Instruction Manual. Part No Rev 2. A Graco Company

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1 Instruction Manual Part No Rev 2 A Graco Company QED Environmental Systems 2355 Bishop Circle West Dexter, MI US Toll Free: Tel: +1 (734) Fax: +1 (734) info@qedenv.com Website: QED Environmental Systems (West) 1670 Alvarado Street, Suite 5 San Leandro, CA US Toll Free: Tel: +1 (510) Fax: +1 (510)

2 Table of Contents Topic Page Introduction. 2 Safety 3 Specifications... 4 Operating Instructions... 6 Disassembly and Reassembly...10 LED Tables. 14 Troubleshooting 15 Pump Parts Drawing...17 Accessories and Spare Parts. 18 Warranty

3 INTRODUCTION The Power Pro ESP portable electric sampling pump was developed exclusively for low-flow ground water sampling. The heart of the pump is a variable speed, brushless motor combined with a high-efficiency impeller. This unique combination consumes 50-75% less power (based on manufacturers published specs), which translates to user benefits of less heat, lighter and more flexible power supply options, and greater reliability than traditional electric sampling pumps. The unique, all-in-one design features the ESP Communications ProtocolSM, which provides simple pump operation with sophisticated control. The In-Water Sensor indicator lights up when the pump is fully submerged, making it easy to position the pump in the well. The RunDry Protection limits drawdown and prevents damage to the motor and seal. The pump and reel weighs just 32 pounds, less than any traditional pump/reel/controller combination currently in the market. 2

4 SAFETY Before connecting the pump to an external battery, always be sure that the flow rate control knob is set at minimum (counterclockwise) and that the water discharge hose is directed into an appropriate container. Failure to do so could result in a splash hazard to personnel or an electric shock hazard if the water discharge is directed at potential sources of electricity. Always wear appropriate eye protection, and personal protective clothing. When checking the rotation of the motor during reassembly, always be sure to keep the motor shaft and impeller away from hair or clothing that could cause an entanglement hazard. The Power Pro ESP pump is driven by an electric motor. It is not intended for use where methane or other flammable materials are present. Consult local authorities and regulations if you have any doubt about its suitability for a specific application. 3

5 Specifications: Model Number: Flow (max): Flow at max depth: Diameter: Length: Weight: Pump Weight: System Power Consumption: Supply Voltage: Current Draw: Cable Insulation: Discharge Port: Discharge Tubing: EP gpm (4.2 Lpm) 0.5 gpm (1.9 Lpm) 1.8 in. (4.6 cm) 16.6 in. (42.16 cm) 5.3 lbs. (2.40 kg) 31.8 lbs. (14.42 kg) watts (typical) 12VDC 3-6 amps (typical) Polyurethane 1/4 FPT 1/2 OD (1.3 cm) x 3/8 ID (1.0 cm) 3/8 OD (1.0 cm) x 1/4 ID (0.6 cm) 1/4" OD (0.65 cm) x 0.16 ID (0.4 cm) 4

6 Battery Reference Table Capacity 65AH 40AH 33AH 26AH 18AH Minutes* Gallons/Liters 690 / 2, / 1, / 1, / / 570 (75 ft. [22.9 m] depth with 150 ft. [45.7 m] of power cable and tubing.) *Typical performance in intermittent use conditions. 5

7 OPERATING INSTRUCTIONS 1. With the cable reel set in position (hanging from well casing or placed on a solid surface), pull the retaining pin from the pump holster and remove the pump. 2. Connect discharge tubing or hose to the discharge barb fitting and clamp in place. 3. If a safety cable will be used, attach the cable to the lift eyebolt on top of the pump. 4. Place the pump into the well with the cable reel rotation lock on to prevent the pump from falling. 5. Place the Water Sensor switch in the ON position you should see a flashing green light. (If the green LED is not lit, see Troubleshooting instructions.) 6. Place the Run Dry Protection switch in the ON position. 7. Lower the pump into the well until the flashing green Water Sensor LED is glowing steady. This indicates that the pump is submerged. Now, lower the pump to the desired sampling depth by counting the 1-foot marks on the power cable. 6

8 8. Set the reel rotation lock, then check to see that the Speed Control knob is set to the fully counter-clockwise OFF position. Place the Water Sensor switch in the OFF position before connecting the power cord to the reel. 9. Connect the 12-volt power supply cord to the reel. Connect the two terminal clamps to a 12-volt power source (e.g., vehicle battery, portable battery, etc.), making sure that the red clamp is clamped to the positive battery terminal, and the black clamp is clamped to the negative battery terminal (connecting these clamps in reverse will blow the fuse, which is located on the control panel inside the reel hub). Return the Water Sensor switch to the ON position and check that the green LED indicator is glowing steadily. 10. If desired, place the end of the discharge tubing or hose into a clean container of water to observe when pumping begins (bubbles will escape from tubing). 11. Slowly turn the Speed Control knob clockwise until pumping begins, and then adjust as needed to reach the desired purging flow rate. The pump flow rate can be decreased as desired to fill sample containers or to use an in-line QuickFilter capsule for collecting filtered samples. 12. Once sampling is completed, turn the Speed Control knob, Water Sensor and Run-Dry Protection switches to the OFF position and disconnect the 12-volt power supply at the reel. The pump can now be removed from the well. 13. If more wells will be sampled, follow your desired decontamination procedure and place the pump back into the storage holster for transport to the next well. If sampling is completed, follow the steps under Preparing Pump for Storage before storing the pump overnight or longer. Preparing pump for storage 1. Remove the inlet screen housing as shown by inserting a screwdriver or rod through the lower inlet holes and turning the housing counter-clockwise. (NOTE: Do not attempt to place anything into the upper inlet holes, as this could damage the inlet screen.) 2. Inspect the inlet screen for debris or solids buildup. If necessary, remove the snap ring retainer and clean the inlet screen. 7

9 3. At the top of the pump, turn the top retaining collar counter-clockwise to release the pump body, and then slide the body downward off of the pump inner tube. 4. Using a clean cloth or paper towel, dry the outside of the inner tube. 5. Using a ¼-20 bolt or the provided eye bolt, remove the inlet plate and O-ring seal. Remove the impeller. Holding the pump upright, allow any water within the pump to drain out and then dry the inlet area. 6. Reassemble the pump by sliding the pump body back up over the inner tube and locking the retaining collar at the top to the body. Reinstall the impeller (or, if worn, replace the impeller as needed), noting the orientation of the impeller (small donut facing outward). Reinstall the inlet plate and the O-ring seal, and then attach the inlet screen housing. 7. The level sensor tip at the top of the pump can accumulate anodic iron deposits after a few hours of use. It is recommended that this tip be lightly brushed daily, using a soft bristle toothbrush, to prevent excessive accumulation. 8. Place the pump back into the holster on the cable reel for transport and storage. General Information 1. When the Run Dry Protection is used during pump operation and water level drops below the top of the pump, pump operation will be paused and the green LED will blink. If the water level recovers or the pump lowered in the water column, the pump will turn back on and the green LED indicator will change from blinking to lit. 2. To override run dry protection, such as for decontamination or testing of the pump in a bucket, turn inner switch (run dry protection switch) OFF. In this mode, the pump will run continuously regardless of whether there is water present. Avoid extended dry operation to prevent damage to the motor shaft seal. 8

10 3. If water pumping doesn't start immediately (typically under low submergence conditions), a slight shake of the pump up and down will help clear any air bubbles from the impeller region. Cleaning/Decontamination Note 1. The pump inlet assembly has a space below the intake holes and internal intake screen where sediment can accumulate after the pump is shut off. As part of the cleaning procedure, it is important to remove the pump inlet assembly (see Disassembly, page 10) and flush out the sediment trap and screen, to avoid cross-contamination between wells. 9

11 DISASSEMBLY Tools needed: Phillips screwdriver #2 or #3 size Snap ring pliers Adjustable wrench, 12 or larger (must open to 1.5 ) 1. Before servicing, always disconnect the pump from the power source. 2. Put a Phillips head screwdriver through the lower holes in the pump inlet housing and twist the housing counter-clockwise (when looking at the bottom) to release the lower bayonet, and remove the pump inlet from the pump body. 3. The pump inlet screen can now be cleaned by back-flushing with water. If desired, the inlet screen can be removed by removing the snap ring that holds the inlet screen in place. 10

12 4. Remove the eyebolt from the top of the pump (or use any ¼-20 bolt) and thread it into the inlet plate. Using the eyebolt, remove the inlet plate and inlet O-ring. 5. To remove the impeller, turn the pump upright and gently tap the bottom until the impeller falls out. Clean the impeller if necessary. Replace the impeller if the impeller blades are noticeably eroded, if there is abrasion on the face of the impeller, or if the D shaped hole in the center of the impeller has worn such that it no longer fits snugly onto the pump shaft. REASSEMBLY Reassemble the pump in reverse order from the above directions, observing the notes below. 1. When installing the impeller, be sure the circular indent faces toward the lower end of the pump, and that the impeller is aligned with the D flat on the shaft. If the impeller is installed upside down, the pump will still pump, but at a greatly reduced flow rate. 11

13 2. Use the eyebolt from the top of the pump (or any ¼-20 bolt) to install the inlet plate. There are two key slots on one end of the inlet plate, and one key slot on the other end. Before pushing the inlet plate into the pump, rotate it so that the key slots line up with the mating keys on the pump. 3. Install the inlet O-ring, making sure it s seated in the groove in the inlet plate. 4. If the inlet screen was removed during disassembly, reinstall it in the screen housing and secure it in place with the snap ring. 12

14 5. Install the pump inlet onto the pump body by twisting the pump inlet clockwise to engage the bayonet. A screwdriver can be used for leverage (see disassembly instructions). 13

15 LED Table 1 Error Indicator (Amber LED) This light indicates that an error is present in the system. Errors are displayed continuously and will not be reset until the operating issue is resolved. If more than one error is present, the most significant error (4 blinks) will be displayed until it has been resolved, then the next most significant error will be displayed and so on (a 1 blink error is the least significant error that can occur). To read the error LED, wait for the light to stop flashing (pause) and then observe the next successive blinks. The number of times the LED blinks before pausing indicates the error that's present. See the table below for a description of the error. LED Table 2 Pump Runtime Meter (Green LED) The Pump Runtime Indicator shows how long the pump s motor has operated since its installation. To access the Pump Runtime Meter, perform the following actions: 1. Remove 12V power from the pump and ensure the Water Sensor switch is in the "Off" position 2. Place the Water Sensor switch in the "On" position 3. The Green LED will turn on and stay solid for one second, then will blink a number of times corresponding to how long the motor has been run. The LED will then turn off and a long pause will follow. See table below to determine the approximate hours of operation based on the corresponding number of blinks. 4. Once the long pause is complete, normal Water Sensor operation will resume. 14

16 TROUBLESHOOTING SYMPTOM WHAT IT MEANS WHAT YOU SHOULD DO One blink amber light Battery voltage of internal 9-volt battery has dropped below 6 volts or external 12-volt power source has dropped below 11.8 volts. Pump will continue to run. Charge or replace battery soon. Turn off Water Sensor switch, then disconnect and reconnect 12-volt power supply to reset error. Two blink amber light Dead battery the 12-volt power source has dropped below 10.5 volts. Pump operation locked out. Connect to fully charged battery or replace your 9v battery. Disconnect/reconnect 12v plug to reset error. Three blink amber light Communication error Contact QED. There is a wiring issue. Four blink amber light Communication error Contact QED. There is a wiring issue. Pump is flowing only a small Your pump could be air locked Turn the speed control knob amount of water (~100 ml/min) back to off and pause for a few or is not flowing at all regardless seconds. Turn it to a 10 of Speed Control position o clock or low speed position and allow the pump to run for at least 15 seconds. Place discharge tube in a container of clean water to confirm water is being pumped (See Step 10). After the 15 seconds and confirmed pumping, you can slowly increase the speed knob to the desired position I completed the steps Your inlet screen could be Remove the inlet screen housing immediately above and my clogged with sediment/debris (see Step 13) using a screw pump is still not producing the driver. Remove the screen using expected flow ID snap ring pliers and clean or replace the screen. 15

17 SYMPTOM WHAT IT MEANS WHAT YOU SHOULD DO My filter is clean but I am still not seeing the expected amount of flow. Your impeller may be restricted Remove the inlet screen housing (Step 13), remove the inlet and inlet O-ring (Step 17) and remove the impeller using the ID snap ring pliers if need be. Inspect the fins and clean the impeller of any debris, or replace if necessary. Inspect the impeller chamber and flush out any debris. Reassemble, ensuring the donut on the impeller is facing you when installed. You can continue to operate the pump to complete your sampling operation, but your motor module should be replaced as soon as possible. Note that using the pump in another well could risk cross-contamination of samples or wells if the flooded motor module should leak. Contact QED for assistance. Reducing the tubing diameter can increase the head pressure, making it easier to get a steady low flow rate. Tubing diameters down to ¼ (6mm) OD can be used. With 12V battery connected, turn water sensor switch to OFF. If the green light turns off, the fuse is blown. Remove the two thumb screws from the face of the reel. Remove control board from its pocket. Remove cover from fuse holder. Replace fuse if there is no conductivity. There is a constantly blinking Your motor chamber has flooded amber light I cannot reduce my flow rate low enough to collect samples. The head pressure against the pump is very low. Pump does not run with a known good 12V battery connected. You may have a blown fuse (located on the control panel inside the reel hub) if the battery clamps were connected in reverse. 16

18 17

19 ACCESSORIES AND SPARE PARTS Drop tube inlet kit Includes threaded inlet housing, 1/2 and 3/8 tubing barbs (2 each) and drop tube weight assembly Easy Fitting quick-connect for 1/2" tubing Easy Fitting quick-connect for 3/8 tubing Easy Fitting discharge check valve (top is 1/4" FPT, uses existing discharge barb fittings) Barb fitting for 1/2" OD tubing x 1/4" MPT Barb fitting for 3/8" OD tubing x 1/4" MPT Barb fitting for 1/4" OD tubing x 1/4" MPT Support cable, stainless steel with polyethylene coating (sold by the foot) 8337 Support cable hardware kit for cable includes (2) SS cable clamps and (2) SS shackles Impeller kit single. Includes impeller and O-rings Impeller kit pack of 10 impellers and O-rings Inlet screen kit screen, snap ring, and O-rings for inlet housing and impeller chamber O-ring kit (6 total inlet screen, inlet housing, impeller, body tube, motor nose and top collar) Motor module replacement kit includes motor/seal assembly and discharge head O-rings Motor lead wire repair kit (repair at pump end only). Includes pin connectors and O-rings Extended power supply cable, 25 feet, with battery clamps O-ring lubricant Molykote 111 grease (purity tested) Inlet screen snap ring kit package of Spare fuse, 10 amp - package of Snap ring pliers, internal adjustable wrench, fits up to 1.5 fittings O&M Manual Quick-Start Guide /2 OD x 3/8 ID low-density polyethylene (LDPE) tubing, 500 ft. roll /8 OD x 1/4" ID low-density polyethylene (LDPE) tubing, 500 ft. roll /4 OD x ID low-density polyethylene (LDPE) tubing, 500 ft. roll 18

20 WARRANTY Q.E.D. ENVIRONMENTAL SYSTEMS, INC. ("QED") warrants to the original purchaser ( Purchaser ) of its Power Pro ESP products ( Products ) that the Products shall be free from defects in materials and workmanship on the date of sale, subject to the limitations below. All warranty durations are calculated from the original date of purchase and all hours of operation determinations are based on hours of operation shown on the internal hour meter. 1. All major components of the Products are warranted for one year. 2. The motor module is warranted for one year or four hundred (400) hours of operation, whichever occurs first. 3. The impeller, seals, O-rings and barb fittings are replaceable wear items and are not warranted. 4. Separately sold parts and spare parts kits for the Products are warranted for ninety (90) days. 5. Repairs performed by QED are warranted for ninety (90) days from date of repair or until the expiration of the full term of the original warranty, whichever is longer. Purchaser s exclusive remedy for breach of said warranty shall be as follows: If Purchaser notifies QED in writing within the applicable warranty period of a claimed defect in the Product and QED determines after inspecting the Product that the defect is covered by the warranty, QED will repair the Product without charge to Purchaser. If QED for any reason cannot repair a Product determined by QED to be covered by this warranty within four (4) weeks after receipt of the defective Product, then QED's sole responsibility shall be, at its option, either to replace the defective Product with a comparable new unit at no charge to Purchaser or to refund the purchase price paid by Purchaser. QED's obligation to repair, replace or refund are conditioned upon the Purchaser's return of the claimed defective Product to QED, after receiving authorization to do so from QED. In no event shall claimed defective Products be returned to QED without its authorization. If the Product is determined not to be defective within the terms of this warranty, then all costs for repair, parts and labor that are authorized by Purchaser shall be borne by Purchaser. THE FOREGOING WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED OR STATUTORY (INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY AND THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE), WHICH OTHER WARRANTIES ARE EXPRESSLY EXCLUDED HEREBY. QED neither assumes, nor authorizes any person to assume for it, any other obligation or liability in connection with the Products. Purchaser agrees that in no event will QED be liable for incidental, consequential or special damages (including but not limited to lost profits, lost sales, or injury to persons or property) and that Purchaser s sole remedy is the above warranty. This warranty will be void in the event of unauthorized disassembly of component assemblies. This warranty will also be void if the defect in a Product results from abuse; operating, installing or maintaining the Product in a manner other than in accordance with QED s written 19

21 recommendations; uses or applications other than the intended use or application, as indicated in the manual; or exposure to chemical or physical environment beyond the designated limits of materials and construction. This warranty does not cover, and QED shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, substitution of non-qed component parts, or the selection of improper material or product configuration for Purchaser s application. Nor shall QED be liable for malfunction, damage or wear caused by the incompatibility of QED equipment with structures, accessories, equipment or materials not supplied by QED, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by QED. QED shall be released from all obligations under all warranties if any Product covered hereby is repaired or modified by persons other than QED's service personnel unless such repair by others is made with the written consent of QED. RESPONSIBILITY OF THE PURCHASER Purchaser is responsible for notifying QED of the defect, malfunction, or other manner in which the terms of this warranty are believed to be breached. In the event of a warranty claim, Purchaser must contact the Customer Service Department of QED and: 1. Identify the product involved (by model or serial number or other sufficient description that will allow QED to determine which product is claimed defective); 2. Specify where, when, and from whom the Product was purchased; 3. Describe the nature of the defect or malfunction; and 4. Send the malfunctioning component, after authorization by QED, to: QED Environmental Systems, Inc Bishop Circle West Dexter, Michigan or Info@qedenv.com 20

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