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QED AP4+ Operation Manual

Autopump controllerless system (for 4 inch wells or larger)
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Leaders in Environmental Compliance Products
MANUAL
ATEX Version
602418-0 2
(doc # 602418 )
(Rev 1 2/10/ 12)
AutoPump Controllerless System
(For 4 inch wells or larger)
DURABLE,
DEPENDABLE,
& DELIVERS
Copyright QED Environmental Systems, Dec . 2012
QED Environmental Systems - P.O. Box 3726 / 2355 Bishop Circle W. Dexter, Michigan 48130-3726
1-800-624-2026 (North America Only) (734) 995-2547 - Tele
(734) 995-1170 - Fax
info@qedenv.com - E-mail
www.qedenv.com
QED Environmental Systems (West) - 1565 Alvarado Street San Leandro, California 94577-2640
1-800-537-1767 (North America Only) (510) 346-0400 - Tele
(510) 346-0414 - Fax

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  • Page 1 DEPENDABLE, & DELIVERS Copyright QED Environmental Systems, Dec . 2012 QED Environmental Systems - P.O. Box 3726 / 2355 Bishop Circle W. Dexter, Michigan 48130-3726 1-800-624-2026 (North America Only) (734) 995-2547 - Tele (734) 995-1170 - Fax info@qedenv.com - E-mail www.qedenv.com...
  • Page 2 "AP" is a Registered Trademark of "QED Environmental Systems" "AutoPump" is a Registered Trademark of "QED Environmental Systems" The QED Environmental Systems logo is a Registered Trademark of "QED Environmental Systems" QED Environmental Systems is a Registered Trademark of "QED Environmental Systems"...

  • Page 3: Table Of Contents

    Table of Contents Introduction_________________________________________________ Safety _______________________________ How to Contact QED _______________________________ Chapter 1: Safety____________________________________________ A Partial List of Safety Procedures _______________________________ Fire and Explosion Protection _______________________________ Chapter 2: ATEX Certification Information ____________________________________________ ATEX Certifications, Label Detail and Explanation _______________________________ Chapter 3: Overview...

  • Page 4: Introduction

    How to Contact QED If for any reason you are unable to find what you need in this manual feel free to contact the QED Service Department at any time. We encourage you to use following communication methods to reach us at any time:...

  • Page 5: Chapter 1: Safety

    WARNING:The air compressor and any other electrical equipment used with this pneumatic system must be positioned outside of any area considered hazardous because of possible combustible materials. These safety procedures should be followed at all times when operating QED equipment on or off site, and should be considered as warnings: •...

  • Page 6: Chapter 2: Atex Certification Information

    9.0 BAR (130 PSI) YEAR AP4+ = 4-inch AutoPump 13.8 BAR (200 PSI) = Genie Pump PAT. 5004405, APPROVED 5641272, 5495890, 5358038 S/N:AP4+C-XXXXX = Bladder Pump = 2-inch Specific SPG2 Gravity Skimmer = 4-inch Specific SPG4 Approving Entity Maximum Operating Pressure...
  • Page 7 Figure 2 ATEX Label Location and Appearance Figure 2 Top Loading Bottom Loading Pump Serial Numbers Located on the Pump’s Head AP4+ Obverse View AP4+ AP4+ Reverse View Ta = APPROVED...

  • Page 8: Chapter 3: Overview

    Chapter 3: Overview The AutoPump® fills and empties automatically, and is very easy to install, use, and maintain. The AutoPump is a pneumatic fluid extraction pump that pumps in pulses. It handles any liquid which flows freely into the pump and is compatible with the component materials and with the connecting hoses. The AP4+ is intended for vertical operation in well casings with a 3.75-inch or greater internal diameter.
  • Page 9 Figure 3 - How it Works Pump Emptying Pump Filling Compressed Air Air Exhausting Flowing Into From Pump Pump Pivoting Lever Pivoting Lever Tipped Upward Tipped Downward By Rising Float By Descending Upper Float Float Stop As Pump Empties, Float Descends As Pump Fills, Float Rises Lower...
  • Page 10 Figure 4 - Overview of the AP4+ System AP4+ System provides everything required for pumping fluid from a well. Filter/Regulator Supply From Cycle Counter Compressor Easy Bolt Fluid Discharge Easy Bolt Wellhead Easy Bolt Note: Support Harness, Rope, and Tubing Sheath Omitted for Clarity Air Exhaust Tubing Easy Fittings...

  • Page 11: Chapter 4: Equipment

    Chapter 4: Equipment Unpacking During the unpacking procedure, check for the following: • All parts on the packing list have been included in the box • All fitting openings are unobstructed • The equipment has not been damaged in shipment Equipment List The equipment list will vary depending on site specifications, but the following list is a typical configuration 1.

  • Page 12: Chapter 5: Installation

    When QED controllerless pumps are used in wells that are under vacuum, and the exhaust air is routed into the well, the well level will be maintained at this normal actuation point. If, however, the...

  • Page 13: Installation

    Chapter 5: Installation Hose Bundles Hose bundling or the use of jacketed tubing reduces equipment entanglement at the well surface, and aids the removal of the pump from the well. Bundling also assists in positioning the pump and down-well hose assembly against one side of the well casing. Maximum space is created for other items, such as probes, to be periodically placed inside the well.
  • Page 14 Figure 6 - Examples of Well Caps...
  • Page 15 Figure 7 - Hose Bundling Support Harness Quick Link Assembly Support Rope Fluid Discharge Hose (Black) Air Exhaust Hose (Blue) AutoPump® Air Hose (Green) Air Exhaust Tie-Wraps in Between Air Exhaust Tie-Wraps Every 4 Ft. (122 Cm) Air Exhaust Tie-Wraps in Between Air Hose Tie-Wraps Every 4 Ft. (122 Cm) Tie-Wrap Detail Air Exhaust Tie-Wrap Fluid Discharge...

  • Page 16: Chapter 6: Maintenance

    Chapter 6: Maintenance Removing the Pump’s Casing 1. Remove the bolt at the bottom of the pump which holds the inlet screen in place (bottom loading pumps only). 2. Remove the three bolts at the bottom of the pump which hold the inlet in place. (See Figures 6,7,8,and 9) 3.
  • Page 19 Figure 10 - Exploded View of Top Loading AP4+ (Long & Short) NOTE: Some Parts are available in alternate materials based...

  • Page 20: Exploded View Of A Top-Loading Autopump Ap-4+ (Low Drawdown)

    Figure 11 - Exploded View of Top Loading AP4+ Low Drawdown NOTE: Some Parts are available in alternate materials based...
  • Page 21 Figure 12 - Exploded View of AP4+ Lever Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 200359 120 P.SI INTAKE POPPET CONNECTOR-LONG 200359 120 P.SI INTAKE POPPET CONNECTOR-SHORT 200665 120 P.SI INTAKE POPPET CONNECTOR-LDD 200337 303 SS 120 P.SI EXHAUST POPPET-LONG 200337 303 SS 120 P.SI EXHAUST POPPET-SHORT 200336...
  • Page 22 Figure 13 - Exploded View of 1 Inch Check Valve Barbed Adapter Fitting Check Ball Check Valve Housing...

  • Page 23: Chapter 7: Troubleshooting & Repairs

    Chapter 7: Troubleshooting & Repairs Problems may occur and usually can be easily resolved by following these instructions. If, after careful reading and service, you cannot resolve the problem, please contact the QED Environmental Systems (QED) Service Department at (800) 537-1767.
  • Page 24 • If the pump is a Top-Loading design, remove the fluid inlet check valve and inspect the seating surface and the ball for debris and wear. 9. Air Inlet Valve Timing • (First check lever pivot wear per #6 above) • Call the QED Service Department for correct air valve timing for your pump.

  • Page 25: Returning Equipment For Service

    6. Include the contact’s name, company, phone number and RMA number given by QED. 7. Write the RMA number on the outside of the packaging so it will be directed immediately to the QED Service Department.

  • Page 26: Pump Specifications

    The AP4+ Long Bottom Inlet AutoPump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site speci c requirements. Call QED for prompt, no-obligation assistance on your pumping project needs. The AutoPump Heritage...
  • Page 27 For applications outside these ranges, consult QED about AP4+ upgrades. Maximum Temperature: 180°F (82°C) pH Range: 4-9 Solvents and Fuels: diesel, gasoline, JP1-JP6,#2 heating oils, BTEX, MTBE, landfill liquids Consult QED for higher flow requirements...
  • Page 28 5 Kg/cm DEPTH 100 120 140 DEPTH 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54.9 Meters IN WELL 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54.9 Meters IN WELL FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE.
  • Page 29 Specifications - Bottom Inlet, Long AP4 B Air Consumption 3/4 inch (19 mm) 11.2 Inside Diameter Discharge Hose (Equivalent to 1-Inch O.D. Tubing) 10.5 100 PSI 7 Kg/cm APPROXIMATE STANDARD STANDARD CUBIC FEET OF AIR LITER OF AIR 70 PSI GALLON PUMPED 5 Kg/cm LITER PUMPED...

  • Page 30: Ap4+ Bottom Inlet Short

    The AP4+ Short Bottom Inlet AutoPump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site speci c requirements. Call QED for prompt, no-obligation assistance on your pumping project needs. The AutoPump Heritage...
  • Page 31 For applications outside these ranges, consult QED about AP4+ upgrades. Maximum Temperature: 180°F (82°C) pH Range: 4-9 Solvents and Fuels: diesel, gasoline, JP1-JP6,#2 heating oils, BTEX, MTBE, landfill liquids Consult QED for higher flow requirements...
  • Page 32 3 Kg/cm DEPTH 5 Kg/cm 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54.9 Meters IN WELL DEPTH 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54.9 Meters IN WELL FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE.
  • Page 33 Specifications - Bottom Inlet, Short AP4 B Air Consumption 3/4 inch (19 mm) 100 PSI 11.2 Inside Diameter Discharge Hose 7 Kg/cm (Equivalent to 1-Inch O.D. Tubing) 10.5 70 PSI 5 Kg/cm APPROXIMATE STANDARD STANDARD CUBIC FEET OF AIR LITER OF AIR GALLON PUMPED LITER PUMPED (SCF/GAL)

  • Page 34: Ap4+ Bottom Inlet Low Drawdown

    7 gpm (26.5 lpm). The AP4+ Low Drawdown Bottom Inlet AutoPump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site speci c requirements. Call QED for prompt, no-obligation assistance on your pumping project needs. The AutoPump Heritage...
  • Page 35 For applications outside these ranges, consult QED about AP4+ upgrades. Maximum Temperature: 180 °F (82 °C) pH Range: 4-9 Solvents and Fuels: diesel, gasoline, JP1-JP6,#2 heating oils, BTEX, MTBE, land ll liquids Consult QED for higher ow requirements...
  • Page 36 5 Kg/cm 100 120 140 160 DEPTH DEPTH 12.2 18.3 24.4 30.5 36.6 42.7 48.8 Meters IN WELL 12.2 18.3 24.4 30.5 36.6 42.7 48.8 Meters IN WELL FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE.
  • Page 37 Specifications - Low-Drawdown Bottom Inlet LDAP4 B Air Consumption 21.7 3/4 inch (19 mm) 100 PSI 20.9 Inside Diameter Discharge Hose 7 Kg/cm 20.2 (Equivalent to 1-Inch O.D. Tubing) 19.4 18.7 18.0 17.2 16.5 15.7 APPROXIMATE STANDARD 14.2 STANDARD CUBIC FEET OF AIR 13.5 LITER OF AIR 12.7...

  • Page 38: Ap4+ Top Inlet Long

    10 gpm* . The AP4+ Long Top Inlet AutoPump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site speci c requirements. Call QED for prompt, no- obligation assistance on your pumping project needs. The AutoPump Heritage...
  • Page 39 For applications outside these ranges, consult QED about AP4+ upgrades. Maximum Temperature: 180 °F (82 °C) pH Range: 4-9 Solvents and Fuels: diesel, gasoline, JP1-JP6,#2 heating oils, BTEX, MTBE, land ll liquids Consult QED for higher ow requirements...
  • Page 40 7 Kg/cm 5 Kg/cm DEPTH DEPTH 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54.9 Meters IN WELL 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54.9 Meters IN WELL FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE.
  • Page 41 Specifications - Top Inlet, Long AP4 T Air Consumption 3/4 inch (19 mm) 11.2 Inside Diameter Discharge Hose (Equivalent to 1-Inch O.D. Tubing) 10.5 100 PSI 7 Kg/cm APPROXIMATE STANDARD STANDARD CUBIC FEET OF AIR LITER OF AIR 70 PSI GALLON PUMPED 5 Kg/cm LITER PUMPED...

  • Page 42: Ap4+ Top Inlet Short

    9 gpm (34 lpm)* . The AP4+ Short Top Inlet AutoPump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site speci c requirements. Call QED for prompt, no- obligation assistance on your pumping project needs. The AutoPump Heritage...
  • Page 43 For applications outside these ranges, consult QED about AP4+ upgrades. Maximum Temperature: 180 °F (82 °C) pH Range: 4-9 Solvents and Fuels: diesel, gasoline, JP1-JP6,#2 heating oils, BTEX, MTBE, land ll liquids Consult QED for higher ow requirements...
  • Page 44 5 Kg/cm 100 120 140 DEPTH DEPTH 12.2 18.3 24.4 30.5 36.6 42.7 48.8 54.9 Meters IN WELL 12.2 18.3 24.4 36.6 42.7 Meters IN WELL 30.5 48.8 54.9 FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE.
  • Page 45 Specifications - Top Inlet, Short AP4 T Air Consumption 3/4 inch (19 mm) 100 PSI 11.2 Inside Diameter Discharge Hose 7 Kg/cm (Equivalent to 1-Inch O.D. Tubing) 10.5 70 PSI 5 Kg/cm APPROXIMATE STANDARD STANDARD CUBIC FEET OF AIR LITER OF AIR GALLON PUMPED LITER PUMPED (SCF/GAL)

  • Page 46: Ap4+ Top Inlet Low Drawdown

    6.4 gpm (24 lpm). The Low Drawdown AP4+ Top Inlet AutoPump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site speci c requirements. Call QED for prompt, no- obligation assistance on your pumping project needs. The AutoPump Heritage...
  • Page 47 For applications outside these ranges, consult QED about AP4+ upgrades. Maximum Temperature: 180 °F (82 °C) pH Range: 4-9 Solvents and Fuels: diesel, gasoline, JP1-JP6,#2 heating oils, BTEX, MTBE, land ll liquids Consult QED for higher ow requirements...
  • Page 48 3 Kg/cm 5 Kg/cm 5 Kg/cm DEPTH DEPTH 12.2 18.3 24.4 30.5 36.6 42.7 48.8 Meters IN WELL 12.2 18.3 24.4 30.5 36.6 42.7 48.8 Meters IN WELL FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE.
  • Page 49 Specifications - Low-Drawdown Top Inlet LDAP4 T Air Consumption 21.7 3/4 inch (19 mm) 100 PSI 20.9 7 Kg/cm Inside Diameter Discharge Hose 20.2 (Equivalent to 1-Inch O.D. Tubing) 19.4 18.7 18.0 17.2 16.5 15.7 APPROXIMATE STANDARD 14.2 STANDARD CUBIC FEET OF AIR 13.5 LITER OF AIR 12.7...

  • Page 50: Terms, Conditions And Warranty

    All warranty durations are calculated from the original date of purchase—determined as beginning the date of shipment from QED facilities and the date QED is notified od a warranty claim. This warranty shall be limited to the duration and conditions set forth below.
  • Page 51 The buyer’s exclusive and sole remedy on account of or in respect to the furnishing of defective material or workmanship shall be to secure replacement thereof as aforesaid. QED shall not in any event be liable for the cost of any labor expended on any such product or material or for any special, direct, indirect or consequential damages to any one by reason of the fact that it shall have been deemed defective or a breach of said warranty.
  • Page 52 Tele. (510) 346-0414 5. Equipment must be cleaned before shipment or it will be cleaned by QED before any work is performed. The customer will be charged for such cleaning. If any product covered hereby is actually defective within the terms of this warranty, purchaser must contact QED, or its appointed agent, for determination of warranty coverage.
  • Page 54 1-800-624-2026 (North America Only) (510) 346-0400 - Tele (734) 995-2547 - Tele (510) 346-0414 - Fax (734) 995-1170 - Fax info@qedenv.com - E-mail www.qedenv.com Operations Manual Leaders in Environmental Compliance Products Copyright QED Environmental Systems, July 2012 Document No. 602418...

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