QED AutoPump AP-2 User manual

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AutoPump Controllerless System
(for 2-inch wells or larger)
AP-2 AutoPump®
Document No. 600395 07
550 Adeline Street
Oakland, California 94607
[phone] — North America Only
[phone] — Tele.
[phone] — Fax
PO Box 3726
6095 Jackson Road
Ann Arbor, Michigan 48106-3726
[phone] — North America Only
[phone] — Tele.
[phone] — Fax
[e-mail] — E-mail
www.qedenv.com
Copyright QED Environmental Systems, August 2007
Environmental Systems
Air-Met Scientic
www.airmet.com.au
SCAN OR CLICK HERE
TO CONTACT US
NEED HELP?

The equipment in this manual is protected under U.S. and foreign patents issued and pending:
U.S. Patents:
Selective Oil Skimmer (SOS) 4,497,370
Specic Gravity Skimmer (SPG) 4,663,037
AutoPump (AP) 5,004,405
Specic Gravity Skimmer (SPG) Product Sensing 5,474,685
Vacuum/Pressure Hydrocarbon Recovery System 4,761,225
SPG PSR technology 5,474,685
AP-2 5,641,272
Genie System 5,704,772
Canada Patent:
Specic Gravity Skimmer (SPG) 1,239,868
"AP" is a Registered Trademark of "QED Environmental Systems"
"AutoPump" is a Registered Trademark of "QED Environmental Systems"
"SOS" is a Registered Trademark of "QED Environmental Systems"
"Genie" is a Registered Trademark of "QED Environmental Systems"
"SPG" 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 i
AP-2 Manual Table of Contents
Revision 7 - August, 2007
Table of Contents
Introduction_________________________________________________1
Safety ........................................................................................................1
How to Contact QED................................................................................2
Chapter 1: Safety ____________________________________________3
A Partial List of Safety Procedures ..........................................................3
Fire and Explosion Protection ..................................................................4
Personal Protection ...................................................................................4
Spill Protection .........................................................................................4
Chapter 2: Overview _________________________________________5
General Specications ..............................................................................5
This is How it Works ................................................................................6
Major AutoPump Features........................................................................6
Special Operating Conditions ................................................................... 8
Cold Weather .....................................................................................8
Actions To Take .................................................................................8
Flow induced freezing .......................................................................10
The well is under a vacuum...............................................................10
Abrasive particles in the well ............................................................ 10
Hard pipe air supply connection to the pump....................................10
Options and Accessories ...........................................................................11

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AP-2 Manual
Page ii
Chapter 3: Equipment________________________________________12
Unpacking.................................................................................................12
Equipment List..........................................................................................12
Tools..........................................................................................................13
Parts List ...................................................................................................13
AP-2 AutoPumps ......................................................................................13
Bottom-Loading AP-2/BL ................................................................13
Top-Loading AP-2/TL ......................................................................13
Specications.....................................................................................16
Component Materials ........................................................................16
Performance and Air Use Curves ......................................................16
Landll Pump Congurations ...........................................................16
Landll Pump Specications.............................................................16
Component Materials ........................................................................16
Single Stage Filter/Regulator....................................................................18
Hoses and Fittings.....................................................................................19
Hose and Tubing Color Code Table................................................... 19
Pump Cycle Counter.................................................................................20
Volumes Pumped Per Cycle ..............................................................20
Pump Support System...............................................................................21
Chapter 4: Assembly & Installation_____________________________22
Cautions ....................................................................................................22
Compressed Air Supply ............................................................................23
Component Assembly...............................................................................23
Quick-Connects/Hose Barbs .............................................................23
AutoPump Assembly .........................................................................23
Dry Test.....................................................................................................28
Pump Support System and Hose Bundling Assembly..............................29
AutoPump Installation..............................................................................34

AP-2 Manual Table of Contents
Revision 7 - August, 2007 Page iii
Chapter 5: Start Up and Operation _____________________________36
Start Up Checklist.....................................................................................36
Adjusting the Pump Cycle Counter ..........................................................37
Observation of System Operation.............................................................38
Downwell Testing of the AutoPump.........................................................38
AutoPump Shutdown while Submerged...................................................38
AutoPump Removal Technique (optional) ...............................................39
Chapter 6: Maintenance ______________________________________40
General Maintenance ................................................................................ 40
Maintenance Table....................................................................................41
Air Quality Check.....................................................................................41
Single Stage Filter/Regulator Maintenance.......................................41
AutoPump Service .................................................................................... 43
AutoPump Shutdown and Removal from Well .................................43
Removing Pump Casing .................................................................... 43
Cleaning Pump Interior .....................................................................44
Iron Build-up Cleaning Procedure.....................................................51
Installing Pump Casing .....................................................................52
Cleaning the Pump Cycle Counter ...........................................................53
Checking Volumes Pumped Per Cycle .....................................................53
Chapter 7: Troubleshooting & Repairs __________________________54
Troubleshooting ........................................................................................ 55
Returning Equipment for Service .............................................................58
Equipment Cleaning Requirements ..........................................................59
Hoses and Fittings .............................................................................59
AutoPumps ........................................................................................59

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AP-2 Manual
Page iv
Appendix A: Performance Curves_______________________________60
Appendix B: Air Consumption Curves ___________________________66
Appendix C: AP-2 Conversions _________________________________72
Appendix D: Vacuum on Well __________________________________75
Appendix E: Air Compressor __________________________________80
Installation ................................................................................................80
Electrical Wiring for the Compressor................................................81
Motor Overload Protection................................................................82
Air Quality and Pressure ...................................................................82
Maintenance..............................................................................................83
Troubleshooting ........................................................................................ 84
Appendix F: Pump Cycle Counter ______________________________86
Introduction...............................................................................................86
Pump Cycle Counter Operation/Installation .....................................87
Digital Display...................................................................................87
Magnet Housing ................................................................................88
Hardware Options..............................................................................88
Materials of Construction .................................................................. 89
Adjusting the Pump Cycle Counter................................................... 89
Cleaning the Pump Cycle Counter ....................................................90
Assembly of the Digital Display .......................................................92
AP-2 Volumes Pumped Per Cycle .....................................................92
Terms, Conditions, and Warranty _______________________________96

AP-2 Manual Table of Contents
Revision 7 - August, 2007 Page v
Figures:
Figure 1 - How it Works..................................................................................... 7
Figure 2 - Overview of the AutoPump System .................................................. 9
Figure 3 - Long and Short Bottom-Loading (AP-2/BL)................................... 14
Figure 4 - Long and Short Top-Loading (AP-2/TL) .......................................... 15
Figure 5 - Long and Short AP-2 Bottom Loading with Leachate Screen.......... 17
Figure 6 - Single Stage Filter/Regulator 60 with Quick-Connects .................... 18
Figure 7 - Locking Quick-Connects .................................................................. 24
Figure 8 - One-Ear Clamp and Hose Barb Assembly Instructions .................... 25
Figure 9 - AP-2 Assembly: Well Cap with Holes .............................................. 26
Figure 10 - AP-2 Assembly: Well Cap with Hose Barbs..................................... 27
Figure 11 - Examples of Well Caps ..................................................................... 30
Figure 12 - Hose Bundling: Part 1 of 2................................................................ 32
Figure 13 - Hose Bundling: Part 2 of 2................................................................ 33
Figure 14 - Removing AP-2 Pump Casing .......................................................... 45
Figure 15 - Exploded View of a Long Top-Loading AP-2................................... 46
Figure 16 - Exploded View of a Short Top-Loading AP-2................................... 47
Figure 17 - Exploded View of a Long Bottom-Loading AP-2............................. 48
Figure 18 - Exploded View of a Short Bottom-Loading AP-2............................. 49
Figure 19 - Exploded View of AP-2 Lever Assembly.......................................... 50
Figure 20 - Long AP-2/BL Performance Curves:
1/2-inch (13 mm) I.D. Discharge US and METRIC UNITS ............ 62
Figure 21 - Long AP-2/TL Performance Curves:
1/2-inch (13 mm) I.D. Discharge US and METRIC UNITS ............ 63
Figure 22 - Short AP-2/BL Performance Curves:
1/2-inch (13 mm) I.D. Discharge US and METRIC UNITS ............ 64

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AP-2 Manual
Page vi
Figure 23 -Short AP-2/TL Performance Curves:
1/2-inch (13 mm) I.D. Discharge US and METRIC UNITS ............ 65
Figure 24 - Long AP-2/BL Air Consumption Curves:
1/2-inch (13 mm) I.D. Discharge US and METRIC UNITS ............ 68
Figure 25 - Long AP-2/TL Air Consumption Curves:
1/2-inch (13 mm) I.D. Discharge US and METRIC UNITS ............ 69
Figure 26 - Short AP-2/BL Air Consumption Curves:
1/2-inch (13 mm) I.D. Discharge US and METRIC UNITS ............ 70
Figure 27 - Short AP-2/TL Air Consumption Curves:
1/2-inch (13 mm) I.D. Discharge US and METRIC UNITS ............ 71
Figure 28 - Conversion from Bottom-Loading
to Top-Loading Autopump ................................................................ 73
Figure 29 - Conversion from Top-Loading
to Bottom-Loading Autopump .......................................................... 74
Figure 30 - AP-2/BL with Vacuum In the Well and
Pump Exhaust Outside the Well........................................................ 76
Figure 31 - AP-2/BL with Vacuum In the Well and
Pump Exhaust In the Well................................................................. 77
Figure 32 - AP-2/TL with Vacuum In the Well and
Pump Exhaust Outside the Well........................................................ 78
Figure 33 - AP-2/TL with Vacuum In the Well and
Pump Exhaust In the Well................................................................. 79
Figure 34 - Pump Cycle Counter ......................................................................... 86
Figure 35 - Pump Cycle Counter Installation ...................................................... 88
Figure 36 - Pump Cycle Counter Exploded View................................................ 91
Figure 37 - Pump Cycle Counter with Magnetic Reed Switch............................ 94
Figure 38 -Pump Cycle Counter Remote Readout Panel .................................... 95

Page 1
AP-2 Manual
Revision 7 - August, 2007
Introduction
Welcome to QED Environmental Systems’ AutoPump® (AP-2) manual.
To ensure the best operator safety and system performance, it is strongly recommended that
the operators read this entire manual before using the system.
This manual reects our many years of experience and includes comments and suggestions
from our sales and service personnel and most importantly from our customers. The chapters,
their contents and sequence were designed with you, the user and installer, in mind. We wrote
this manual so it can be easily understood by users who may not be familiar with systems of
this type or are using a QED system for the rst time.
Safety
Safety has been a cornerstone of our design which has been proven out in building and
shipping systems throughout the world. Our high level of performance is achieved by using
quality components, building in redundancies or backup systems, and not compromising
our commitment to quality manufacturing. The net result is the highest quality and safest
pneumatic pump recovery system on the market. We feel so strongly about safety, based
on years of working with the hydrocarbon industry, that it is the rst section in all of our
manuals.

QED Environmental Systems
AP-2 Manual
Page 2
How to Contact QED
If for any reason you are unable to nd what you need in this manual please 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:
Service Department
QED Environmental Systems
www.qedenv.com
Oakland Service Center
1133 Seventh Street
Oakland, California 94607
[phone] – North America Only
[phone] – Tele.
[phone] – Fax
Ann Arbor Service Center
PO Box 3726
6095 Jackson Road
Ann Arbor, Michigan 48106-3726
[phone] — North America Only
[phone] — Tele.
[phone] — Fax
[e-mail] — E-mail
QED can be reached 24 hours a day
We welcome your comments and encourage your feedback regarding anything in this
manual and the equipment you have on-site.
Thank you again for specifying QED remediation equipment.

Page 3
AP-2 Manual
Revision 7 - August, 2007
Chapter 1: Safety
Safety has been a prime consideration when designing the AutoPump System. Safety
guidelines are provided in this manual, and the AutoPump System safety features are listed
below. Please do not attempt to circumvent the safety features of this system.
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 the equipment and uids. If you have any
questions, please contact the QED Service Department for guidance.
As you read through this manual, you will encounter three kinds of warnings. The following
examples indicate how they appear and lists their respective purposes.
Note: Highlights information of interest.
Caution: Highlights ways to avoid damaging equipment.
WARNING: Highlights personal safety issues.
A Partial List of Safety Procedures
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:
• Wear safety goggles when working with the AutoPump System to protect eyes from any
splashing or pressure release.
• Wear chemically resistant rubber gloves, boots, and coveralls when handling the AutoPump
and uid discharge hose to avoid skin contact with the uid being recovered..

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AP-2 Manual
Page 4
• Point all hoses away from personnel and equipment when connecting or disconnecting.
• Always ensure that the uid discharge hose is connected before the air hose to prevent
accidental discharge.
The AutoPump System minimizes the potential for accidents with the following safeguards:
Fire and Explosion Protection
Almost all of QED underground uid extraction systems are pneumatic. This offers many
inherent re and explosion protection features:
• Compressed air lines eliminates electrical wiring in hazardous areas.
• Aluminum or berglass enclosures prevent sparking.
• Standard systems use brass ttings to eliminate sparking hazard.
Personal Protection
On-site, service and maintenance personnel can safely use QED equipment. Safety-in-use is
the primary design feature in all systems. Following are some samples:
• All standard high pressure air hoses have automatic shut off quick-connects on the supply
side which prevents injury due to hose whip or air blown particles. Tubing does not usually
have quick-connect ttings, but is pushed over barbs or pushed into compression ttings.
• Metal regulators and lter bowls are rated for an inlet pressure of 200 psi. The metal air
lter bowl is made of zinc, providing greater pressure and chemical resistance than plastic
bowls and it is less prone to damage if dropped.
Spill Protection
On-site spills cannot always be prevented. QED equipment is designed to take into
consideration such unpredictable occurrences that may happen despite strict adherence to
standardized safety practices.
• The standard air and uid hoses are rated at over 800 psi burst pressure to prevent
accidental hose breakage.
• Down well quick-connects have locking features to prevent accidental disconnections.

Page 5
AP-2 Manual
Revision 7 - August, 2007
Chapter 2: Overview
The AutoPump® lls and empties automatically, and is very easy to install, use, and maintain.
The AutoPump is a pneumatic uid extraction pump that pumps in pulses. It handles any
liquid which ows freely into the pump and is compatible with the component materials and
with the connecting hoses.
The AutoPump is very versatile and available in a range of lengths and uid inlet
arrangements to meet particular site specications.
Equipment will vary by application and site specications. (See Chapter 3)
General Specications
1.75 inch 44.5 mm
5-130 psi 0.4-9.2 Kg/cm2
Long BL 0 to 2.3 gallons per minute (GPM) 0 to 8.8 liters per minute (LPM)
Long TL 0 to 1.9 gallons per minute (GPM) 0 to 7.2 liters per minute (LPM)
Short BL 0 to 2.0 gallons per minute (GPM) 0 to 7.6 liters per minute (LPM)
Short TL 0 to 1.6 gallons per minute (GPM) 0 to 6.1 liters per minute (LPM)
Flow Range
Pressure Range
Pump Diameter

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AP-2 Manual
Page 6
This is How it Works
The AutoPump is a submersible compressed air-driven pump which lls and empties
automatically. It also controls the uid level in a well automatically. The pump lls (see
Figure 1) when uids enter either the top or bottom check valve. Air in the pump chamber
exits through the exhaust valve as the uid lls the pump. The oat inside the pump is carried
upwards by the uid rising inside the casing until it pushes against a stop on the control rod,
forcing the valve mechanism to switch to the discharge mode.
The switching of the valve causes the exhaust valve to close and the air inlet valve to open.
This causes the pump to empty (see Figure 1) by allowing compressed air to enter the pump.
This pressure on the uid closes the inlet check valve and forces the uid up the discharge
tube and out of the pump through the outlet check valve. As the uid level falls in the
pump, the oat moves downwards until it pushes against the lower stop on the control rod,
forcing the valve mechanism to switch to the ll mode. The outlet check valve closes and
prevents discharged uids from re-entering the pump. The lling and discharging of the pump
continues automatically.
Note: The gures shown here are simplied schematics.
Major AutoPump Features
• The AutoPump System is small and lightweight and can be easily moved from site to site,
allowing quick response to changing conditions.
• The hoses are color coded and all the ttings are different so only the proper connections
can be made.
• Rugged construction ensures long system life, even under harsh conditions.
• The entire system is pneumatically powered with no electrical components, thus avoiding
sparks in control power and sensing devices.

Page 7
AP-2 Manual
Revision 7 - August, 2007
Figure 1 - How it Works
Chapter 2: Overview
601345

QED Environmental Systems
AP-2 Manual
Page 8
• The AP-2 only uses air while pumping. Unlike systems that rely on bleeding air sensors or
timers which pressurize and depressurize the air hoses for each stroke, the air hose for the
AP-2 remains pressurized to the pumps at all times. Air compressor power consumption,
compressor lter maintenance, and thus operating costs are substantially reduced.
• The AP-2 can be congured to ll from the top or the bottom.
Figure 2 on the next page illustrates an overview of an AutoPump System.
The AP-2 System provides everything required for pumping uid from a well. QED can also
supply the air compressor, if desired.
The system is designed to perform for years and comes with a one year warranty.
Note:
An automatic drain on the compressor is highly recommended since it
dramatically decreases air lter maintenance. QED can supply an automatic
drain.
Caution:
Alteration of the System: Do not change or modify the equipment without
the expressed written approval of QED.
Special Operating Conditions
Conditions may require adjustment or adaptations to the equipment. Below is a list of some of
these conditions, their possible effects, and solutions.
Since every site is different, please contact your QED representative for detailed assistance
if needed.
Cold Weather
Moisture in the pneumatic lines can freeze causing problems with the system. Such
freezing could result in regulators not reducing the air pressure, valves sticking, and
hoses clogging.
Actions To Take
• Use water traps and automatic compressor tank drains. These are available at
industrial distributing companies (e.g., W.W. Graingers®).

Page 9
AP-2 Manual
Revision 7 - August, 2007
Figure 2 - Overview of the AutoPump System
Chapter 2: Overview

QED Environmental Systems
AP-2 Manual
Page 10
• Reduce air line freezing by burying air hoses below the frost line, or insulating
and heating with heat tape, or running hoses through a PVC pipe with warm air
being blown through it.
• Remove all the moisture you can from the air by using drains on the compressor,
lter, and low points in the air line. Use an air dryer to lower the dew point of
the compressed air below the temperature of exposed lines.
• Protect the air regulator from freezing. During freezing conditions regulators
may fail “open”, allowing high pressure (e.g. 150 psi from the compressor) to
enter components (e.g. gauges, hoses, uid receptacles) that may be damaged,
cause a safety problem, or release contaminating material.
• Locate the air intake to the compressor so the coolest (driest) air is drawn in.
Usually it is better to draw air from outside a building than from the inside.
Flow induced freezing
Although it rarely occurs, air ow through an AutoPump may cause freezing internally at
water temperatures well above 32˚F, slowing down the system. Cold water, moisture in
the compressed air, high air pressure, a high pumping rate, and back pressure on the pump
are variables that alone, or in combination with each other, may induce freezing. Should
it occur, there are system adaptations which can decrease or eliminate the freezing. Please
contact QED for advice.
The well is under a vacuum
The pump will work in a well that is under a vacuum, but there several conditions that
must be considered.
(See Appendix D)
Abrasive particles in the well
Please contact QED service if you encounter problems with abrasives in the well.
Hard pipe air supply connection to the pump
These can cause debris and scale to travel down to the pump. It can also prevent the pump
from cycling smoothly due to a solid connection (non-exing) to the top of the pump.
Blow out all of the hard pipe before connecting the pump. A short (6 feet) length of hose
should be used between the hard pipe and the pump to allow the natural movement of the
pump to occur without restraint. A small screen lter should be used at the lower end of
the metal air pipe to prevent scale from reaching the air valve.

Page 11
AP-2 Manual
Revision 7 - August, 2007
Options and Accessories
The following options and accessories are available from QED. Contact your QED
Representative regarding the following:
• AP Data Module – This water-resistant enclosure protects and shields surface
instrumentation from weather and/or harsh site conditions while providing easy visual
access to key system instrumentation readings. The options available for inclusion inside
the NEMA 3R enclosure are a lter/regulator, pump cycle counter, level sensor regulator
and gauge with air ow meter. Also included are a uid level indicator with an On/Off
switch, an Air Inlet Supply Gauge, and a Vacuum/Pressure reference with Gauge.
• Pump Cycle Counter (PCC) – A PCC counts the number of times a pump cycles.
The counter provides information for maintenance, service, and statistical purposes with
minimal loss in air pressure or performance. A PCC is easily attached on the air inlet
hose to the pump.
• TFSO – The Tank-Full Shut-Off (TFSO) System is a unique, self-contained pneumatic
system that shuts down other pneumatic systems in the event of a liquid level rise or a
pressure increase in a container. The TFSO provides dual safety by using two sensors.
The system is expandable—the button sensor of the system can be teed to monitor many
containers.
• Inlet Conversions – AutoPumps can be converted from Top- to Bottom-Loading and vice
versa. See Appendix C for more information.
• Extended Leachate Screens – (see gure 5)
Chapter 2: Overview

QED Environmental Systems
AP-2 Manual
Page 12
Chapter 3: Equipment
Unpacking
During the unpacking procedure, check for the following:
• All parts on the packing list have been included in the box
• All tting openings are unobstructed
• The equipment has not been damaged in shipment
Equipment List
The equipment list will vary depending on site specications, but the following list is a typical
conguration:.
1. Top-Loading or Bottom-Loading AP-2 with support eyebolt
2. Single stage lter/regulator with:
• 5 micron lter with manual drain (auto drain option)
• Pressure regulator with gauge
3. Pump Cycle Counter (PCC)
4. Hoses:
• Fluid discharge hose (black)
• System air supply hose (blue)
• AutoPump air hose (green)
• Air exhaust hose (blue)
Note:
Black nylon tubing can be used in place of hose.