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Page 49

AP-3 Manual

Revision 3 - April, 2009

Chapter 6: Maintenance

STEP 4 -

If you suspect the pump of being clogged with mud or other particles,

prevent the outer casing from turning while the lower plug or check valve

is unscrewed.

STEP 5 -

Have a second person hold a strap wrench around the pump casing. If

there is only one person, hold the upper head in a vise while unscrewing

the lower head. This allows a free hand to hold the strap wrench which

prevents the pump casing from rotating.

STEP 6 -

When the plug or check valve is removed, use a pump casing removal tool

to remove the pump casing. The pump casing removal tool is a specially

threaded pipe with internal threads at one end and a cap at the other.

STEP 7 -

Thread the tool onto the bottom of the discharge pipe (onto the same

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 and strike the pump casing removal tool on

the ground. This will cause the pump casing to slide off the upper O-ring

and will allow it to slide off the pump.

Cleaning Pump Interior

The inner workings of the pump should now be exposed for inspection and cleaning.

(See Figures 22 through 26)

Note:

A Scotch Brite® abrasive pad is useful for cleaning debris from the pump

components.

STEP 1 -

Gently brush off built-up solids from the float, the discharge tube, the

pump casing and the control rod guide.

STEP 2 -

The pump can be steam cleaned without damage.

STEP 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.

Содержание AutoPump AP-3

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

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

Страница 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...

Страница 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...

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

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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