Apeks I.2000 Manuel utilisateur

Updated 4/25/2018 © Apeks LLC, 2014

i.2000 AND 2000PSI

BOTANICAL OIL EXTRACTION SYSTEM

OPERATION MANUAL

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 the operating

instructions.

Updated 4/25/20182 © Apeks LLC, 2014

Table of Contents

Page

1. Critical Safety Overview ………………………………………………………………………………………………3

2. System Operation ……………………………………………………………………………………………………..4

2.1. 2000 System Overview …………………………………………………………………………………..…….4

2.2. Automation Overview …………………………………………………………………………………………..4

2.3. Pre-Cleaning …………………………………………………………………………………………………....6

2.4. Depressurizing System After Recovery ………………………………………………………………………6

2.5. Remaining Oil from Separator #1 ……………………………………………………………………………..6

2.6. Closing Separation Vessels …………………………………………………………………………………...8

2.7. Maintenance After Every Run …………………………………………………………………………………9

2.8. Opening Extraction Vessel …………………………………………………………………………………...11

2.9. Removing Spent Material from Extraction Vessel ………………………………………………………….12

2.10. Loading Botanical Material or Other Media …………………………………………………………………12

2.11. Closing Extraction Vessel …………………………………………………………………………………….13

2.12. Chiller Startup …………………………………………………………………………………………………13

2.13. Evacuating System (Pulling Vacuum) ………………………………………………………………………14

2.14. Conducting an Extraction …………………………………………………………………………………….14

2.15. Recommended Operating Parameters ……………………………………………………………………..15

3. Troubleshooting ………………………………………………………………………………………….................17

3.1. Ice on Separator or Collection Cup ………………………………………………………………………….17

3.2. Low Extractor Pressure ………………………………………………………………………………………17

3.3. Extractor Overpressure ………………………………………………………………………………………17

3.4. Low Separator Pressure ……………………………………………………………………………………...18

3.5. Wrong Orifice Size …………………………………………………………………………………………….18

3.6. Differing Separator Pressure ………………………………………………………………………………...18

3.7. Oil Carryover to Separator #2 or Filter Housing …………………………………………………………….18

4. System Maintenance ………………………………………………………………………………………………...19

4.1. Extraction System Maintenance………………………………………………………………….................19

4.2. Diaphragm Compressor Maintenance……………………………………………………………………....20

4.3. Chiller Maintenance …………………………………………………………………………………………..20

5. References ……………………………………………………………………………………………………………21

6. Appendix A. Screen Shot ……………………………………………………………………………………………22

7. Appendix B. Belt Tension Testing/Adjustment …………………………………………………………………….27

8. Diaphragm Pump Priming Instruction ………………………………………………………………………………31

9. Electrical Screw Torque Requirements …………………………………………………………………………….33

10. Piping and Instrumentation Diagram ……………………………………………………………………………….35

11. CO2Phase Diagram …………………………………………………………………………………………………38

12. Pre-Training Checklist ……………………………………………………………………………………………….40

Updated 4/25/20183 © Apeks LLC, 2014

1. Critical Safety Overview

Throughout these instructions, this symbol is used to indicate that the instructions are critically

important to your safety and the safety of your system. Failure to follow the instructions as written

can result in a rapid release of high pressure CO2potentially causing equipment or personnel

damage.

WARNING

Subcritical and Supercritical CO2systems operate under high pressure. Operators must be fully trained and

familiar with the system. Failure to operate the system can result in equipment damage and/or bodily injury.

WARNING

Subcritical and Supercritical CO2systems use large amounts of CO2during operation. Ensure that system is

installed in a well-ventilated area to prevent buildup of CO2 which can cause asphyxiation. Use of a CO2monitor

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 corresponding pressure gage reads zero prior to loosening the vessel hammer unions.

WARNING

Subcritical and Supercritical CO2systems are designed to operate indoors. Extreme temperatures (below 60°F

and above 80°F) will negatively impact the functionality of the system. The environmental temperature range is

for the system, chiller, pump and CO2bottles.

WARNING

Only use Propylene Glycol and distilled water in the chiller and cooling system. Never use Deionized Water in

the chiller or cooling system.

Updated 4/25/20184 © Apeks LLC, 2014

2. System Operation

The following operating instructions are for the Apeks 2000 psi CO2-basedBotanical Oil Extraction systems.

Instructions manuals for the Thermo-Fisher chiller and Diaphragm Compressor are supplied separately.

Failure to follow the instructions provided below may void the warranty of the extraction system and its

components.

2.1. 2000 System Overview

Figure 1. System Components

NOTE: Alternate system setup shown for clarity, setup type can be requested at time of order,

additional cost may apply

2.2. Automation Overview

2.2.1. The Human Machine Interface (HMI) is a 10-inch color touch screen. Almost all of the inputs,

outputs and human/machine interactions are managed through the HMI. The features are not

controlled or reported through the Diaphragm Compressor or the Chiller.

2.2.2. The HMI has two functions; 1) to provide information and 2) to accept inputs from the operator.

Description of some of the interaction is here:

2.2.2.1. If a display value or message is colored orange, an operator must take action before

progressing forward.

Chiller

Separation

Vessels

Collection

Cup

Extraction

Vessels

Diaphragm

Pump

Controller/

HMI

Updated 4/25/20185 © Apeks LLC, 2014

2.2.2.1.1. Orange indicates that an operator activity is required before the Start button can be

depressed. Messages highlighted orange are indicative of a scheduled maintenance

interval being reached.

2.2.2.2. Red messages indicate that a component of the system has either failed to reach the

minimum operating pressures or temperatures, or that it exceeded the programmed

operating limits. Red messages are typically reserved for alarms that could potentially shut

down the machine if the condition causing the alarm is not returned to normal.

2.2.2.2.1. Red messages may require user acknowledgement or may simply disappear when

an abnormal condition returns to normal parameters. If there is a button that

appears, user intervention will be required.

2.2.2.3. Yellow messages will typically be displayed on a button that has to be pressed to

acknowledge that the operator has read the message before it will disappear.

2.2.3. 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 2. Indicator vs. Button

2.2.4. The controller has safety interlocks programmed into it. These safety interlocks prevent unsafe

operations from occurring by monitoring the system parameters and by removing unsafe

action/input control buttons from the HMI. When buttons appear to be missing from the home

screen, it is because the system is performing an operation that would be unsafe in

combination with the missing button/action.

2.2.5. The HMI will provide message popups (in yellow boxes) to instruct the operator what steps are

required next in order in to complete any action selected. Most message popups are also

acknowledgement buttons that must be pressed before any further action can be taken.

2.2.6. The primary operating valves on the Apeks system are air actuated valves controlled by the

systems controller. In the event of an air compressor failure or a power failure all air actuated

valves will return to their normal resting state. Valves 0 and 17B will be normally open and all

others will be closed.

2.2.7. Each air actuated valve has an indicator on the top to inform the operator which valves are

open and which ones are closed. The indicator lines correspond with the flow direction. The

following figure illustrates both and open and closed valve. Note that it does not matter which

way the air actuator is oriented, rather the direction of CO2flow is important.

Title/Output Display

with solid edge

Input Button with

Chamfered edge

Updated 4/25/20186 © Apeks LLC, 2014

Figure 3. a) Valve 1 in the open position, b) Valve 1 in the closed position

2.3. Pre-Cleaning

2.3.1. The Apeks system is constructed from 304 and 316 stainless steel and can be cleaned with

any cleaner that is compatible with both stainless steel and your extracted product. Alcohol

(200 proof) works well for most applications.

2.3.2. The system should be cleaned to the appropriate level (determined by your application and

corresponding regulations) prior to processing each batch of botanical material.

2.3.2.1. Apeks takes great care to clean all systems prior to shipping, however, it is the user’s

responsibility to ensure that the system meets their required level of cleanliness before

processing material.

2.4. Depressurizing System after Recovery

2.4.1. After completion of recovery, Valve 4 (4A and 4B for dual vessel) will open to relieve residual

extractor pressure. A yellow acknowledge button will appear in the home screen

2.4.2. Follow directions in order:

2.4.2.1. Close (turn clockwise) CO2 Bottle(s)

2.4.2.2. Open Valve 10 to relieve separator pressure

2.4.2.3. Press acknowledge box, this will relieve the pressure in the CO2 bottle lines and the rest of

the system.

2.4.3. Open all manual valves.

2.4.4. Turn off the chiller/heater.

2.4.5. NOTE: any time the diaphragm pump stops the system will automatically vent CO2 from valve

0 in order to relieve stress on the diaphragm head.

2.4.6. If system was stopped unexpectedly and system needs recovered proceed to the “Manual

Screen” to recover CO2and then follow steps 1 thru 5.

2.5. Removing Oil from Separator #1

WARNING

DO NOT ATTEMPT TO OPEN A VESSEL UNDER PRESSURE! Always make

sure a vent path for the vessel is opened and the corresponding pressure

gauge(s) reads zero prior to loosening the vessel closure bolts.

2.5.1. Ensure Valve 10 is open

2.5.2. Ensure that the all three gauges on separator vessels (shown below) and separator pressure

on the home screen reads zero.

Flow Direction

CO2Flow Direction

Updated 4/25/20187 © Apeks LLC, 2014

Figure 4. Gauges to Check when Removing Sanitary Clamps

2.5.3. Remove the flexible metal line and connection pipe from the top of the separators. Use two

wrenches to prevent the bending tubes or NPT fittings from loosening in the separator cap.

Figure 5. Illustration of using two wrenches to remove lines

2.5.4. Remove the yellow wire connected to the Separator #1 thermocouple.

2.5.5. Remove the white vent tube attached to the pressure relief.

2.5.6. Use the 5/8-in ratchet wrench to remove the high pressure sanitary clamps from the top of

Separator #1.

2.5.7. Remove the cap from the top of separator.

2.5.8. Collect any available oil from the separator cap.

2.5.9. Use alcohol to clean the caps and orifice tube.

Updated 4/25/20188 © Apeks LLC, 2014

2.5.10. Use the supplied round squeegee or hard plastic scrapper to push any residual oil from the

sides of the Separator #1 down to the bottom and in the collector cup.

2.5.11. Disconnect the two blue water line quick connects on the collection cup.

2.5.12. Attach the collector cup quick connects together and attach the bottom separator 1 quick

connect to the heat exchanger quick connect. This will ensure water flow even if collector cup

connections are not re-attached in assembly.

2.5.12.1.Caution if removing the cup in the middle of a run with the pump on this step must be

followed or the system may automatically shut down due to lack of water flow.

2.5.13. Use caution to support and not to drop the collector cup, remove the high pressure sanitary

clamps from the bottom of the separator 1 with 5/8-in ratchet wrench.

2.5.14. Remove the collection cup from Separator #1.

2.5.15. Collect the oil from inside the collection cup.

2.5.15.1.Note: Oil will be carbonated with CO2 and some dry ice may be present. This carbonation

or 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 6. Image of collection cup after removal from separator.

2.5.16. Use the round squeegee and alcohol to thoroughly clean the inside of the separator and

collection cup.

2.5.17. Separator #1 and the collection cup must be cleaned after each extraction.

2.5.18. Reassemble separator #1 by reversing the steps above, excluding the connection piping from

Separator #1 to #2.

2.5.19. When reassembling, check gaskets for integrity and groove seals for cleanliness.

2.5.20. Prior to reassembling separator #1 cap, check orifice for clog and orientation.

2.5.21. Reconnect the collector cup water lines with quick connect to original configuration before

turning on the chiller/heater.

2.6. Closing Separation Vessels

2.6.1. The separators are closed with sanitary clamps.

2.6.2. Clamps are considered tight when both nuts are torqued to 20 ft-lbs. Uses the supplied torque

wrench to accomplish this tightness.

2.6.3. A final visual check before starting the system is good practice, gaps between clamps should

be around a 1/16-In to 1/8-In between opposing sides of the clamp as seen in the figure

below).

Figure 7. Appearance of tight sanitary clamp

2.7. Maintenance After Every Run

2.7.1. Includes harvesting oil and cleaning separator #1 as described above in Section 2.5.

2.7.2. Separator #2

2.7.2.1. Remove Separator #2 inlet and outlets line from separator cap.

2.7.2.2. Remove the top sanitary clamps and inspect Separator #2 for oil carryover.

2.7.2.3. Clean Separator #2 if any oil is present.

2.7.2.3.1. Remove bottom sanitary clamp.

2.7.2.3.2. Use the 3” squeegee and cleaning agent to thoroughly clean the inside of the

separator

2.7.2.3.3. Clean bottom cap and check gasket for integrity and grove cleanliness prior to

reassembly.

2.7.2.4. If there is no oil carryover than check top cap gasket for integrity and groove for

cleanliness prior to reassembling clamps.

2.7.2.5. Clean connection piping between Separator #1 and #2 and reassemble.

2.7.2.6. Ensure separator caps are secured on top and bottom of separators, and all flexible metal

hoses are connected with the exception of the Separator #2 outlet line.

2.7.3. Separator #2 Outlet to Pump Inlet

2.7.3.1. Ensure Valve 11 is open

2.7.3.1.1. If Valve 11 isn’t open, then go to the manual screen and hit “Evacuate”. This will

open up Valve 11.

Figure 8. Valve 11 open.

2.7.3.1.2. If the evacuation button is not present this means there is entrained pressure

somewhere in the system still and you may need to reassemble the vessels and

finish the recovery. Check for pressure on the I/O Screen

2.7.3.2. Disconnect the separator outlet line, if not already disconnected, from the cap of Separator

#2 as shown below.

Figure 9. Image of separator outlet line after being disconnected.

2.7.3.3. Remove the filter housing and filter on the back of the system. Inspect filter and housing for

oil. Clean housing and clean/replace filter as necessary.

Figure 10. Filter Housing.

Disconnect

Here

Ce manuel convient aux modèles suivants

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