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:
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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
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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
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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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2
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4
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8
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1
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6
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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