QED AP4 Ultra User manual

®
AutoPump Ultra 4.0
ATEX Version
Original Instructions
MANUAL
OPERATIONS
1-800-537-1767 (North America Only) [phone] - Tele [phone] - Fax
QED Environmental Systems (West) - 1670 Alvarado Street San Leandro, Suite 5, California 94577-2640
1-800-624-2026 (North America Only) [phone] - Tele [phone] - Fax [email protected] - E-mail www.qedenv.com
QED Environmental Systems - P.O. Box 3726 / 2355 Bishop Circle W. Dexter, Michigan 48130-3726
Copyright QED Environmental Systems, 2015
602569 602569-01 (doc # 602569) (3/26/15)

The equipment in this manual is protected under U.S. and foreign patents issued and pending:
U.S. Patents:
AutoPump (AP) 5,004,405
"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"
Patents/Trademarks
Revision 3 - December, 2013

Pump Specifications
Table of Contents
Introduction _________________________________________________
Safety
How to Contact QED
Chapter 1: Safety
____________________________________________
A Partial List of Safety Procedures
Fire and Explosion Protection
Chapter 3: Overview
_________________________________________
This is How it Works
General Specifications
Chapter 4: Equipment
________________________________________
Unpacking
Equipment List
Single Stage Filter/Regulator
Chapter 5: Installation
_____________________________
Installation
Chapter 6: Maintenance
______________________________________
Cleaning Pump Interior
Iron Build-up Cleaning Procedure
Chapter 7: Troubleshooting & Repairs __________________________
Equipment Cleaning Requirements
_______
_______________________________
_______________________________
_______________________________
_______________________________
Hose Bundling
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
Terms, Conditions and Warranty
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
Figures:
_______________________________
8
1
1
1
2
2
2
5
5
5
8
8
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9
9
_______________________________
_______________________________
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_______________________________
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Figure -4
Examples of Well Caps
Figure -5
Hose Bundling
_______________________________
_______________________________
_______________________________
Figure -8
Figure -6
Figure -7
Figure
6
8
7
_______________________________
_______________________________
Figure 1 -
Figure 2 -
3
4
Chapter 2: ATEX Certification Information
____________________________________________
ATEX Certifications, Label Detail and Explanation
_______________________________
3
3
ATEX Label Detail and Explanation
ATEX Label Location and Appearance
Revision 3 - December, 2013Revision 3 - December, 2013
11
14
14
14
12
13
15
9 -
Figure 10-
Figure 11-
16
17
18
Exploded View of a Bottom-Loading AP Ultra Pump (Long & Short)
Exploded View of a Top-Loading APUltra Pump (Long & Short)
Exploded View of AP Ultra Lever Assembly
Exploded View of 1-Inch Check Valve
19
21
Troubleshooting 19
22
22- 25
26- 29
30- 33
34 - 37
38
Returning Equipment for Service 21
AP Ultra Bottom Inlet Long
AP Ultra Bottom Inlet Short
AP Ultra Top Inlet Long
AP Ultra Top Inlet Short

Introduction
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 reflects 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 first 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 first section of all our manuals
Service Department
QED Environmental Systems
www.qedenv.com
San Leandro Service Center
1670 Alvarado Street, Suite 5
San Leandro, California 94577-2640
ylnOaciremAhtroN—7671-735)008
(
[phone] — Tele.
[phone] — Fax
Ann Arbor Service Center
PO Box 3726
Ann Arbor, Michigan 48106-3726
Dexter, Michigan 48130
[phone] — North America Only
[phone] — Tele.
[phone] — Fax
[e-mail] — E-mail
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
Thank you again for specifying QED equipment.
We welcome your comments and encourage your feedback regarding anything in this manual and the equipment you
have on-site.
QED can be reached 24 hours a day
1
2355 Bishop Circle W.
Revision 3 - December, 2013Revision 3 - December, 2013
Welcome to QED Environmental Systems’ AutoPump® (AP4 Ultra 4.0) manual.
at any time. We encourage you to use the following communication methods to reach us at any time:

Chapter 1: Safety
Warning:
A Partial List of Safety Procedures
Almost all of QED underground fluid extraction systems are pneumatic. This offers many inherent fire and explosion
protection features.
Fire and Explosion Protection
•
•
•
•
2
Highlights information of interest.
Highlights ways to avoid damaging equipment.
Highlights personal safety issues.
Note:
Caution:
Revision 3 - December, 2013Revision 3 - December, 2013
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 equipment and fluids. 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.
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 chemically resistant rubber gloves, boots, and coveralls when handling the AutoPump and fluid
discharge hose to avoid skin contact with the fluid being removed
The AutoPump System minimizes the potential for accidents with the following safeguards:
Wear safety goggles when working with the AutoPump System to protect eyes from any splashing or
pressure release.
Point tubing/hoses away from personnel and equipment when connecting or disconnecting.

Chapter 2 ATEX Certifications, Label Detail and Explanation
3
Equipment with an ATEX label similar to the example in Figure 1, is ATEX certified.
Equipment without the label is not ATEX certified.
Figure 1 explains the ATEX label, Figure 2, (following Page) shows the label location and
appearance.
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This equipment has been certified to Hazardous Area Classification:
Equipment Model:
AP2
AP3
AP4
AP4+
GNE
BP
SPG2
SPG4
SOS2
SOS4
= 2-inch AutoPump
= 3-inch AutoPump
= 4-inch AutoPump
= 4-inch AutoPump
= Genie Pump
= Bladder Pump
= 2-inch Specific
Gravity Skimmer
= 4-inch Specific
Gravity Skimmer
= 2-inch Selective
Oil Skimmer
= 4-inch Selective
Oil Skimmer
T1
T2
T3
T4
T5
T6
450° C
300° C
200° C
135° C
85° C
100° C
Minimum Auto
Ignition Temperature
of Surrounding
Substance by Class
CE
Symbol
Code No. of Notified
Body Certifying
Quality Management
System
of Manufacturer
Indicates That
the Equipment
May Be Used in
a Hazardous Area
Allowable Ambient
Temperature Range
for Equipment
Protection Method
is by Construction
The Equipment
May be Located
Where Flammable
Gases and Vapors
of Group IIB May
be Present
G D G D G D
II
123
Group
Catagory
Atmosphere*
*G=Gas D=Dust
QED, 94577-2640, USA FM08ATEX0028
MAXIMUM PRESSURE
FM
APPROVED
9.0 BAR (130 PSI)
13.8 BAR (200 PSI)
YEAR
PAT. 5004405,
5641272, 5495890, 5358038 S/N:AP4+C-XXXXX
Manufacturer, Zip Code, Country
Approving Entity
Certificate Number
Maximum Operating Pressure
*Serial Number May be
LocatedOutside the Label
Year of Manufacture
Patent Number(s)
Serial Number*
X
as Appropriate and as Noted
TL EX DIS IN
Figure 1
Revision 3 - December, 2013Revision 3 - December, 2013
= 4-inch AutoPump
AP Ultra
AP Ultra

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Figure 2 ATEX Label Location and Appearance
Reverse View
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Figure 2
Pump Serial Numbers
Located on the Pump’s Head
Revision 3 - December, 2013Revision 3 - December, 2013
Obverse View
AP Ultra

Chapter 3: Overview
The AutoPump is very versatile and available in a wide range of lengths, valve arrangements, and materials of
construction to meet particular site specifications.
Equipment will vary by application and site specifications. (See Chapter 3)
Pump Diameter:
Pressure Range:
High Pressure Option:
Flow Ranges:
3.6 inch (91 mm)
5 - 120 psi (0.4 - 8.5 Kg/cm²)
5 - 200 psi (0.4 - 14.1 Kg/cm²)
0-14 gallons per minute (0-53 liters per minute)
This is How it Works
General Specifications
The AutoPump® fills and empties automatically, and is very easy to install, use, and maintain.
NOTE:The figures shown here are simplified schematics.
5
Revision 3 - December, 2013Revision 3 - December, 2013
The AutoPump is a pneumatic fluid extraction pump that pumps in pulses. It handles any liquid which flows freely
for vertical operation in well casings with a 3.75-inch(9.53cm) or greater internal diameter. It can pump particles up
to 1/8-inch in diameter.
The AutoPump is a submersible compressed air-driven pump which fills and empties automatically. It also controls
the fluid level in a well automatically. The pump fills (See Figure 3) when fluids enter either the top or bottom check
valve. Air in the pump chamber exits through the exhaust valve as the fluid fills the pump. The float inside the pump
is carried upwards by the fluids rising in 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 3) by allowing compressed air to enter the pump. This pressure on the fluid closes the inlet
check valve and forces the fluids up the discharge line and out of the pump through the outlet check valve. As the
fluid level falls in the pump, the float moves downward until it pushes against the lower stop on the control rod, forcingthe
valve mechanism toswitchtothe fill mode. The outlet check valve closes and prevents discharged fluids from re-entering
the pump. The filling and discharging of the pump continues automatically.
into the pump and is compatible with the component materials and with the connecting hoses. The AP Ultra is intended

As Pump Fills,
Float Rises
Lower
Float Stop
Check Valve
Unseated
Allowing
Liquid into
Pump
Pivoting Lever
Tipped Downward
By Descending
Float
Upper
Float Stop
Compressed Air
Flowing Into
Pump
As Pump Empties,
Float Descends
Lower
Float Stop
Check Valve Seated
Sealing Inlet
Pivoting Lever
Tipped Upward
By Rising Float
Air Exhausting
From Pump
Pump FillingPump Emptying
6
Figure 3 - How it Works
Revision 3 - December, 2013Revision 3 - December, 2013

Fluid
Discharge
Easy Fittings
Air Exhaust
Cycle Counter
Air
Supply
From
Compressor
Note: Support Harness, Rope, and
Tubing Sheath Omitted for Clarity
7
Pump
Tubing
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0
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2
0
4
0
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1
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6
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4
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1
1
www.qedenv.com
Easy Bolt
Easy Bolt
Easy Bolt
Filter/Regulator
Revision 3 - December, 2013Revision 3 - December, 2013
Wellcap
AP Ultra System provides everything required for pumping fluid from a well.
Figure 4 - Overview of the AP Ultra System

Chapter 4: Equipment
Unpacking
During the unpacking procedure, check for the following:
The equipment list will vary depending on site specifications, but the following list is a typical configuration
•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
2. Single stage filter/regulator with:
•5 Micron filter with auto drain tap
A single stage 5 Micron particulate air filter/regulator has a manual or an optional automatic drain and is installed
on the system air supply line. The filter/regulator removes particles and water droplets from the
NOTE: Too much air pressure can result in low pump efficiency
•Pressure regulator with gauge
•Maximum operating pressure 120 P.S.I. (8.4 Kg/cm²)
3. Pump Cycle Counter (PCC)
4. Pump support system:
•paclleW
•eporeriwSSroylbmessaknil-kciuqhtiweportroppusenelyporpyloP
(Alternate materials as required)
Single Stage Filter/Regulator
8
Maximum operating pressure 120 P.S.I. (8.4 Kg/cm²)
Part # 302468
For Standard Systems
Part # 302470
For Systems with Pump Cycle Counter
Figure 5 - Single Stage Filter/Regulator with Quick-Connects
Revision 3 - December, 2013Revision 3 - December, 2013
1. Top-Loading or Bottom-Loading AP Ultra with support harness
air passing to the AP Ultra.

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.
3. Slip clamps over appropriate tubing/hose prior to connecting the tubing/hose to the pump barbs.
4. Push tubing/hose down flush with the fitting's nut if possible; cover at least three barbs if three or more
are present (Note: when installing tubing in freezing weather, tubing can be dipped in warm water for a
few seconds to soften the nylon).
Note: Submerging the pump before supplying it with air can also result in fluid entering the air supply line.This
fluid from the well can contain particles, which could interfere with operation of the pump's air valve.
9
Revision 3 - December, 2013Revision 3 - December, 2013
Chapter 5: Installation
9. Lower the pump to the desired depth in the well.
10. Secure the pump by tying off the pump support line or by placing the well cap (or flange) on the well.
Caution: Submerging the pump before supplying it with air will result in fluid entering the exhaust
tubing/hose. Those fluids will be discharged from the exhaust tubing/hose during the first few cycles
of the pump. If this discharge will not be confined to the well; i.e., if the air exhaust line is routed
7. Connect the pump air supply and liquid discharge lines to the appropriate surface lines/headers.
8. Turn on the air pressure to the pump (minimum of 0.5 psi per foot of vertical static head).
5. Attach pump support rope/cable to the pump. "See figure 7"
6. Attach pump air supply and liquid discharge lines to the well cap. "See Figure 6". Attach the air
exhaust line to the well cap if the pump air is to exhaust outside the well (Note: the liquid discharge line
is always the largest diameter of the three lines, and the air supply line is always the smallest diameter).
outside the well*, it is important to make sure that the air exhaust line is not directed such that
equipment/ personnel could be splashed by the discharged fluid when air is turned on to the pump.

Chapter 5: Installation
* Routing the air exhaust in vacuum wells:
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
well is under vacuum and the exhaust air is routed outside of the well (to atmospheric pressure),
the actuation point of the pump will be higher than the normal actuation point by a distance equal
to the amount of vacuum applied to the well (expressed in "inches of water column"). Please note
that the pump will still function normally and maintain the liquid level, albeit a higher level.
QED controllerless pumps automatically control the liquid level in the well. Under normal conditions,
the liquid level will be maintained at a point approximately one foot below the top of a bottom load
pump (this is the pump's actuation point). The pump will automatically start and stop as needed to
maintain the level at this actuation point.
Note: If the well environment is such that deposition occurs on stainless steel parts, the operator
may wish to raise the pump above the water level during a shutdown of the system.
11. Increase the air pressure to the pump until the pump is pushing the fluid out at the desired rate. With
sufficient air pressure (at least 10 to 15 psi higher than the vertical static head), the pump will gradually
draw down the fluid level in the well to the level of the pump. The time required for this draw down varies
with the yield of the well as compared to the flow rate of the pump. The maximum recommended pump
operating pressure is 120 psi.
10

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.
Follow these instructions to create a hose bundle:
2. If a well cap is supplied, install it on the hoses. (See Figure 4).
Note: To make the next step easier, pull the support rope and the hoses taut.
Note: After completing this step, the fluid discharge hose will be attached to the support rope and
the exhaust hose. At this point the air supply hose is still lying free.
6. Place the next tie-wrap two feet towards the well cap from the first. Secure the air supply hose
rather than the exhaust hose.
Note: It is important to put the tie-wraps approximately two feet apart to keep a proper discharge
hose/support rope bundle. Experience has shown that spreading the tie-wraps further apart than
two feet increases the probability for hose kinking.
7. Continue to alternate the air exhaust and the air supply tie-wraps every two feet, stopping about
five feet from the wellhead.
8. Being careful not to leave any sharp edges, cut the excess from the tie-wraps.
You now have a down-well bundled hose assembly that supports both the hoses and the down-well
equipment.
Revision 3 - December, 2013Revision 3 - December, 2013
1. Lay the equipment on the ground and make all of the necessary hose connections. (See Figure 4).
3. Connect the quick-link assembly on the support rope to the eyebolt on the AP4+ and lay the
support rope out along with the hoses. Make sure that none of the hoses or support ropes are
crossing over each other (See Figure 7).
4. Starting at the AutoPump end of the hose, put a tie-wrap through the center of the braided support
rope just above the uppermost quick-connect or barb on the AutoPump (See Figure 7).
5. Pulling the rope taut, put the tie-wrap around the fluid discharge hose with the rough surface
outwards. Cross the ends and complete the connect the tie-wrap make sure it is straight and is not
kinking the hoses (See Figure 7).
11

Figure 6 - Examples of Well Caps
Revision 3 - December, 2013Revision 3 - December, 2013
12

Figure 7 - Hose Bundling
Tie-Wrap Detail
Figure 8 Tie-Wrap Layout
Thread Tie-Wraps
Through Support Line
Air Exhaust Tie-Wrap
AutoPump Air
Hose (Green)
Fluid Discharge
Hose (Black)
Air Exhaust
Hose (Blue)
Air Exhaust
Tie-Wrap
Support Rope
AutoPump® Air
Hose (Green)
Fluid Discharge
Hose (Black)
Air Exhaust
Hose (Blue)
Quick Link Assembly
Support Rope
Support Harness
Air Hose Tie-Wrap
AutoPump Air
Hose (Green)
Fluid Discharge
Hose (Black)
Air Exhaust
Hose (Blue)
Air Hose
Tie-Wrap
Support Rope
Air Exhaust Tie-Wraps in Between Air Hose Tie-Wraps Every 4 Ft. (122 Cm)
Air Exhaust Tie-Wraps in Between Air Exhaust Tie-Wraps Every 4 Ft. (122 Cm)
Revision 3 - December, 2013Revision 3 - December, 2013
13

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.
Removing the Pump’s Casing
1. Disconnect the air supply from the pump.
2. Remove the bolt at the bottom of the pump which holds the inlet screen in place (bottom loading pumps only).
4. Remove. the inlet from the pump’s casing by pulling it out.
5. Twist and slide the casing down off the pump’s frame.
Cleaning the Pump Interior
Gently brush off built-up solids from the float, discharge tube, pump casing and control rod.
Mineral Build-up Cleaning Procedure
1. The bottom “spider” casting should be removed by unthreading it from the discharge tube. (See Figures 8
2. Visually inspect the fluid discharge pipe for scale build-up or debris. Also, do the same with the float that slides up
3. Should there be scale deposits on either the discharge tube or float, remove the float from the discharge tube as Follows:
and spring cup will allow you to remove the spring, sliding stop and float from the SS discharge pipe.
4. The fluid discharge tube can now be cleaned using a damp cloth. To aid in cleaning, the discharge tube can be
soaked in vinegar. To remove tougher build-up, scour pads that are made for non-stick cookware can be used.
5. Both the internal and external surfaces of the float can be cleaned using a damp cloth. To aid in cleaning, the float
can be soaked in vinegar. To remove tougher build-up, scour pads that are made for non-stick cookware can be used. The
float end plates can be removed to ease cleaning. After cleaning, the plates should be replaced on the same end
of the float from which they came.
6. The white plastic square control rod is the next component to be cleaned. The control rod is the item that fits
through the smaller hole in the float plate and is adjacent to the discharge tube in the assembled pump. To
clean the control rod, use an abrasive pad or a razor or utility knife (not sandpaper).
7. The final component to be cleaned is the outer casing. The fastest and most effective way to clean out
the inside surface of the pump casing is to use a three-stone honing tool. The technique is to move the hone in
and out a half dozen times or so, through each end of the casing. The time for the casing cleaning should take
no longer than 5 minutes.
The AutoPump is now ready for re-assembly by following the steps above in reverse order.
Note: Before threading the bottom “spider” onto the pump’s discharge tube, be sure to wrap the discharge
Note: Before inserting the two assemblies back into the pump’s casing, apply PTFE grease to the two o-rings
(#16 on the next page) to make the next disassembly easier.
1 4
and down on the discharge tube .
tube ’s threads completely with Teflon tape.
3. Remove the three bolts at the bottom of the pump which hold the inlet in place (See Figures 8 and 9 ) .
The inner workings of the pump should now be exposed for inspection and cleaning (See Figures 8 and 9 ) .
and 9)
.
(See Figures 8 and 9 )Remove the small steel hairpin from the bottom spring cup. Removing the hairpin

Figure 8 - Exploded View of Bottom-Loading Ultra (Long and Short)Figure 8 - Exploded View of Bottom-Loading Ultra (Long and Short)
1 15

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

ITEM NO. PART NUMBER DESCRIPTION QTY.
11
11
21
21
3
316 SS 120 P.SI EXHAUST POPPET-LONG
316 SS 120 P.SI EXHAUST POPPET-SHORT
2
4
120 P.SI INTAKE POPPET CONNECTOR-LONG
120 P.SI INTAKE POPPET CONNECTOR-SHORT
2
316 SS LEVER CONNECTING NUT
5201626
LEVER HALF
2
6202889
NITRONIC 60 POPPET PIN-BUSHING
4
200330
201616
201616
201623
201623
206445
201033
1
8201053
VITON BUMPER O-RING
9 201520
201520
316 SS LEVER CONNECTING PIN
1
9 1
10 200496
PVDF CONTROL ROD ROLLER
4
11 201052 1
12 201458
316 SS CONTROL ROD ADAPTER BUSHING
2
17-7 COUNTERWEIGHT ROLLER
316 SS COUNTERWEIGHT-LONG
316 SS COUNTERWEIGHT-SHORT
316 SS COUNTERWEIGHT BUSHING
Parts Assembled
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4
5
5
6
6
7
8
9
10
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7
1
Figure 10 - Exploded View of AP Ultra Lever Assembly
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