Apeks 1500-5L User manual

1500-5L AND 1500-20L

BOTANICAL OIL EXTRACTION SYSTEM

OWNER’S 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

614-809-1160

www.apekssupercritical.com

Updated 8/8/2018 Copyright Apeks LLC, 2014

Table of Contents

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

2. Unpacking Instructions...........................................................................................................4

2.1. Shipping Crate Inspection................................................................................................4

2.2. Unpacking Instructions....................................................................................................5

3. System Requirements............................................................................................................7

3.1. General System Specifications........................................................................................7

3.2. Facility .............................................................................................................................7

3.3. Electrical..........................................................................................................................7

3.4. Recirculating Water Chiller/Heater ..................................................................................8

4. Setup and Assembly..............................................................................................................8

4.1. Leveling Feet...................................................................................................................8

4.2. Coolant Connections.......................................................................................................8

4.3. CO2Connections...........................................................................................................10

4.4. Air System Connections ................................................................................................11

4.5. Electrical Connections...................................................................................................11

4.6. Chiller/Heater Setup......................................................................................................12

5. System Operation ................................................................................................................13

5.1. 1500-5L and 20L Overview............................................................................................13

5.2. Automation Systems Overview......................................................................................14

5.3. Pre-Cleaning..................................................................................................................15

5.4. Opening Extraction Vessel ............................................................................................15

5.5. Loading Botanical or Other Media.................................................................................16

5.6. Closing Extraction Vessel..............................................................................................16

5.7. Chiller Start Up..............................................................................................................17

5.8. Evacuating the System..................................................................................................17

5.9. Conducting an Extraction...............................................................................................18

5.10. Removing Spent Botanical ............................................................................................19

5.11. Oil Collection .................................................................................................................19

6. Troubleshooting ...................................................................................................................22

6.1. Ice On Separator...........................................................................................................22

6.2. Opened Bottle Too Early...............................................................................................22

6.3. Low Extractor Pressure.................................................................................................22

6.4. Extractor Overpressure – Orifice Clog...........................................................................22

6.5. Low Separator Pressure – Orifice Clog.........................................................................23

6.6. Low Separator Pressure – Wrong Orifice Size..............................................................23

6.7. High Separator #1 Pressure (>350-psi) and Low Separator #2 Pressure......................25

7. System Maintenance............................................................................................................27

8. Replacement and Spare Parts List.......................................................................................29

Appendix A. 1500-5L and 20L Automated System Screen Shots...............................................30

Appendix B. 1500-5L and 1500-20L Piping and Instrumentation Diagram.................................34

Appendix C. CO2Phase Diagram...............................................................................................36

Appendix D. Pre-Training Checklist............................................................................................37

Updated 8/8/2018 Copyright 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 closure bolts.

WARNING

Subcritical and Supercritical CO2systems are designed to operate in doors. Extreme

temperatures (below 50°F and above 85°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.

WARNING

Never turn on the chiller without the thermocouple probe installed and connected to the chiller.

Updated 8/8/2018 Copyright Apeks LLC, 2014

2. Unpacking Instructions

Apeks 1500-5L and 1500-20L systems are shipped in three separator crates. One containing

the chiller, one containing the air compressor and one containing the botanical extraction

system. Following are the steps for removing the system from the crates and making service

connections for initial use.

2.1. Shipping Crate Inspection

2.1.1. Prior to opening the crate(s), verify that that there was no external damage caused

to the wood crate. If damage is found, do not accept the delivery from the

shipping company without first opening the crate to verify that there was no

damage to the system. Additionally, call Apeks at 614-354-4451 to report damage

and start the reporting process with the shipping company.

Figure 1. Approximate appearance of 1500-5L and 1500-20L Shipping Crate

2.1.2. Locate the two TiltWatch Plus sensors on the outside of the crate. Ensure that the

crate has not exceeded 30° in any direction. If the crate has exceeded 30°, do not

accept the delivery from the shipping company until contacting Apeks at 614-354-

4451.

Figure 2. TiltWatch Sensor

Updated 8/8/2018 Copyright Apeks LLC, 2014

2.2. Unpacking Instructions

2.2.1. Remove the plywood from the all four sides and the top of the crate using a

Phillips head screwdriver.

Figure 3. Appearance of crate with top removed

2.2.2. Remove the support hardware inside the crate. Support hardware should include

a cordless impact wrench, impact wrench socket, 11/16-in open end wrench, 5/8-

in ratchet wrench, aluminum funnel, two O-rings, four sanitary gaskets, a flexible

metal hose, a vacuum hose, vacuum pump and four rubber coated leveling feet.

Figure 4. Overview image of support hardware

2.2.3. Remove the horizontal 2x3s from the top of the crate using a hammer or crowbar.

2.2.4. Remove the vertical 2x4s from the four corners of the crate using a hammer or

crowbar.

2.2.5. Remove the two 2x3s running across the top of the system frame and the two

2x3s running alongside the system frame using a Phillips head screwdriver.

Updated 8/8/2018 Copyright Apeks LLC, 2014

Figure 5. Image of 2x3s support top and sides of system frame

Figure 6. Appearance of crate with 2x3s removed

2.2.1. Using a forklift or pallet jack lift the system off the base of the crate. It may be

necessary to tip the system slightly towards the back in order to slide the forks

under the stainless steel horizontal frame support members.

2.2.1.1. The system weighs in excess of 600-lbs, take extreme caution when lifting or

moving the system. Do not attempt this step without adequate help.

WARNING

The system weighs over 600-lbs (275-kg), use a minimum of three

people to stabilize the system while moving.

2.2.2. Remove the chiller (in cardboard box) from the second crate.

WARNING

The chiller over 120-lbs, use a minimum of two people or a lift cart

when moving the chiller assembly.

2.2.3. Retain the crate and all packing materials for future shipping should the system

ever need to be moved to another facility or shipped back to Apeks.

Updated 8/8/2018 Copyright Apeks LLC, 2014

3. System Requirements

3.1. General System Specifications

1500-5L

Extraction System

Chiller/Heater

System

Compressor

Vessel Size (liter)

5-L

15-L

80-Gal

Max Pressure (psi)

1500-psi

100-psi

125-PSI

Operating Temperature (F)

14°F - 122°F

N/A

Dimensions (in)

45 X 30 X 77

28 X 15 X 23

54 X 29 X 61

Weight (lbs)

460-lbs

168-LBS

1000-LBS

Power (V/A/Phase)

110/15/1PH

230/12/1PH

230/40/3PH

1500-20L

Extraction System

Chiller/Heater

System

Compressor

Vessel Size (liter)

20-L

45-L

80-Gal

Max Pressure (psi)

1500-psi

100-psi

125-PSI

Operating Temperature (F)

14°F - 122°F

N/A

Dimensions (in)

45 X 30 X 77

28 X 15 X 23

54 X 29 X 61

Weight (lbs)

460-lbs

168-LBS

1000-LBS

Power (V/A/Phase)

110/15/1PH

230/12/1PH

230/60/3PH

3.2. Facility

3.2.1. Temperature – The 1500-5L and 1500-20L are designed to run in a climate

controlled facility, where the temperature is maintained between 50°F and 85°F.

3.2.2. Dust Control – The 1500-5L and 1500-20L should not be placed in an environment

that has excess dust from other manufacturing operations.

3.2.3. Location – The system is designed to be installed on a concrete or similarly stable

and flat floor.

3.2.4. Compressed Air – Compressed air must be non-lubricated and should be filtered

to between 5μ and 40μ and have a dew point between 0°F and 50°F

3.3. Electrical

3.3.1. The 1500-5L and 1500-20L have three independent electrical requirements; a

110V, 15A, 60Hz, 1 phase NEMA 5-15 male plug for the systems controller, a

220V, 15A, 60Hz, 1 phase NEMA 6-15 male plug for the chiller/heater, and a

hardwired 230-V, 3 phase connection for the air compressor. See chiller and air

compressor manuals for additional electrical requirements.

3.3.1.1. Note that the air compressors can also be ordered prewired for 440-V to

480-V circuits.

WARNING

Do not modify the power connections.

Updated 8/8/2018 Copyright Apeks LLC, 2014

3.4. Recirculating Water Chiller/Heater

3.4.1. Recirculating chiller/heater fluid should be a mixture of 50/50 distilled water and

propylene glycol.

WARNING

Do not use Deionized Water

4. Setup and Assembly

1500-5L and 1500-20L system, chiller and air compressor come fully assembled and require

only facility hookup and system interconnect installation.

4.1. Leveling Feet

4.1.1. Use a fork lift or pallet jack to raise the system approximately 6-in off the ground,

use clamps or tie down straps to secure the system to the forks/jack to prevent it

from tipping.

4.1.2. Insert the supplied leveling feet into the four threaded holes on the bottom of the

extraction system. Ensure that the leveling feet are not threaded into the scale

receiver too far or they will hit the frame and negate scale functionality.

Figure 7. Extraction system leveling feet.

4.2. Coolant Connections

WARNING

Never turn on the chiller without the remote temperature probe

installed and connected to the chiller.

4.2.1. Connect the blue cooling lines to the back of the chiller.

4.2.1.1. Connect the free end of the coiled heat exchanger blue cooling line to the

outlet port on the back of the chiller. Connect the free end of the upper

separator #2 blue cooling line to the inlet port on the back of the chiller.

Updated 8/8/2018 Copyright Apeks LLC, 2014

Figure 8. Location and orientation of coolant lines

4.2.2. The separator 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.

4.2.2.1. For systems with a 4-in separator upgrade. The collection cup has baffles

installed that control the coolant flow path. Therefore either cooling line port

on the collection cup can be connected to the inlet or outlet.

Figure 9. Image of separator coolant lines; a) standard separator b) 4-in separator

4.2.3. The remote temperature probe is typically pre-assembled into the bottom of the

1500-5L and 1500-20L extraction vessels. If it is not installed or it was removed

after receipt of the system, install the probe into the tube fitting located off center

on the bottom flange of the extraction vessel. The nut on the tube fitting should be

tighten 1/8-turn past finger tight or until it is leak free. Additional instructions

regarding these tube fittings is available at

http://www.swagelok.com/downloads/webcatalogs/EN/MS-13-151.pdf

Figure 10. Location of remote temperature probe on bottom of extraction vessel

4.3. CO2Connections

WARNING

CO2cylinders are under high pressure. Use proper storage and

handling procedures to prevent damage and sudden release of CO2

from the cylinder

4.3.1. CO2used with the 1500-5L and 1500-20L system should be a 99% purity or better

(medical or food grade typically suffice), gas feed, 50-lb, 75-lb or 100-lb high

pressure cylinder.

4.3.1.1. The CO2cylinder connection is a standard CGA-320 and is provided with

the system.

4.3.2. The supplied hose should be connected directly to the CO2cylinder valve. No

regulator is required. A supplied CGA-320 plastic gasket is required to seal the

connection between the hose and the CO2cylinder.

Figure 11. CO2cylinder connection

4.3.3. The CO2line is typically preassembled on the 1500-5L and 1500-20L systems. If

the line was not connected or was removed for cleaning/shipping, reconnect the

line to the tube fitting located on top of Valve 12. The connection is a metal-to-

metal seal and does not require 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.

Remote

Temperature

Probe

Remote

Temperature Probe

RS232 Connection

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