurel, NJ 08054 Tel: (856) 722-1333
www.plcsusa.com
February 11
th
, 2019
1
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Summary of Contents for ALH System-One
- Page 1 ALH System-One Gas-Free Tapping System for ¾" to 2½" NPT tapped holes (60psig Maximum Allowable Operating Pressure) Operating Manual February 11 , 2019 PLCS, LLC 102 Gaither Drive Unit 1, Mt Laurel, NJ 08054 Tel: (856) 722-1333 www.plcsusa.com February 11...
- Page 2 INTRODUCTION: The ALH System-One tapping machine cuts and taps ¾” – 2 ½” NPT holes gas-free in cast iron and steel live mains operating at up to 60psig and 3” – 48” diameter. The system is mostly aluminum with a very low-profile sliding gate valve making it extremely compact and lightweight.
- Page 3 OPERATING PROCEDURE Initial Set Up 1. Clean all components of the System-One prior to use paying particular attention to any “O” rings, grooves and matching surfaces. Any dirt in these areas should be wiped off. 2. Clean the area of the pipe where the saddle will be positioned, removing all corrosion and scale so that the saddle rubber will seal properly.
- Page 4 Preparing the Drill Head 1. Screw the drill head feed cap down until the grub screw(s) are exposed at the bottom of the drill shaft. 2. Wipe the tapered hole in the shaft clean with a rag to ensure there is no dirt in it to prevent the tap seating properly.
- Page 5 “Open” mark on the valve body. Remove the valve wrench. 12. Pressures test the ALH system through the drill head ball valve to the gas mains actual operating pressure x 1.5 but not greater than 60psi. For leaks around the drill head base, re-tighten the swing bolts.
- Page 6 Install the air power drive and socket onto the drill shaft to operate in a clockwise direction. 5. Hold the power drive with one hand so that it will be pulling away from you under load. If the cutter jams the power drive will be pulled from your grasp and will stop automatically as your fingers are released from the trigger.
- Page 7 5. Tapping is complete when the tap rear stops come into contact with the pipe crown. The stops are there to prevent over-tapping of a tapered hole. Do not force the stops over the crown of the pipe as the tap will be very difficult to unscrew and may break the stops off. (This is very easy to do if you are power tapping, which is one more reason we recommend against this practice.) 6.
- Page 8 7. Place the canopy on the valve and attach with the swing bolts. 8. Tighten the bolts alternately with the short valve wrench until snug (Photo 13). 9. Lift the plug off the valve gate by pulling up the shaft and then open the slide valve (Photo 14).
- Page 9 Installing Malleable Iron Plug using the Magnetic Plug Holder 1. Select the correct sized magnetic plug carrier to suit the plug being installed and attach it to the plug fitting spindle using the T-Handle hex wrench to tighten the large set screw (Photo 16).
- Page 10 Bolt with Bonded Low-Profile NPT Seal Washer Plug Body Instructions and tooling is ONLY intended for the installation of PLCS/ALH Low-Profile plugs Low-Profile plugs are available for insertion gas-free through the ALH System-One in the following sizes: PLCS Part # Description 46-A0163 1 ¼”...
- Page 11 10. Lower the shaft/plug down to the tapped hole. 11. Using the valve wrench, turn the shaft counter-clockwise until you feel the plug skip over the leading thread of the tapped hole. 12. Now turn the shaft clockwise and screw the plug in tightly (Photo 15). 13.
- Page 12 Stand the tee carrier shaft upright on a flat surface, place the canopy over the shaft/tee carrier and push the canopy down the shaft making sure the tee is fully inside the canopy (Photo 20). (Photo 20) (Photo 21) (Photo 22) Place the canopy on the valve and attach the swing bolts (Photo 21).
- Page 13 The amount of force necessary to do this is not excessive, though noticeable. We did not use a cheater bar. The mechanical advantage of a screw thread is sufficient. System-One tapping machines are designed for ease of operation. Excessive force should never be needed during normal operation. If abnormal force is required STOP and investigate the cause before attempting to continue.
- Page 14 Neodymium Magnet Safety The neodymium magnets we sell are extremely strong, and must be handled with care to avoid personal injury and damage to the magnets. Fingers and other body parts can get severely pinched between two attracting magnets. Neodymium magnets are brittle, and can peel, crack or shatter if allowed to slam together.
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Page 15: Actual Size
The perfect sizes to cut a hole to suit standard NPT threads are as shown in the chart. PLCS/ALH Hole Saw Identification Chart Part #... - Page 16 ALH SYSTEM-ONE CONTROL VALVE OPERATING SPINDLE 46 - M3004 BY PASS PLUNGER 46 - M3005 ORING ORING 46 - M1050 46 - M1049 BALL 46 - M3010 GREASE NIPPLE SPRING 46 - M2145 46 - M3011 GRUB SCREW VALVE TOP...
- Page 17 ALH SYSTEM-ONE DRILLING MACHINE 46 - A4500 SHAFT COLLAR - ALUMINIUM SHAFT SNAP ON COLLAR NYLON "C" 46 - M2177 46 - M2176 SHAFT LOCKING CAP HANDLES SCREW 46 - M2173 46 - M4155 DRILL HEAD CAP WITH HANDLES 46 - A0041...
- Page 18 ALUMINIUM SHAFT COLLAR 46 - M2177 RATCHET DRILL SHAFT 46 - M4162 46 - A0045 SHAFT LOCKING SCREW NYLON SHAFT COLLAR 46 - M4155 46 - M2176 SERVICE VALVE KNUCKLE 46 - M3031 FEED CAP 46 - A0041 BALL VALVE US-10631 SYSTEM 1 SERVICE VALVE...
- Page 19 CHAIN BOLT SERVICE VALVE 46 - M3007 46 - A0001 PIVOT PIN 46 - M3032 CHAIN PULL UP HOOK 46 - M3008 SADDLE CHAIN CHAIN STEADY VALVE WRENCH WRENCH 46 - A0012 46 - A0014 Saddles Chains SIZE PART # SIZE PART # 3"...
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