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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

Содержание AutoPump AP-2

Страница 1: ...7 1767 North America Only 510 891 0880 Tele 510 444 6789 Fax 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 info qedenv...

Страница 2: ...72 Genie System 5 704 772 Canada Patent 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...

Страница 3: ...fety Procedures 3 Fire and Explosion Protection 4 Personal Protection 4 Spill Protection 4 Chapter 2 Overview _________________________________________5 General Specifications 5 This is How it Works 6...

Страница 4: ...dfill Pump Configurations 16 Landfill Pump Specifications 16 Component Materials 16 Single Stage Filter Regulator 18 Hoses and Fittings 19 Hose and Tubing Color Code Table 19 Pump Cycle Counter 20 Vol...

Страница 5: ..._______________________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 R...

Страница 6: ...0 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 _____________________...

Страница 7: ...ll 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 Vie...

Страница 8: ...charge 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 t...

Страница 9: ...taller 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 corn...

Страница 10: ...denv com Oakland Service Center 1133 Seventh Street Oakland California 94607 800 537 1767 North America Only 510 891 0880 Tele 510 444 6789 Fax Ann Arbor Service Center PO Box 3726 6095 Jackson Road A...

Страница 11: ...three 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...

Страница 12: ...the primary design feature in all systems Following are some samples All standard high pressure air hoses have automatic shut off quick connects on the supply side which prevents injury due to hose w...

Страница 13: ...rsatile and available in a range of lengths and fluid inlet arrangements to meet particular site specifications Equipment will vary by application and site specifications See Chapter 3 General Specifi...

Страница 14: ...e fluid closes the inlet check valve and forces the fluid up the discharge tube and out of the pump through the outlet check valve As the fluid level falls in the pump the float moves downwards until...

Страница 15: ...Page 7 AP 2 Manual Revision 7 August 2007 Figure 1 How it Works Chapter 2 Overview 601345...

Страница 16: ...a one year warranty 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...

Страница 17: ...Page 9 AP 2 Manual Revision 7 August 2007 Figure 2 Overview of the AutoPump System Chapter 2 Overview...

Страница 18: ...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...

Страница 19: ...Gauge and a Vacuum Pressure reference with Gauge Pump Cycle Counter PCC A PCC counts the number of times a pump cycles The counter provides information for maintenance service and statistical purposes...

Страница 20: ...nt 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 2 with support eyebolt 2 Single stage filter...

Страница 21: ...pump through a check valve located at the top of the pump This check valve prevents the fluid from reentering the pump Bottom Loading AP 2 BL The Bottom Loading AutoPump fills through a check valve a...

Страница 22: ...QED Environmental Systems AP 2 Manual Page 14 Figure 3 Long and Short Bottom Loading AP 2 BL...

Страница 23: ...Page 15 AP 2 Manual Revision 7 August 2007 Chapter 3 Equipment Figure 4 Long and Short Top Loading AP 2 TL...

Страница 24: ...nches 139 cm 0 14 gal 0 17 gal 53 L 64 L 7 8 lb 3 6 kg 1 75 in 4 45 cm Short AP 2 BL 33 inches 85 cm 0 05 gal 0 08 gal 19 L 30 L 5 4 lb 2 5 kg 1 75 in 4 45 cm Long AP 2 TL 57 inches 144 cm 0 14 gal 0...

Страница 25: ...Page 17 AP 2 Manual Revision 7 August 2007 Chapter 3 Equipment Figure 5 Long and Short AP 2 Bottom Loading with Leachate Screen...

Страница 26: ...the system air supply hose The filter regulator removes particles and some oil vapor and water droplets from the air passing to the AP 2 The regulator should produce at least as much pressure as requi...

Страница 27: ...ile Nitrile Nitrile Nitrile D I e z i S e s o H o t h c n i 4 1 h c n i 8 3 o t h c n i 2 1 h c n i 4 3 o t h c n i 4 1 h c n i 8 3 o t h c n i 8 3 h c n i 2 1 r o l o C g n i b u T k c a l B k c a l...

Страница 28: ...sure in the surface lines hose size fittings vertical and horizontal pumping distance the number of pumps feeding the hose system air pressure to the pump and the type of pump The effects of some of t...

Страница 29: ...Figure 12 on page 33 and Figure 13 on page 34 Well caps with various fitting combinations are available See Figure 11 on page 31 Caution Although it may be possible to support the pump using only tubi...

Страница 30: ...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...

Страница 31: ...r WARNING The compressor should not provide more pressure than the filter can accept The metal bowl can accept 200 psi Maximum output air pressure setting on the standard regulator is 120 psi A higher...

Страница 32: ...QED Environmental Systems AP 2 Manual Page 24 Figure 7 Locking Quick Connects...

Страница 33: ...Page 25 AP 2 Manual Revision 7 August 2007 Chapter 4 Assembly Installation Figure 8 One Ear Clamp and Hose Barb Assembly Instructions...

Страница 34: ...QED Environmental Systems AP 2 Manual Page 26 Figure 9 AP 2 Assembly Well Cap with Holes...

Страница 35: ...Page 27 AP 2 Manual Revision 7 August 2007 Chapter 4 Assembly Installation Figure 10 AP 2 Assembly Well Cap with Hose Barbs...

Страница 36: ...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 hose to the sin...

Страница 37: ...oat slide or the 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 s...

Страница 38: ...QED Environmental Systems AP 2 Manual Page 30 Figure 11 Examples of Well Caps...

Страница 39: ...r See Figure 12 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...

Страница 40: ...QED Environmental Systems AP 2 Manual Page 32 Figure 12 Hose Bundling Part 1 of 2...

Страница 41: ...Page 33 AP 2 Manual Revision 7 August 2007 Chapter 4 Assembly Installation Figure 13 Hose Bundling Part 2 of 2 600487 03...

Страница 42: ...wish 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 WARNI...

Страница 43: ...uld be due to 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 I...

Страница 44: ...ns 6 A method of rapid disconnect and exhaust or at least a shut off of compressed air to the pump is available in case of an unexpected occurrence 7 When pumping is to begin either gradually raise th...

Страница 45: ...Page 37 AP 2 Manual Revision 7 August 2007 Adjusting the Pump Cycle Counter Refer to Appendix F Pump Cycle Counter Chapter 5 Start Up and Operation...

Страница 46: ...counter readjustment Downwell Testing of the AutoPump While the AutoPump is in the well it can be tested by putting compressed air into the exhaust hose of the pump Note The air supply hose must be s...

Страница 47: ...on AutoPump Removal Technique optional By pressurizing the exhaust hose as noted above and airlifting the fluids out of the well the fluid in an AutoPump and discharge hose can be reduced significantl...

Страница 48: ...2 System should perform 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...

Страница 49: ...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 regulator use t...

Страница 50: ...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 Optional Float Drain Wash...

Страница 51: ...uid from the pump and discharge hose STEP 5 Disconnect the fluid discharge hose from the pump STEP 6 Drain the fluid by turning the pump upside down and allowing fluid to flow from the air inlet fitti...

Страница 52: ...rom the pump casing Note The O rings at the top and bottom of the pump may have swollen due to solvents in the fluid being pumped and therefore make turning the lower head difficult Prevent the outer...

Страница 53: ...Page 45 AP 2 Manual Revision 7 August 2007 Chapter 6 Maintenance Figure 14 Removing AP 2 Pump Casing...

Страница 54: ...QED Environmental Systems AP 2 Manual Page 46 Figure 15 Exploded view of a Long Top Loading AutoPump AP 2...

Страница 55: ...Page 47 AP 2 Manual Revision 7 August 2007 Figure 16 Exploded View of a Short Top Loading AutoPump AP 2 Chapter 6 Maintenance...

Страница 56: ...QED Environmental Systems AP 2 Manual Page 48 Figure 17 Exploded View of a Long Bottom Loading AutoPump AP 2...

Страница 57: ...Page 49 AP 2 Manual Revision 7 August 2007 Chapter 6 Maintenance Figure 18 Exploded View of a Short Bottom Loading Autopump AP 2...

Страница 58: ...QED Environmental Systems AP 2 Manual Page 50 Figure 19 Exploded View of AP 2 Lever Assembly...

Страница 59: ...discharge pipe or float then remove the float from the SS fluid discharge pipe as follows Remove the control rod guide See Figures 15 through 18 Remove the small SS nut from the bottom spring cup See...

Страница 60: ...nspect the O rings to ensure they are capable of sealing no discernible cuts or abrasions STEP 2 Lubricate both inside ends of the casing to a depth of 1 2 with a thin layer of food grade grease Ensur...

Страница 61: ...Per Cycle See page 21 for information on the AutoPump volumes pumped per cycle Ensure that volumes correspond with the previous experience on site and with the ranges indicated on page 21 If it doesn...

Страница 62: ...completed 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 disass...

Страница 63: ...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 In order for t...

Страница 64: ...loat foam contact with the pipe 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...

Страница 65: ...check valve 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 pump is a Top Loading design remove the fluid inl...

Страница 66: ...omer will be charged 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...

Страница 67: ...shipment Hoses 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 equi...

Страница 68: ...ryer 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 2 AutoPumps See Figures 20 and 21 Short Bottom an...

Страница 69: ...duces 1 0 GPM 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...

Страница 70: ...QED Environmental Systems AP 2 Manual Page 62 Figure 20 Long AP 2 BL Performance Curves 1 2 inch 13 mm I D Discharge US and METRIC UNITS...

Страница 71: ...Page 63 AP 2 Manual Revision 7 August 2007 Appendix A Performance Curves Figure 21 Long AP 2 TL Performance Curves 1 2 inch 13 mm I D Discharge US and METRIC UNITS...

Страница 72: ...QED Environmental Systems AP 2 Manual Page 64 Figure 22 Short AP 2 BL Performance Curves 1 2 inch 13 mm I D Discharge US and METRIC UNITS...

Страница 73: ...Page 65 AP 2 Manual Revision 7 August 2007 Appendix A Performance Curves Figure 23 Short AP 2 TL Performance Curves 1 2 inch 13 mm I D Discharge US and METRIC UNITS...

Страница 74: ...ameter 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 following steps On the horizontal...

Страница 75: ...very rate times 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 No...

Страница 76: ...QED Environmental Systems AP 2 Manual Page 68 Figure 24 Long AP 2 BL Air Consumption Curves 1 2 inch 13 mm I D Discharge US and METRIC UNITS...

Страница 77: ...Page 69 AP 2 Manual Revision 7 August 2007 Appendix B Air Consumption Curves Figure 25 Long AP 2 TL Air Consumption Curves 1 2 inch 13 mm I D Discharge US and METRIC UNITS...

Страница 78: ...QED Environmental Systems AP 2 Manual Page 70 Figure 26 Short AP 2 BL Air Consumption Curves 1 2 inch 13 mm I D Discharge US and METRIC UNITS...

Страница 79: ...Page 71 AP 2 Manual Revision 7 August 2007 Appendix B Air Consumption Curves Figure 27 Short AP 2 TL Air Consumption Curves 1 2 inch 13 mm I D Discharge US and METRIC UNITS...

Страница 80: ...sions The AP 2 can be converted the from Top to Bottom Loading or Bottom to Top Loading by rearranging the check valves For Bottom Loading to a Top Loading conversion see Figure 28 on the next page Fo...

Страница 81: ...Page 73 AP 2 Manual Appendix C AP 2 Conversions Revision 7 August 2007 Figure 28 Conversion From Bottom Loading to Top Loading AutoPump...

Страница 82: ...QED Environmental Systems AP 2 Manual Page 74 Figure 29 Conversion From Top Loading to Bottom Loading AutoPump...

Страница 83: ...ion 7 August 2007 Appendix D Vacuum on Well The AP 2 will work in a well that is under vacuum but there are several conditions that must be considered These conditions are described in Figure 30 Figur...

Страница 84: ...QED Environmental Systems AP 2 Manual Page 76 Figure 30 AP 2 BL with Vacuum In the Well and Pump Exhaust Outside the Well...

Страница 85: ...Page 77 AP 2 Manual Appendix D Vacuum on Well Revision 7 August 2007 Figure 31 AP 2 BL with Vacuum In the Well and Pump Exhaust In the Well...

Страница 86: ...QED Environmental Systems AP 2 Manual Page 78 Figure 32 AP 2 TL with Vacuum In the Well and Pump Exhaust Outside the Well...

Страница 87: ...Page 79 AP 2 Manual Appendix D Vacuum on Well Revision 7 August 2007 Figure 33 AP 2 TL with Vacuum In the Well and Pump Exhaust In the Well...

Страница 88: ...Environmental Systems QED does not usually supply the air compressor It is best to buy the compressor from a local supplier who provides service Follow the instructions that accompany the compressor...

Страница 89: ...and 10 HP compressors should have at least a 120 gallon tank Storage tanks and automatic pressure shut off switches provide a buffer so the compressor motor can cool between each time the tank is pres...

Страница 90: ...local power company regarding proper fuse size Air Quality and Pressure In compressors requiring lubricating oil do not use synthetic oil Synthetic oil can adversely affect some materials Non detergen...

Страница 91: ...rance of 18 inches to allow for circulation of air and additional clearance if required for servicing Lubrication Fill the crankcase to the level mark on the oil gauge Use the type of industrial compr...

Страница 92: ...ir from the compressor maintenance will be significantly reduced I Problem Slow Pumping or Insufficient Pressure Solutions A Clogged filter element clean or replace B Leaks in air lines retighten or r...

Страница 93: ...d foreign objects Force air through enclosure if necessary C Restricted air intakes clean or replace D Loose or restricted valves retighten clean or replace E Incorrect installation allow 18 inches mi...

Страница 94: ...ttle and a digital display The position of the digital display is adjustable allowing the counter to be used on many different kinds of pumps and at various distances from the well See Figure 34 The P...

Страница 95: ...tal display senses the completion of this to and from movement and records the cycle increasing the number one digit that is shown in the clear plastic display This process repeats itself for each pum...

Страница 96: ...the correct direction of air flow It is made of anodized aluminum It has a 1 4 inch FNPT inlet and a 3 8 inch or 1 4 inch FNPT outlet It handles air pressures from 40 200 psi Hardware Options Inlet a...

Страница 97: ...Loosen but do not remove the thumb screw item 3 that locks the Display Assembly See Figure 36 STEP 2 Slide the Display Assembly on the magnet housing item 6 back and forth or up and down as the case m...

Страница 98: ...the thumb screw item 3 since movement of the Display Assembly is unnecessary for cleaning STEP 1 Remove the inlet fitting item 11 not the thumb screw item 3 as noted above STEP 2 Remove the magnet shu...

Страница 99: ...Page 91 AP 2 Manual Appendix F Pump Cycle Counter Revision 7 August 2007 Figure 36 Pump Cycle Counter Exploded View...

Страница 100: ...isplay item 4 on the flat of the display seat item 5 See Figure 36 STEP 2 Slide the cycle counter sleeve item 2 over the display seat item 5 and the bottom lip portion of the digital display item 4 Bo...

Страница 101: ...mped per cycle will be to the lower end of the gallon range in the table below The TDH depends upon back pressure in the surface lines hose size fittings vertical and horizontal pumping distance the n...

Страница 102: ...QED Environmental Systems AP 2 Manual Page 94 Figure 37 Pump Cycle Counter with Magnetic Reed Switch...

Страница 103: ...Page 95 AP 2 Manual Appendix F Pump Cycle Counter Revision 7 August 2007 Figure 38 Pump Cycle Counter Remote Readout Panel...

Страница 104: ...cilities and the date QED is notified of a warranty claim This warranty shall be limited to the duration and conditions set forth below 1 AP 2 AutoPumps warranted for one 1 year 100 material and 100 w...

Страница 105: ...uthorized disassembly of component assemblies Defects in any equipment that result from abuse operation in any manner outside the recommended procedures use and applications other than for intended us...

Страница 106: ...ts 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 manufacturer whatever a...

Страница 107: ...s contained or referred to in the Seller s quotation acknowledgments and to those listed here and to no others whatsoever No waiver alteration or modification of these terms and conditions shall be bi...

Страница 108: ...mination of warranty coverage If the return of a component is determined to be necessary QED or its appointed agent will authorize the return of the component at Purchasers expense If the product prov...

Страница 109: ...Page 101 AP 2 Manual Revision 7 August 2007 Log Notes...

Страница 110: ...Clean Environment Equipment AP 2 Manual Page 102...

Страница 111: ...Page 103 AP 2 Manual Revision 7 August 2007 Log Notes...

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