QED AutoPump AP-2 User manual

O
P
E
R
A
T
I
O
N
S
M
A
N
U
A
L
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

QED Environmental Systems
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

QED Environmental Systems
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

QED Environmental Systems
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.