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QED Environmental Systems

AP-3 Manual

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How to Contact

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If for any reason you are unable to find what you need in this manual please feel free to

contact the

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Service Department

QED Environmental Systems

www.qedenv.com

San Leandro Service Center

1565 Alvarado Street

San Leandro, California 94577-2640

(800) 537-1767 — North America Only

(510) 346-0400 — Tele.

(510) 346-0414 — Fax

Ann Arbor Service Center

PO Box 3726

6095 Jackson Road

Ann Arbor, Michigan 48106-3726

(800) 624-2026 — North America Only

(734) 995-2547 — Tele.

(734) 995-1170 — Fax

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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.

Summary of Contents for AutoPump AP-3

Page 1: ...treet San Leandro California 94577 2640 800 537 1767 North America Only 510 346 0400 Tele 510 346 0414 Fax PO Box 3726 6095 Jackson Road Ann Arbor Michigan 48106 3726 800 624 2026 North America Only 7...

Page 2: ...atent Specific 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...

Page 3: ...ist of Safety Procedures 5 Fire and Explosion Protection 6 Personal Protection 6 Spill Protection 6 Chapter 2 Overview _________________________________________7 General Specifications 7 This is How i...

Page 4: ...s 18 Leachate Screens 19 Optional WYE Fitting 20 Short Top Loading Cup 21 Long Top Loading Cup 22 Single Stage Filter Regulator 23 Hoses and Fittings 24 Hose and Tubing Color Code Table 24 Volumes Pum...

Page 5: ...neral Maintenance 43 Maintenance Table 44 Air Quality Check 44 Single Stage Filter Regulator Maintenance 44 AutoPump Service 46 AutoPump Shutdown and Removal from Well 46 For Bottom loading pumps 46 F...

Page 6: ...________________________65 Appendix B Air Consumption Curves ___________________________79 Appendix C AP 4 Conversions _________________________________93 Appendix D Vacuum on Well____________________...

Page 7: ...n 21 Figure 10 Long AP 3 TLC and Long AP 3 TL Comparison 22 Figure 11 Single Stage Filter Regulator 60 with Quick Connects 23 Figure 12 Locking Quick Connects 28 Figure 13 Two Ear Clamp and Hose Barb...

Page 8: ...S 71 Figure 32 Long AP 3 TL Performance Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS 72 Figure 33 Short AP 3 BL Performance Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS 73 Figure...

Page 9: ...L Air Consumption Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS 89 Figure 48 Short AP 3 TL Air Consumption Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS 90 Figure 49 Short AP 3 TL...

Page 10: ...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 leve...

Page 11: ...QED Environmental Systems AP 3 Manual Page 2 Figure 1 ATEX Label Detail Example and Explanation...

Page 12: ...2206 03 Pump Serial No BOTTOM LOADER TOP LOADER 6 9 BAR 100 PSI MAXIMUM PRESSURE 80 PSI 5495890 5358038 5 5 BAR PAT 5004405 YEAR QED 94577 2640 USA FM08ATEX0028 II 1 G c IIB T6 Ta 1 C to 65 C 1725 AP3...

Page 13: ...m San Leandro Service Center 1565 Alvarado Street San Leandro California 94577 2640 800 537 1767 North America Only 510 346 0400 Tele 510 346 0414 Fax Ann Arbor Service Center PO Box 3726 6095 Jackson...

Page 14: ...hree 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 W...

Page 15: ...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 q...

Page 16: ...Chapter 3 General Specifications Bottom Loading 2 8 inch I D and larger 7 2 cm I D and larger Top Loading with Standard Fluid Inlet Fitting 3 75 inch I D and larger 9 53 cm I D and larger Top Loading...

Page 17: ...es against the lower stop on the control rod forcing the valve mechanism to switch to the fill mode The outlet check valve closes and prevents discharged fluids from re entering the pump The filling a...

Page 18: ...Page 9 AP 3 Manual Revision 3 April 2009 Figure 3 How it Works 601345 Chapter 2 Overview...

Page 19: ...ty Note An automatic drain on the compressor is highly recommended since it dramatically decreases air filter maintenance QED can supply an automatic drain Caution Alteration of the System Do not chan...

Page 20: ...Page 11 AP 3 Manual Revision 3 April 2009 Figure 4 Overview of the AutoPump System Chapter 2 Overview...

Page 21: ...ernally 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 a...

Page 22: ...r 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 i...

Page 23: ...ent List The equipment list will vary depending on site specifications but the following list is a typical configuration 1 Top Loading or Bottom Loading AP 3 with support ring 2 Single stage filter re...

Page 24: ...hrough a check valve located at the top of the pump This check valve prevents the fluid from reentering the pump Bottom Loading AP 3 BL The Bottom Loading AutoPump fills through a check valve at the b...

Page 25: ...QED Environmental Systems AP 3 Manual Page 16 Figure 5 Long and Short Bottom Loading AP 3 BL...

Page 26: ...Page 17 AP 3 Manual Revision 3 April 2009 Figure 6 Long and Short Top Loading AP 3 TL Chapter 3 Equipment...

Page 27: ...ange 5 to 100 psi 0 4 7 0 Kg cm2 52 in 132 cm 2 63 in 6 68 cm Long AP 3 TL Pump 57 in 145 cm 3 40 in 8 64 cm 5 to 100 psi 0 4 7 0 Kg cm2 Short AP 3 BL Short AP 3 TL 42 in 107 cm 47 in 119 cm 11 lbs 5...

Page 28: ...Page 19 AP 3 Manual Revision 3 April 2009 Chapter 3 Equipment Figure 7 Long and Short AP 3 Bottom Loading with Leachate Screen...

Page 29: ...QED Environmental Systems AP 3 Manual Page 20 Figure 8 Short AP 3 Top Loading with Optional Brass WYE Fitting...

Page 30: ...Page 21 AP 3 Manual Revision 3 April 2009 Chapter 3 Equipment Figure 9 Short AP 3 TLC and Short AP 3 TL Comparison...

Page 31: ...QED Environmental Systems AP 3 Manual Page 22 Figure 10 Long AP 3 TLC and Long AP 3 TL Comparison...

Page 32: ...led on the system air supply hose The filter regulator removes particles and some oil vapor and water droplets from the air passing to the AP 3 The regulator should produce at least as much pressure a...

Page 33: ...c s i d r i a s t r o p s n a r T m o r f o t r o t a l u g e r r e t l i f p m u P o t u A r i a s t s u a h x E p m u P o t u A m o r f s g n i t t i F d n a b r a b e s o H e n o r o p m a l c k c...

Page 34: ...e to vary from pump to pump on a single site All figures above are dependent on site specific conditions under which the pump is operating Pump Volume per Cycle Range Volume per Cycle Typical Long AP3...

Page 35: ...sure look at the respective fittings on the pump Blow out all water and particles from compressed air conduits trunk lines sensor hoses air supply hoses etc and fluid lines for at least 10 seconds aft...

Page 36: ...oil may foul the filter regulator WARNING The compressor should not provide more pressure than the filter can accept The metal bowl can accept 150 psi Maximum output air pressure setting on the standa...

Page 37: ...QED Environmental Systems AP 3 Manual Page 28 Figure 12 Locking Quick Connects 600259 02...

Page 38: ...Page 29 AP 3 Manual Revision 3 April 2009 Chapter 4 Assembly Installation Figure 13 Two Ear Clamp and Hose Barb Assembly Instructions 600519 03...

Page 39: ...QED Environmental Systems AP 3 Manual Page 30 Figure 14 Worm Drive Clamp and Hose Barb Assembly Instructions 600518 02...

Page 40: ...Page 31 AP 3 Manual Revision 3 April 2009 Chapter 4 Assembly Installation Figure 15 AP 3 Assembly Well Cap with Holes...

Page 41: ...QED Environmental Systems AP 3 Manual Page 32 Figure 16 AP 3 Assembly Well Cap with Hose Barbs...

Page 42: ...sor Use Teflon tape or sealant on the threads b Attach the air hose plug end of the system air supply hose to the socket now attached to the compressor c Attach the socket on the discharge end of the...

Page 43: ...e air valve moves open the pump and inspect for interference Pump Support System and Hose Bundling Assembly A pump support system can be created to support the pump and hoses The pump support system u...

Page 44: ...Page 35 AP 3 Manual Revision 3 April 2009 Chapter 4 Assembly Installation Figure 17 Examples of Well Caps...

Page 45: ...8 Note To make the next step easier pull the support rope and the hoses taut STEP 4 Starting at the AutoPump end of the hose put a tie wrap through the center of the braided support rope just above th...

Page 46: ...Page 37 AP 3 Manual Revision 3 April 2009 Chapter 4 Assembly Installation Figure 18 Hose Bundling Part 1 of 2...

Page 47: ...QED Environmental Systems AP 3 Manual Page 38 Figure 19 Hose Bundling Part 2 of 2 600487 03...

Page 48: ...to install the pump with a low air pressure supplied to the pump To obtain the value of that low pressure in psi multiply the number of feet that the pump is to be submerged by one half 0 5 WARNING B...

Page 49: ...a brief residual pressure in the pump which discharges fluid and air even after the exhaust valve is opened Under normal operating conditions no air should exit the pump with the fluid If the pump is...

Page 50: ...ressed air to the pump is available in case of an unexpected occurrence 7 When pumping is to begin either gradually raise the air pressure to the pump or gradually open the air valve to the pump to al...

Page 51: ...the exhaust hose of the pump Note The air supply hose must be shut off or pressurized when this is done The compressed air will enter the pump through the exhaust valve and push any fluids in the pum...

Page 52: ...rform reliably for years Check the air filters and filter bowl drains on the filters regulator for saturation and operation every few weeks Periodically drain the air filters on the air hose to the pu...

Page 53: ...the AutoPump System should operate trouble free for years The air filter is normally a 5 micron filter with a replaceable element To replace the element in the air filter on the single stage filter re...

Page 54: ...it Make sure to replace the correct filter element Blue or black filter bowl QED Filter element Part No 205071 Silver filter bowl QED Filter element Part No 205800 STEP 3 Bowl Drain Standard Float Dr...

Page 55: ...nal pump removal technique STEP 2 Pull the pump and hoses to the surface STEP 3 Shut off the air to the pump and disconnect the air hose from the pump STEP 4 Ensure that there is a safe place to drain...

Page 56: ...e to ensure that the lever will trip Unscrew the bottom check valve or plug from the discharge tube See Figure 20 STEP 1 Fit a spanner wrench in one of the holes in the circumference of the lower head...

Page 57: ...QED Environmental Systems AP 3 Manual Page 48 Figure 20 Removing AP 3 Pump Casing...

Page 58: ...ame threads from which the lower head was unscrewed STEP 8 Hold the pump vertically upright with the pump casing removal tool extending down out of the pump casing STEP 9 Hold the pump by the casing a...

Page 59: ...QED Environmental Systems AP 3 Manual Page 50 Figure 21 Internal View of a Bottom Loading and Top Loading AP 3...

Page 60: ...Page 51 AP 3 Manual Revision 3 April 2009 Chapter 6 Maintenance Figure 22 Exploded View of a Top Loading Long AP 3...

Page 61: ...QED Environmental Systems AP 3 Manual Page 52 Figure 23 Exploded View of a Bottom Loading Long Short...

Page 62: ...Page 53 AP 3 Manual Revision 3 April 2009 Chapter 6 Maintenance Figure 24 Exploded View of AP 3 Lever Assembly...

Page 63: ...QED Environmental Systems AP 3 Manual Page 54 Figure 25 Exploded View of a Top Loading Short AP 3...

Page 64: ...Page 55 AP 3 Manual Revision 3 April 2009 Chapter 6 Maintenance Figure 26 Exploded View of Bottom Intake Check Valve Assembl with Standard Flat Screen and Leachate Screen...

Page 65: ...om the SS fluid discharge pipe as follows Remove the control rod guide See Figure 22 and Figure 23 Remove the small SS pin from the bottom spring cup Stop The Stop is the small white part located just...

Page 66: ...sing 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 Installing Pump Casing STEP 1 Inspect...

Page 67: ...rn the bottom check valve or the plug in the reverse direction counter clockwise so it is looser by 1 4 turn Checking Volumes Pumped Per Cycle See page 25 for information on the AutoPump volumes pumpe...

Page 68: ...ompleted and before assembling the pump slowly move the float through its range to ensure that the lever will trip even if the pump fills and empties slowly Note See Chapter 6 Maintenance for disassem...

Page 69: ...well the well must be vented to the atmosphere or a functioning vapor recovery line If the air exhausts to the atmosphere outside the well and a vacuum is drawn on the well the pump may fail to fill I...

Page 70: ...loat prevent float contact Call QED for repair options Note If viscous materials cause continual problems contact QED for possible solutions 7 Debris in Air Inlet Valve Open the pump Connect the air s...

Page 71: ...f it is obviously out of round replace it with a new ball If the pump is a Bottom Loading design inspect the seat of the bottom check valve for debris and wear Clean or replace if necessary If the pum...

Page 72: ...d for the cleaning and disposal of material if necessary Cost can be 200 00 per piece of equipment cleaned Drain and dry all equipment after cleaning STEP 3 Package the equipment so that it will not b...

Page 73: ...and Fittings STEP 1 Pump clean water or water with a gentle soap solution e g Dove Dish Soap through the pump to remove free product and particles STEP 2 Rinse all soap off of the equipment STEP 3 So...

Page 74: ...ir dryer on the compressed air line The following charts show the performance flow rate curves for the Long and Short pumps Long Bottom and Top Loading AP 3 AutoPumps See Figures 27 through 32 Short B...

Page 75: ...Note These flow rates are only applicable for the designated well head conditions Any additional resistance from out of well equipment e g surface hoses valves etc will affect the values shown on thes...

Page 76: ...Page 67 AP 3 Manual Revision 3 April 2009 Appendix A Performance Curves Figure 27 Long AP 3 BL Performance Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS...

Page 77: ...QED Environmental Systems AP 3 Manual Page 68 Figure 28 Long AP 3 BL Performance Curves 3 4 inch 19 mm I D Discharge US and METRIC UNITS...

Page 78: ...Page 69 AP 3 Manual Revision 3 April 2009 Appendix A Performance Curves Figure 29 Long AP 3 BL Performance Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS...

Page 79: ...QED Environmental Systems AP 3 Manual Page 70 Figure 30 Long AP 3 TL Performance Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS...

Page 80: ...Page 71 AP 3 Manual Revision 3 April 2009 Appendix A Performance Curves Figure 31 Long AP 3 TL Performance Curves 3 4 inch 19 mm I D Discharge US and METRIC UNITS...

Page 81: ...QED Environmental Systems AP 3 Manual Page 72 Figure 32 Long AP 3 TL Performance Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS...

Page 82: ...Page 73 AP 3 Manual Revision 3 April 2009 Appendix A Performance Curves Figure 33 Short AP 3 BL Performance Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS...

Page 83: ...QED Environmental Systems AP 3 Manual Page 74 Figure 34 Short AP 3 BL Performance Curves 3 4 inch 19 mm I D Discharge US and METRIC UNITS...

Page 84: ...Page 75 AP 3 Manual Revision 3 April 2009 Appendix A Performance Curves Figure 35 Short AP 3 BL Performance Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS...

Page 85: ...QED Environmental Systems AP 3 Manual Page 76 Figure 36 Short AP 3 TL Performance Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS...

Page 86: ...Page 77 AP 3 Manual Revision 3 April 2009 Appendix A Performance Curves Figure 37 Short AP 3 TL Performance Curves 3 4 inch 19 mm I D Discharge US and METRIC UNITS...

Page 87: ...QED Environmental Systems AP 3 Manual Page 78 Figure 38 Short AP 3 TL Performance Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS...

Page 88: ...nch or 1 inch I D A larger diameter may yield significantly lower air use rates depending upon site conditions 3 Air pressure With the above information obtain the probable flow rate by using the foll...

Page 89: ...the air use factor This air use can be diminished if the regulator pressure is reduced The maximum pump rate for the lower air pressure can be predicted using the performance curves Note These air use...

Page 90: ...Page 81 AP 3 Manual Revision 3 April 2009 Appendix B Air Consumption Curves Figure 39 Long AP 3 BL Air Consumption Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS...

Page 91: ...QED Environmental Systems AP 3 Manual Page 82 Figure 40 Long AP 3 BL Air Consumption Curves 3 4 inch 19 mm I D Discharge US and METRIC UNITS...

Page 92: ...Page 83 AP 3 Manual Revision 3 April 2009 Appendix B Air Consumption Curves Figure 41 Long AP 3 BL Air Consumption Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS...

Page 93: ...QED Environmental Systems AP 3 Manual Page 84 Figure 42 Long AP 3 TL Air Consumption Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS...

Page 94: ...Page 85 AP 3 Manual Revision 3 April 2009 Appendix B Air Consumption Curves Figure 43 Long AP 3 TL Air Consumption Curves 3 4 inch 19 mm I D Discharge US and METRIC UNITS...

Page 95: ...QED Environmental Systems AP 3 Manual Page 86 Figure 44 Long AP 3 TL Air Consumption Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS...

Page 96: ...Page 87 AP 3 Manual Revision 3 April 2009 Appendix B Air Consumption Curves Figure 45 Short AP 3 BL Air Consumption Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS...

Page 97: ...QED Environmental Systems AP 3 Manual Page 88 Figure 46 Short AP 3 BL Air Consumption Curves 3 4 inch 19 mm I D Discharge US and METRIC UNITS...

Page 98: ...Page 89 AP 3 Manual Revision 3 April 2009 Appendix B Air Consumption Curves Figure 47 Short AP 3 BL Air Consumption Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS...

Page 99: ...QED Environmental Systems AP 3 Manual Page 90 Figure 48 Short AP 3 TL Air Consumption Curves 1 inch 25 4 mm I D Discharge US and METRIC UNITS...

Page 100: ...Page 91 AP 3 Manual Revision 3 April 2009 Appendix B Air Consumption Curves Figure 49 Short AP 3 TL Air Consumption Curves 3 4 inch 19 mm I D Discharge US and METRIC UNITS...

Page 101: ...QED Environmental Systems AP 3 Manual Page 92 Figure 50 Short AP 3 TL Air Consumption Curves 5 8 inch 16 mm I D Discharge US and METRIC UNITS...

Page 102: ...versions Page 93 Revision 3 April 2009 AP 3 Manual Appendix C Conversions The AP3 AutoPump can be converted from top to bottom loading and from bottom to top loading Please see the following pages for...

Page 103: ...similar blunt tool inserted into the open end of the casing 6 Remove the o ring from the plug and install it on the bottom of the check valve H 7 Lubricate the first 3 4 in of the inside of the casing...

Page 104: ...Appendix C Conversions Page 95 Revision 3 April 2009 AP 3 Manual Figure 51 Conversion from Top Loading to Bottom Loading...

Page 105: ...ck valve F with a spanner wrench If the casing comes off with the valve the valve may be knocked out with a wooden 2x2 or similar blunt tool inserted into the open end of the casing 6 Remove the o rin...

Page 106: ...Appendix C Conversions Page 97 Revision 3 April 2009 AP 3 Manual Figure 52 Conversion from Long Bottom Loading to Long Top Loading...

Page 107: ...d are even with the indentations on each side of the WYE 5 Remove the casing and the intake check valve See page 47 6 Install the middle stop spring cups and spring To remove the float drive out the b...

Page 108: ...Appendix C Conversions Page 99 Revision 3 April 2009 AP 3 Manual Figure 53 Conversion from Short Bottom Loading to Short Top Loading...

Page 109: ...Manual Page 100 Appendix D Vacuum on Well The AP 3 will work in a well that is under vacuum but there are several conditions that must be considered These conditions are described in Figure 54 55 56...

Page 110: ...Page 101 AP 3 Manual Revision 3 April 2009 Appendix D Vacuum on Well Figure 54 AP 3 BL with Vacuum In the Well and Pump Exhaust Outside the Well...

Page 111: ...QED Environmental Systems AP 3 Manual Page 102 Figure 55 AP 3 BL with Vacuum In the Well and Pump Exhaust In the Well...

Page 112: ...Page 103 AP 3 Manual Revision 3 April 2009 Appendix D Vacuum on Well Figure 56 AP 3 TL with Vacuum In the Well and Pump Exhaust Outside the Well...

Page 113: ...QED Environmental Systems AP 3 Manual Page 104 Figure 57 AP 3 TL with Vacuum In the Well and Pump Exhaust In the Well...

Page 114: ...nd the date QED is notified of a warranty claim This warranty shall be limited to the duration and conditions set forth below 1 AP 3 AutoPumps warranted for two 2 years 100 material and 100 workmanshi...

Page 115: ...the event of unauthorized disassembly of component assemblies Defects in any equipment that result from abuse operation in any manner outside the recommended procedures use and applications other tha...

Page 116: ...erning products or accessories not manufactured by QED In the event of failure of any such product or accessory QED will give reasonable assistance to Buyer in obtaining from the respective manufactur...

Page 117: ...o no others whatsoever No waiver alteration or modification of these terms and conditions shall be binding unless in writing and signed by an executive officer of the Seller All orders subject to writ...

Page 118: ...or its appointed agent will authorize the return of the component at Purchasers expense If the product proves not to be defective within the terms of this warranty then all costs and expenses in conne...

Page 119: ...QED Environmental Systems AP 3 Manual Page 110 Log Notes...

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