QED AP4+ User manual

Leaders in Environmental Compliance Products
OPERATIONS
MANUAL
QED Environmental Systems - P.O. Box 3726 / 2355 Bishop Circle W. Dexter, Michigan 48130-3726
1-800-624-2026 (North America Only) [phone] - Tele [phone] - Fax [email protected] - E-mail www.qedenv.com
QED Environmental Systems (West) - 1565 Alvarado Street San Leandro, California 94577-2640
1-800-537-1767 (North America Only) [phone] - Tele [phone] - Fax
DEPENDABLE,
& DELIVERS
DURABLE,
AutoPump Controllerless System
(For 4 inch wells or larger)
+
AutoPump
ATEX Version
602418-02(doc # 602418 ) (Rev 12/10/12)
Copyright QED Environmental Systems, Dec.2012

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 RegisteredTrademark of "QED Environmental Systems"
QED Environmental Systems is a RegisteredTrademark of "QED Environmental Systems"
Patents/Trademarks

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 __________________________
Troubleshooting
Returning Equipment for Service
Equipment Cleaning Requirements
_______
_______________________________
_______________________________
_______________________________
_______________________________
Hose Bundling
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
_______________________________
AP4+ Bottom Inlet Long
AP4+ Bottom Inlet Short
AP4+ Bottom Inlet Low Drawdown
Terms, Conditions and Warranty
_______________________________
_______________________________
_______________________________
_______________________________
AP4+ Top Inlet Long
AP4+ Top Inlet Short
AP4+ Top Inlet Low Drawdown
_______________________________
_______________________________
_______________________________
Figures:
_______________________________
8
1
1
1
2
2
2
5
5
5
8
8
8
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9
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20
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23 - 26
27 - 29
31 - 34
35 - 38
39 - 42
43 - 46
47
_______________________________
_______________________________
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_______________________________
_______________________________
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Figure -4
Examples of Well Caps
Figure -5
Hose Bundling
_______________________________
_______________________________
_______________________________
Figure -8
Exploded View of a Top-Loading AutoPump AP-4+ (Long & Short)
Figure -6
Exploded View of a Bottom-Loading AutoPump AP-4+ (Long & Short)
_______________________________
Figure -7
Exploded View of a Bottom-Loading AutoPump AP-4+ (Low Drawdown)
_______________________________
Figure -9
Exploded View of a Top-Loading AutoPump AP-4+ (Low Drawdown)
Figure -01
Exploded View of AP-4+ Lever Assembly
Figure -11
Exploded View of 1-Inch Brass Check Valve
6
15
14
12
11
8
7
_______________________________
_______________________________
Figure 1 -
Figure 2 -
Figure 12 -
Figure 13 -
3
4
16
17
18
19
Chapter 2: ATEX Certification Information
____________________________________________
ATEX Certifications, Label Detail and Explanation
_______________________________
3
3
ATEX Label Detail and Explanation
ATEX Label Location and Appearance

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
1565 Alvarado Street
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
at any time. We encourage you to use following communication methods to reach us at any time:
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
Welcome to QED Environmental Systems’ AutoPump® (AP4+) manual.
1
2355 Bishop Circle W.

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 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:
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 theAutoPump and fluid discharge
hose to avoid skin contact with the fluid being removed
Point tubing/hoses away from personnel and equipment when connecting or disconnecting.
Always ensure that the fluid discharge line is connected before the air line to prevent accidental discharge.
The AutoPump System minimizes the potential for accidents with the following safeguards:
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:

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
AP4+
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

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Bottom Loading
Figure 2 ATEX Label Location and Appearance
Obverse View
Reverse View
AutoPump
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Figure 2
Pump Serial Numbers
Located on the Pump’s Head

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.
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 AP4+ is intended
for vertical operation in well casings with a 3.75-inch 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 1) 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 1) 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, forcing
the 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.
NOTE:The figures shown here are simplified schematics.
5

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

AP4+ System provides everything required for pumping fluid from a well.
Fluid
Discharge
Easy Fittings
Air Exhaust
Cycle Counter
Air
Supply
From
Compressor
Note: Support Harness, Rope, and
Tubing Sheath Omitted for Clarity
7
Figure 4 - Overview of the AP4+ System
Pump
Tubing
Wellhead
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www.qedenv.com
pmuPotuA
Easy Bolt
Easy Bolt
Easy Bolt
Filter/Regulator

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
1. Top-Loading or Bottom-Loading AP-4 with support harness
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
air passing to the AP4+.
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

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.
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).
5. Attach pump support rope/cable to the pump.
6. Attach pump air supply and liquid discharge lines to the well cap. 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).
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).
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. 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.
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.
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 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.
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.
* 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.
9

Chapter 5: Installation
Hose Bundles
10
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:
1. Lay the equipment on the ground and make all of the necessary hose connections. (See Figure 5).
2. If a well cap is supplied, install it on the hoses. (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 5).
Note: To make the next step easier, pull the support rope and the hoses taut.
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 5).
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 5).
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.

Figure 6 - Examples of Well Caps
11

Figure 7 - Hose Bundling
12
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)

Chapter 6: Maintenance
Cleaning Pump Interior
Removing the Pump’s Casing
.1 Gently brush off built-up solids from the float, the discharge line, the pump casing and the control rod guide.
1. Remove the bolt at the bottom of the pump which holds the inlet screen in place (bottom loading pumps only).
2. The pump can be steam cleaned without damage.
2. Remove the three bolts at the bottom of the pump which hold the inlet in place. (See Figures 6,7,8,and 9)
3. Remove thick deposits of hardened scale on the discharge tube by using a handbrush or by lightly tapping the
discharge tube with a small hammer. Be careful not to strike any pins or other components, since they may be
damaged.
4. Twist and slide the casing down off the pump’s frame.
3. Remove. the inlet from the pump’s casing by pulling it out.
The inner workings of the pump should now be exposed for inspection and cleaning. (See Figures 6 Through 11)
Note: A Scotch Brite® abrasive pad is useful for cleaning debris from the pump components.
Iron Build-up Cleaning Procedure
1. The bottom “spider” should be removed by unthreading it from the pump’s discharge pipe. (See Figures 6,7,8,and 9)
2. Visually inspect the 1 inch stainless steel fluid discharge pipe for scale build-up or debris. Also, do the same with the float
that rides up and down on the SS discharge pipe.
3. Should there be scale deposits on either or both the discharge pipe or float, then remove the float from the SS fluid discharge
pipe as follows . (See Figures 6,7,8,and 9)
4. The 1 inch stainless steel fluid discharge pipe can now be cleaned using either a ScotchBrite pad, a wire brush or
a wire wheel on either a drill or a grinding machine. After removing the scale/debris, it is recommended the pipe
be water rinsed.
Both the internal and external surfaces of the float will generally require cleaning. The cleaning material choices
include a Scotch Brite pad, and a light grade 150 sandpaper.
The plates are removed to ease cleaning, they should be replaced on the same float end from which they came.
That is, the plates should maintain their original top and bottom positions.
5. 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 and is adjacent to the SS discharge pipe in the assembled pump. To Clean
use the Scotch Brite pad or a razor or Exacto knife (not sandpaper).
6. The final component to be cleaned is the outer AP4+ 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.
After the casing has been removed from the AutoPump please follow the procedure below:
Remove the small SS hairpin from the bottom spring cup. Removing the hairpin and spring cup will allow you to
remove the spring, sliding stop and float from the SS discharge pipe.
The AutoPump is now ready for re-assembly by following the steps above in reverse order.
13
Note: Before threading the bottom “spider” onto the pump’s discharge pipe, be sure to wrap the discharge pipe’s
threads completely with Teflon tape.

Figure 10 - Exploded View of Top Loading AP4+ (Long & Short)
NOTE: Some Parts are available in
alternate materials based
16

Figure 11 - Exploded View of Top Loading AP4+ Low Drawdown
NOTE: Some Parts are available in
alternate materials based
17