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QED AP4 Ultra Operation Manual

Atex version
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AutoPump Ultra 4.0
®
MANUAL
Original Instructions
ATEX Version
602569
602569-01 (doc # 602569)
(3/26/15)
Copyright QED Environmental Systems, 2015
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) - 1670 Alvarado Street San Leandro, Suite 5, California 94577-2640
1-800-537-1767 (North America Only) (510) 346-0400 - Tele
(510) 346-0414 - Fax

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Summary of Contents for QED AP4 Ultra

  • Page 1 602569-01 (doc # 602569) (3/26/15) Copyright QED Environmental Systems, 2015 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 the following communication methods to reach us at any time:...

  • Page 5: Chapter 1: Safety

    We have also listed some possible hazards involved when applying this system to site remediation. Nothing will protect you as much as understanding the system, the site at which it is being used, and the careful handling of all equipment and fluids. If you have any questions, please contact the QED Service Department for guidance.

  • Page 6: Atex Certifications, Label Detail And Explanation

    300° C 200° C 135° C 100° C 85° C Manufacturer, Zip Code, Country Certificate Number Equipment Model: QED, 94577-2640, USA FM08ATEX0028 AP U lt r a = 2-inch AutoPump = 3-inch AutoPump 1725 II G = 4-inch AutoPump MAXIMUM PRESSURE 9.0 BAR (130 PSI)
  • Page 7 Figure 2 ATEX Label Location and Appearance Figure 2 Top Loading Bottom Loading Pump Serial Numbers Located on the Pump’s Head Obverse View AP Ultra 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 AP Ultra is intended for vertical operation in well casings with a 3.75-inch(9.53cm) 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 AP Ultra System AP Ultra System provides everything required for pumping fluid from a well. Filter/Regulator Supply From Cycle Counter Compressor Easy Bolt Fluid Discharge Easy Bolt Well cap Easy Bolt Note: Support Harness, Rope, and Tubing Sheath Omitted for Clarity Air Exhaust Tubing...

  • 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

    Chapter 5: Installation 1. Cover the pump tubing/hose ends with tape if they are to be pulled through trenches or laid on the ground. This is to prevent debris from entering the lines. 2. Blow out all water and particles from compressed air conduits (including downwell pump air supply lines) and fluid lines for at least 10 seconds after the water and particles exit before connecting them to the system.

  • Page 13: 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 14 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 15 Figure 6 - Examples of Well Caps...

  • Page 16: Hose Bundling

    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 17: Cleaning Pump Interior

    Cleaning the AutoPump Ultra 4.0 Caution: Wear goggles, gloves, and coveralls when servicing this system. Note: The Ultra 4.0 uses non-stick finishes on the float and discharge tube. To protect these finishes, never use any type of abrasive pad, wire brush, steel wool or sandpaper to clean these two components.
  • Page 18 Figure 8 - Exploded View of Bottom-Loading Ultra (Long and Short) Figure 8 - Exploded View of Bottom-Loading Ultra (Long and Short) 1 1 5...
  • Page 19 Figure 9 - Exploded View of Top-Loading Ultra (Long and Short) Figure 9 - Exploded View of Top-Loading Ultra (Long and Short) 1 1 6...
  • Page 20 Figure 10 - Exploded View of AP Ultra Lever Assembly ITEM NO. PART NUMBER DESCRIPTION QTY. 201616 120 P.SI INTAKE POPPET CONNECTOR-LONG 201616 120 P.SI INTAKE POPPET CONNECTOR-SHORT 201623 316 SS 120 P.SI EXHAUST POPPET-LONG 201623 316 SS 120 P.SI EXHAUST POPPET-SHORT 206445 NITRONIC 60 POPPET PIN-BUSHING 201033...
  • Page 21 Figure 11 - Exploded View of 1 Inch Check Valve Barbed Adapter Fitting Check Ball Check Valve Housing...

  • Page 22: 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 23: Fluid Inlet Clogged

    Chapter 7: Troubleshooting & Repairs • If the air exhausts to the atmosphere (outside the well) and a vacuum is drawn on the well, the pump may fail to fill. In order for the pump to fill under these conditions, the pump must be submerged to make up for the pressure difference between the atmosphere and the partial vacuum in the well.

  • Page 24: 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 25 The AP4.0 Bottom Inlet Long pump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site-specific requirements. Call QED for prompt, no-obligation assistance on your pumping project needs. The AutoPump Heritage The AutoPump Ultra 4.0 Bottom Inlet Long is part of the famous...
  • Page 26 AutoPump Ultra 4.0 pumps are designed to handle the application ranges described below. For applications outside these ranges, consult QED about AP4 upgrades. Maximum Temperature: Up to 250 °F (121 °C) with certain models pH Range: 2-12 Consult QED for higher flow requirements...
  • Page 27 5 Kg/cm DEPTH DEPTH 100 120 140 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 28 Specifications - Bottom Inlet, Long Specifications - Bottom Inlet, Long Bottom Inlet, Long Air Consumption 3/4 inch (19 mm) Inside Diameter Discharge Hose 11.2 (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 5 Kg/cm...
  • Page 29 The AP4.0 Bottom Inlet Short pump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site-specific requirements. Call QED for prompt, no-obligation assistance on your pumping project needs. The AutoPump Heritage The AutoPump Ultra 4.0 Bottom Inlet Short is part of the...
  • Page 30 AutoPump Ultra 4.0 pumps are designed to handle the application ranges described below. For applications outside these ranges, consult QED about AP4 upgrades. Maximum Temperature: Up to 250 °F (121 °C) with certain models pH Range: 2-12 Consult QED for higher flow requirements...
  • Page 31 3 Kg/cm 5 Kg/cm DEPTH 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 Meters IN WELL 54.9 FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE.
  • Page 32 Specifications - Bottom Inlet, Short Specifications - Bottom Inlet, Short Bottom Inlet, Short Air Consumption 3/4 inch (19 mm) Inside Diameter Discharge Hose 100 PSI 11.2 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...
  • Page 33 The AP4.0 Top Inlet Long pump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site-specific requirements. Call QED for prompt, no-obligation assistance on your pumping project needs. The AutoPump Heritage The AutoPump Ultra 4.0 Top Inlet Long is part of the famous...
  • Page 34 1/2 in. (13 mm) ID Material upgrages available PVDF - Polyvinylidene Fluoride O.D. 3.6" (9.1 cm) Applies to QED supplied tubing; other tubing sources may not conform to QED fittings. Standard Application Limits AutoPump Ultra 4.0 Long and Short pumps are warranted (standard model) for five (5) years: 100% materials and workmanship.
  • Page 35 3 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 36.6 42.7 IN WELL 24.4 30.5 48.8 54.9 Meters FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE.
  • Page 36 Specifications - Top Inlet, Long Specifications - Top Inlet, Long Top Inlet, Long Air Consumption 3/4 inch (19 mm) Inside Diameter Discharge Hose 11.2 (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...
  • Page 37 The AP4.0 Top Inlet Short pump is complemented by the most comprehensive selection of accessories to provide a complete system to meet site-specific requirements. Call QED for prompt, no-obligation assistance on your pumping project needs. The AutoPump Heritage The AutoPump Ultra 4.0 Top Inlet Short is part of the famous...
  • Page 38 Air Exhaust 1/2 in. (13 mm) ID Material upgrages available PVDF - Polyvinylidene Fluoride Applies to QED supplied tubing; other tubing sources may not conform to QED fittings. Standard Application Limits AutoPump Ultra 4.0 Long and Short pumps are warranted (standard model) for five (5) years: 100% materials and workmanship.
  • Page 39 3 Kg/cm 100 120 140 DEPTH DEPTH 12.2 18.3 24.4 36.6 42.7 Meters IN WELL 30.5 48.8 54.9 12.2 18.3 36.6 42.7 IN WELL 24.4 30.5 48.8 54.9 Meters FLOW RATES MAY VARY WITH SITE CONDITIONS. CALL QED FOR TECHNICAL ASSISTANCE.
  • Page 40 Specifications - Top Inlet, Short Specifications - Top Inlet, Short Top Inlet, Short Air Consumption 3/4 inch (19 mm) Inside Diameter Discharge Hose 100 PSI 11.2 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...

  • Page 41: 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 of a warranty claim. This warranty shall be limited to the duration and conditions set forth below.
  • Page 42 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 43 Warranty Claims Procedure (Responsibility of purchaser) The original purchaser’s sole responsibility in the instance of a warranty claim shall be to notify QED or its appointed agent, of the defect, malfunction, or other manner in which the terms of this warranty are believed to be violated. The...

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