Apeks 2000 PSI Series, Owner'S Manual

Page 1: ...L WARNING FAILURE TO FOLLOW THE SETUP AND OPERATION PROCEDURE PROVIDED IN WITHIN THIS MANUAL MAY VOID THE EXTRACTION SYSTEM S WARRANTY Apeks LLC 150 Commerce Blvd Johnstown OH 43031 844 446 4262 www apekssupercritical com Scan this QR code to get the most recent version of this manual ...

Page 2: ... Separation vessels 26 4 1 34 After Every Run Maintenance 26 4 1 41 Opening Extraction Vessel 289 4 1 47 Removing Spent Material from Extraction Vessel 30 4 1 48 Loading Botanical or Other Media 30 4 1 51 Closing Extraction Vessel 30 4 1 55 Chiller Start Up 311 4 1 59 Evacuating the System Removing air from the system prior to extraction 311 4 1 64 Conducting an Extraction 322 4 1 74 Recommended O...

Page 3: ...ure that system is installed in a well ventilated area to prevent buildup of CO2 which can cause asphyxiation Use of a CO2 monitor is strongly recommended WARNING Opening a vessel under pressure can result in a rapid release of pressure and ejection of the material inside the vessel DO NOT ATTEMPT TO OPEN A VESSEL UNDER PRESSURE Always make sure a vent path for the vessel is opened and the corresp...

Page 4: ...res shown below Also please verify that that there is no external damage to the wood crate s If damage is found do not accept the delivery from the shipping company IF ACCEPTNG MINOR DAMAGED CRATE S WRITE ON ALL SHIPPING DOCUMENTS MINOR DAMAGE FOUND ON CRATE S Additionally call Apeks at 740 809 1160 to report damage and take pictures of each damaged location Diaphragm Compressor Crate Extractor Cr...

Page 5: ...ood from the all four sides and the top of the crate using a Phillips head screwdriver Figure 2 Appearance of crate with top and sides removed 1 1 4 Remove the support hardware from inside the crate Ensure that all the material in the table below is present Figure 3 Overview image of support hardware ...

Page 6: ... Indicator Light 1 Polyscience Chiller 1 Versilube 1 Vacuum Pump w vacuum hose assembly 1 Write on squeeze bottle 1 3 8 Compression Plug 1 Air Compressor 1 4 Ft 5 16 In O D Air Hose 1 5 16 x 1 4 MNPT fitting for Air Compressor 1 Connecting hoses 2 1 1 6 Remove the horizontal 2x3s from the top of the crate using a hammer or crowbar 1 1 7 Remove the vertical 2x4s from the four corners of the crate u...

Page 7: ...out adequate help WARNING The system weighs over 700 lbs 318 kg use a minimum of three people to stabilize the system while moving 1 1 2 Remove the chiller from the second crate WARNING The chiller weighs over 150 lbs use a minimum of two people or a lift cart when moving the chiller assembly 1 1 3 KEEP the crate and all packing materials for future shipping should the system ever need to be moved...

Page 8: ...ion when lifting or moving the system Do not attempt this step without adequate help WARNING The compressor weighs over 1500 lbs 680 kg use a minimum of three people to stabilize the system while moving 2 3 2 2 Before lowering the diaphragm compressor to the floor install the rubber feet provided to the frame These rubber feet can then be anchored to the floor 2 3 4 The orientation of the diaphrag...

Page 9: ... 1 12 2 NEMA 6 15R receptacle 1 5HP Large 12 5HP diaphragm compressor systems eff 10 15 2015 230VAC 1 31 4 Field wired Polyscience recommends 40Amp dedicated hard wired circuit Control Panel Goes with Voltage Phase Main Fuse or breaker size Apeks recommended connection 1L 115VAC 1 10A NEMA 5 15R wall receptacle with surge protector All other systems 115VAC 1 10A NEMA 5 15R wall receptacle with sur...

Page 10: ...essor would require a different electrical service Contact Apeks at 740 809 1160 ext 703 to discuss this before installing electrical service if you choose the 480V option 2 1 4 3 Refer to section 4 5 for electrical connections between the Apeks system and the diaphragm compressor 2 1 4 4 Note different size chillers are dependent of diaphragm pump size WARNING Do not modify the power connections ...

Page 11: ...unctionality Figure 8 Extraction system leveling feet Coolant Connections 3 1 1 Connect the blue cooling line from the outlet of the chiller to the temperature control coiled heat exchanger on the far left side of the Apeks system as shown below Please note that these lines should not lay on any sharp edges where abrasion can occur 3 1 2 Connect the blue cooling line from the inlet of the chiller ...

Page 12: ... side of the extraction system will be pre assembled In the event that adjustments need to be made or the system gets taken apart during use the water flow path should always be from bottom to top in any vertically oriented vessel Figure 11 Image of 4 inch separator coolant lines Please note that these lines should not lay on any sharp edges where abrasion can occur ...

Page 13: ... CO2 cylinders are under high pressure Use proper storage and handling procedures to prevent damage and sudden release of CO2 from the cylinder 3 1 2 CO2 used with Apeks systems should be 99 purity or better Medical Food or Instrument grade typically suffice gas feed not liquid feed 50 lb 75 lb or 100 lb high pressure cylinders 3 1 3 The two supplied hoses should be connected directly to the CO2 c...

Page 14: ...any thread sealant Tighten 1 8 turn past finger tight or until leak free Additional instructions regarding these tube fittings is available at http www swagelok com downloads webcatalogs EN MS 13 151 pdf Figure 14 Double Bottle CO2 Hose Connection Air System Connections 3 1 5 Replace the quick release fitting on the front of the air compressor with the 5 16 push to connect provided Figure 15 Switc...

Page 15: ... 3 1 6 Connect the 5 16 pink air hose from the air compressor to the push to connect fitting on the back of the Apeks 2000 5LD 20LD 5LDx5LD or 20LDx20LD system as shown below Figure 16 Connecting the air compressor to the back of the Apeks system ...

Page 16: ...terminal on the din rail immediately to the left of the motor starter NOTE 3 Phase motors are wired differently Figure 17 Electrical connections from Diaphragm compressor to the Apeks system 3 1 8 Wires for the pressure switches on the pump need to be wired in this panel as well 3 1 8 1 Insert the conduit coming from the junction box on the pump into the receptacle in the middle of the pump 3 1 8 ...

Page 17: ...lled water and propylene glycol DO NOT USE DEIONIZED WATER is added to the system through the reservoir cap on the top of the chiller 3 1 15 1 On the initial fill the chiller will pump contents of the reservoir into the system which will require additional fluid to be added until the system water jackets and hose are full 3 1 15 2 After the system is operational recheck the coolant level while the...

Page 18: ...The outlet tubing on the pump insulated is connected between the regenerative heat exchanger attached to the pump and the tube coming down off valve 17A Figure 18 Stainless steel tubing connections from the diaphragm compressor to the Apeks system Figure 19 CO2 flexible hoses from the diaphragm compressor to the Apeks system Please note that these lines should not lay on any sharp edges where abra...

Page 19: ... for the Apeks system The Apeks system will then send messages to a designated email and then this email will send messages to any person s phone numbers you decide to forward messages to 3 1 22 After connecting your system to the internet via an Ethernet cable and after you ve setup your designated email for the system please contact our Software Electrical Support at 740 809 1160 ext 703 or Tech...

Page 20: ...election button located on the bottom of the alarm screen 3 1 23 2 Now chose which messages you would like to have sent to your email on the message section screen Figure 22 Message selection screen used to determine which messages you would like to have sent to your email ...

Page 21: ...anty of the 2000 5L 20L 5Lx5L and 20Lx20L systems Please note that ambient conditions must be between 65 degrees F and 80 degrees F Failure to meet these ambient temperatures could cause the system to run incorrectly In warmer climates an air conditioner may be needed to maintain proper ambient temperatures 2000 5LD 20LD 5LDx5LD and 20LDx20LD Overview NOTE Alternate system setup shown for clarity ...

Page 22: ...he operator has read the message before it will disappear 4 1 3 Any variable or message that needs to be or can be controlled by the operator are graphically raised to illustrate that the message is a button An example of the different graphical representations is shown below Figure 23 Indicator vs button 4 1 1 The controller has safety interlocks programmed into it These safety interlocks prevent...

Page 23: ...ystem meets their required level of cleanliness Depressurize System after Recovery 4 1 7 After completion of recovery Valve 4 4A and 4B for dual vessel will open to relieve residual extractor pressure A yellow knowledge will appear in the home screen 4 1 8 Follow directions in order 4 1 8 1 Close turn clockwise CO2 Bottle s 4 1 8 2 Open Valve 10 to relieve separator pressure 4 1 8 3 Press acknowle...

Page 24: ...s to remove flexible metal lines 4 1 15 Remove the yellow wire connected to the Separator 1 thermocouple 4 1 16 Use the 5 8 in ratchet wrench to remove the high pressure sanitary clamps from the top of separator 1 4 1 17 Remove the cap from the top of separator 4 1 18 Collect any available oil from the separator cap 4 1 19 Use alcohol to clean the caps and orifice tube 4 1 19 1 Separator 1 cap mus...

Page 25: ...lect the oil from inside the collection cup 4 1 25 1 Note there is typically residual dry ice in the collection cup mixed in with the oil The dry ice will sublimate without any additional heat It is sometimes more efficient to remove the dry ice oil mixture and place it in collection device like a Pyrex dish Figure 26 Image of collection cup after removal from separator 4 1 26 Use the round squeeg...

Page 26: ... check gasket for integrity and grove for cleanliness prior to reassembly the bottom of separator 2 4 1 34 3 5 Connect orifice bypass flexible line to separator 2 4 1 34 4 If there is no oil carryover than check top cap gasket for integrity and grove for cleanliness prior to reassembling clamps 4 1 34 5 Clean connection piping between separator 1 and 2 and reassemble 4 1 34 6 Ensure separator caps...

Page 27: ...Updated 6 16 2016 Copyright Apeks LLC 2014 27 Figure 27 Image of separator outlet line after being disconnected Figure 37 Valve 11 open ...

Page 28: ... and the pump 4 1 39 Reconnect the separator outlet line and put filter back together making sure not to pinch the o ring in the filter if the o ring is swelled replace with another o ring and allow swelled o ring to contract back to original size 4 1 40 Ensure that the pressure difference between Separator 2 gauge and the Filter Gauge is less than 50 PSI If it is more than 50 PSI difference pleas...

Page 29: ...t all CO2 present in the vessel out of valve 4 4 1 43 3 If the extractor is under pressure the system will require the operator to acknowledge that they want to vent all the CO2 in the extractor 4 1 44 When the extractor vessel gauge on top of the vessel and on the home screen both read zero it is safe to move to the next step 4 1 45 Use the supplied dead blow hammer to loosen the extractor hammer...

Page 30: ...e and injury 4 1 49 Material to be extracted is loaded directly into the extraction vessel A supplied funnel can be used to help minimize spillage 4 1 49 1 Typically botanicals perform best in CO2 extractions when ground to a particle size between 50 µin and roughly the consistency of coffee grounds 4 1 49 2 Any amount of material can be loaded into the Extraction Vessel the vessel does not have t...

Page 31: ...l briefly display dF indicating it is set to display temperature in degrees Fahrenheit Evacuating the System Removing air from the system prior to extraction 4 1 59 After loading material and ensuring all vessels are closed and ready for normal operation from the Home Screen see Figure 29 click the Manual Screen Button 4 1 60 From the Manual Screen see Figure 30 click the Evacuate Button 4 1 61 Ve...

Page 32: ...erial is loaded into extraction vessel and extraction vessel is properly closed 4 1 66 1 The system can be run with no material in the extraction vessel This can be used as a way to clean the stainless steel tubing upstream of the separation vessel 4 1 67 Verify that the Separator vessels are both closed and sanitary clamps are tight clamps are considered tight when there is a 1 16 in to 1 8 in be...

Page 33: ... 70 Once the target extractor pressure is reached the system information box will change from Filling to Running An additional information box will appear indicating the direction of the flow either Forward Flow or Reverse Flow 4 1 70 1 The system routinely switches the flow direction to keep the filters from clogging with plant material and to prevent the CO2 from forming flow channels inside the...

Page 34: ...Temperatures 5 degrees around 23F Extraction Time 3 4 hours per pound Supercritical Extractor Pressure 1 800 psi Extractor Temperature 100F Orifice Size 18 Separator Pressure 350 380psi Separator Temperatures 5 degrees around 64F Extraction Time 2 3 hours per pound 4 1 76 PDC 4 Diaphragm Compressor Subcritical Extractor Pressure 1 200 psi Extractor Temperature 75F Orifice Size 37 Separator Pressur...

Page 35: ...cation Finally check to see if the pump outlet is hot Caution can be up to 160 F If pump outlet is cool the pump may have lost prime Extractor Overpressure Orifice Clog or Orifice is to small The valveless expansion technology uses a small orifice to regulate pressure This orifice can become plugged when foreign material is entered into the plumbing between the extraction vessel and separator vess...

Page 36: ...shipped with each machine that will run any parameter on the machine but additional sizes for any specific optimization are available on the online store Follow clear clogged orifice instructions to change orifices High Separator 1 Pressure 380 psi and Low Separator 2 Pressure High Separator 1 pressure is most often caused by a clog dry ice or oil in the flexible line between Separator 1 and Separ...

Page 37: ...the welded downtube on your separator cap has not been turner or bent out of the acceptable angles in the figure below 5 1 30 2 Separator temperatures are above 40F after system is equalized usually after 1 hour after initialing The temperature set point on the chiller has a direct relationship with separator temperature Turn the set point on the chiller down until separator temperature is below 4...

Page 38: ...ty Maintenance on the system is critical to proper operation Failure to follow these maintenance items can cause premature system failure and void the warranty The maintenance items below pertain to the CO2 system only Follow the manufacturer s recommended maintenance plan for the chiller heater unit The chiller has a cabinet filter that will need blown out with compressed air periodically We incl...

Page 39: ...greased with the provided bottle of anti seize failure to apply anti seize will result in damaged threads which could cause injury and void the systems warranty Every 80 hours Check chiller heater water level is between min and max line on back of chiller Clean all flexible metal lines going into and out of both separators Clean CO2 flow lines between the pump and the coiled heat exchanger with al...

Page 40: ...tension with belt tension tester PDC 4 belts should be tensioned to 10lbs and PDC 3 belts should be tensioned to 6 7lbs a If you need help using your tension tester tool please view the following video b https www youtube com watch v bYEHvfo8t6A 3 If the belt needs adjusted loosen the 4 bolts holding the motor to the base ...

Page 41: ... due to the belt tension 5 Adjust the set screws on the motor base in or out to tighten or loosen the bolt as necessary 6 Be sure to check motor shaft alignment note can be up to 1 8 difference from side to side 7 Retighten motor bolts 8 Rotate belt by hand around one turn failure to do so could result in incorrect reading 9 Check belt tension again and repeat as necessary ...

Page 42: ...Updated 6 16 2016 Copyright Apeks LLC 2014 42 Appendix A 2000 5LD 20LD 5LDx5LD and 20LDx20LD System Screen Shots and Descriptions ...

Page 43: ...and start your extractions Figure 33 Home Screen 5LD and 20LD system left 5LDx5LD and 20LDx20LD right A 2 Manual Screen 5 1 32 The manual screen is used quite often and is where to go to perform any operations other than normal operation such as clearing a clogged orifice recovering C02 before the entered run time is complete opening the extractor vessel or changing a CO2 bottle Figure 34a Manual ...

Page 44: ...e Selected 5 1 34 When in automatic flow reversal the machine will only change flow direction when a new extraction is started meaning that forward flow at the beginning will remain forward flow until the next run The next run will be reverse flow and will remain reverse flow for the entire run Figure 43b A 3 Maintenance Screen The Maintenance Screen is rarely used The Maintenance screen is where ...

Page 45: ...used for troubleshooting On this screen you can monitor which valves are supposed to be open and closed if the pump is on or off and if the light on top of the machine is green or red There are also indicators showing thermocouple raw input data as well as air and CO2 pressures in PSI Figure 37 I O Status Screen A 6 Alarm Screen 5 1 37 The Alarm screen is used for troubleshooting and where navigat...

Page 46: ...14 46 on the alarm screen A lot of times the fault you see on the home screen may have been caused be a series of faults By looking at the alarm screen you can see all the previous faults in the order that they occurred Figure 38 Alarm Screen ...

Page 47: ...Updated 6 16 2016 Copyright Apeks LLC 2014 47 Appendix B 2000 5LD 20LD 5LDx5LD and 20LDx20LD Piping and Instrumentation Diagram ...

Page 48: ...Updated 6 16 2016 Copyright Apeks LLC 2014 48 2000 5LD and 20LD Piping and Instrumentation Diagram 2000 5LDx5LD and 20LDx20LD Piping and Instrumentation Diagram ...

Page 49: ...Updated 6 16 2016 Copyright Apeks LLC 2014 49 ...

Page 50: ...Updated 6 16 2016 Copyright Apeks LLC 2014 50 Appendix C CO2 Phase Diagram ...

Page 51: ...Updated 6 16 2016 Copyright Apeks LLC 2014 51 ...

Page 52: ...Updated 6 16 2016 Copyright Apeks LLC 2014 52 Appendix D Training Process ...

Page 53: ...agm System Operating Instructions pdf o Must be complete before scheduling Training Apeks system and diaphragm compressor are unpacked and setup in its location of operation Refer to unpacking instructions Ch 2 4 in the manual o Must be complete before scheduling training Insure you have the following electrical receptacles o independent 220V 15A 1 phase NEMA 6 15R receptacle for the chiller heate...

Page 54: ...f ethanol o Future maintenance will require o Shop Vacuum with a long slim nozzle for removing material from extractor o Pencil Type Tension Tester Gates Pencil Type Tension Tester 30 lbs Deflection Force o CO2 Monitor Amprobe CO2 100 o Material to be extracted must be very dry food dehydrator and grinded blender to the consistence of coffee grounds Have ready the day of training as a courtesy to ...

Page 55: ...ables Input Variables Output Variables Start Time Facility Temp Facility Humidity Botanical Designator Botanical Weight Orifice Size Chiller Set Point Extractor Target Pressure Target Run Time Extractor Temp Separator Temp Separator Pressure Oil Weight Water Weight ...

Page 56: ...nstructional Videos https www youtube com channel UCzo7qXTIt01wfoKB2b9EO g Apeks online store 740 809 1166 ext 4 http www apekssupercritical com online store Software Updates and Text Messaging Alerts 740 809 1166 ext 1 or ext 5 http www apekssupercritical com service ...