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Apeks THE FORCE 2-STAGE Operation Manual

5000psi botanical oil extraction system
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THE FORCE™ 2-STAGE 5000PSI
B
O
E
S
OTANICAL
IL
XTRACTION
YSTEM
O
M
PERATION
ANUAL
WARNING
FAILURE TO FOLLOW THE SET UP AND OPERATION PROCEDURE
PROVIDED IN WITHIN THIS MANUAL MAY VOID THE EXTRACTION
SYSTEM'S WARRANTY
Apeks Supercritical
150 Commerce Blvd.
Johnstown OH 43031
740-809-1160
service@apekssupercritical.com
Scan this QR code to get the
www.apekssupercritical.com
most recent version of the
operating instructions.
Updated 04/23/2019
©Apeks, LLC 2019

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  • Page 1 PROVIDED IN WITHIN THIS MANUAL MAY VOID THE EXTRACTION SYSTEM’S WARRANTY Apeks Supercritical 150 Commerce Blvd. Johnstown OH 43031 740-809-1160 service@apekssupercritical.com Scan this QR code to get the www.apekssupercritical.com most recent version of the operating instructions. Updated 04/23/2019 ©Apeks, LLC 2019...

  • Page 2: Table Of Contents

    The Force™ 2-Stage Operation Manual Table of Contents Content Page # 1. Critical Safety Overview ..........................5 2. System Overview ............................6 2.1. Diaphragm System Overview ........................ 8 2.1.1. Diaphragm Compressor ......................8 2.1.2. Extractor Vessel Stand ....................... 10 2.1.3. Separation Vessel/Control Stand ..................
  • Page 3 The Force™ 2-Stage Operation Manual 3.2.3. System Response on Startup ..................... 31 3.3. Recommended Operating Parameters ....................31 3.3.1. Subcritical ........................... 31 3.3.2. Supercritical ........................31 3.4. During the Cycle ..........................31 3.4.1. Service Separator/Cleaning out Separator that is offline ............. 31 3.4.2.
  • Page 4 7.4. D – Piping and Instrumentation Diagram ..................... 45 7.5. E – CO Phase Diagram ........................48 7.6. F – Pre-Training Checklist ........................49 7.7. G – Electrical Screw Torque Requirement ..................52 7.8. H – Apeks Automatic Machine Fault Troubleshooting Guide .............. 53 Revision Date 4/23/2019...

  • Page 5: Critical Safety Overview

    The Force™ 2-Stage Operation Manual 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 CO potentially causing equipment or personnel damage.

  • Page 6: System Overview

    The Force™ 2-Stage Operation Manual 2. System Overview TheForce ™ Two Stage Diaphragm Separator TCU Extractor TCU Surge Vessel Extractor Vessel Stands Separator Vessel Stand Revision Date 4/23/2019...
  • Page 7 The Force™ 2-Stage Operation Manual Extraction Cap Hoists Main Control Enclosure Fork Pockets Revision Date 4/23/2019...

  • Page 8: Diaphragm Compressor

    The Force™ 2-Stage Operation Manual 2.1. The Force™ 2-Stage System Overview 2.1.1. Diaphragm Compressor – The diaphragm compressor for The Force™ 2-Stage system is a dual head compressor where both heads work in series to compress CO to the desired target pressure in the extractors.
  • Page 9 The Force™ 2-Stage Operation Manual 2.1.1.1.2. Leak Detect Gauges – There is a leak detect switch on each pump head. This gauge monitors the cavity between the oil side and CO side to ensure that there is no crossover between the two systems. This gauge should display no pressure. See Section 5 “Troubleshooting”...
  • Page 10 The Force™ 2-Stage Operation Manual 2.1.2. Extraction Vessel Stand Extractor Closure Switch Flow Switch Extractor Extractor Locking Vessel Isolation Valves Temperature Control Heat Exchangers 2.1.2.1. Extraction Vessels – There are two extraction vessels on their own stand. Vessel A is located on the right-hand stand of the stand and Vessel B is located on the left.
  • Page 11 The Force™ 2-Stage Operation Manual face surface and threads clean. Failure to keep these surfaces clean can cause the vessel not to seal properly. 2.1.2.2. Locking Vessel Isolation Valves – Each extractor has two locking isolation valves that should be utilized whenever the operator is working in any vessel. These valves are intended to valve off the inlet and outlet of the vessel to protect the user from any release of pressure.

  • Page 12: Separation Vessel/Control Stand

    The Force™ 2-Stage Operation Manual 2.1.3. Separation Vessel/Control Stand Control Panel Mount E-Stop Closure Pin Vent Valve (Valves 10A and B) Rupture Disc Bank 1 Bank 2 Flow Switch Evacuation Valve Separator Filter Water Valves Collection Valve 2.1.3.1. Separation Vessels – The Separator stand holds four separators that work in banks of two.
  • Page 13 The Force™ 2-Stage Operation Manual Separator banks that have identical gauges, filters and manual valving. SEPARATOR ORIFICE SIZE DICTATE SYSTEM PHASE. 2.1.3.2. Main Control Enclosure/HMI (Human Machine Interface) – Unless otherwise stated at time of purchase, the separator stand will be where the main control enclosure and HMI are located.

  • Page 14: Bottle Connections

    The Force™ 2-Stage Operation Manual Main Supply and Recovery Bottles Make-Up Supply Bottle 2.1.4. Bottle Connections (Behind Separator 2B) 2.1.4.1. Main Supply and Recovery Bottles – Three 75 lb Gas Supply CO bottles should be used as the main bottles for The Force™ 2-Stage system. These bottles are connected to the location shown above.

  • Page 15: Automation Overview

    Contact Apeks for current version information (740) 809-1160 option 2. 2.2.2. Home/Main Screen – This screen is the most common area to monitor the system during a cycle.

  • Page 16: Cycle Parameter Screen

    (Single or Double Extractor or Continuous Batch) cannot be adjusted after the run begins. 2.2.4. Valve Control Screen – This screen is for Apeks use only and is locked from customer use. Valve positioning can be seen on this screen. Current valve position will be highlighted.

  • Page 17: Manual Screen

    The Force™ 2-Stage Operation Manual 2.2.5. Manual Screen – Aside from the Main Screen this screen is the most common screen the operator will interact with. The manual screen is where to go to reset any alarms, service/switch separators, change bottle and more. See Manual Screen Buttons Section 2.4 on page 27 for more information.

  • Page 18: Message Screen

    The Force™ 2-Stage Operation Manual 2.2.7. Message Screen – This screen is where the operator selects which messages to receive. This email messaging will require an initial setup which can be scheduled at http://www.apekssupercritical.com/customer-support/service-request/. Set up will require a dedicated email address for the system. Messaging ability requires connection to the internet. Data collection data and remote viewing will also be set up with this alerting service.

  • Page 19: Code Entry Screen

    The Force™ 2-Stage Operation Manual 2.2.8. Code Entry Screen – This screen is used for systems that are leased. Leased systems will require a monthly passcode. 2.2.9. I/O (Input/Output) Screens – This screen is used for more precise system monitoring. The operator can monitor every input and output of the Program Logic Controller (PLC) from these screens.
  • Page 20 The Force™ 2-Stage Operation Manual 2.2.9.1. PLC Digital Inputs 2.2.9.2. PLC Digital Outputs Revision Date 4/23/2019...
  • Page 21 The Force™ 2-Stage Operation Manual 2.2.9.3. PLC Analog Inputs Revision Date 4/23/2019...
  • Page 22 The Force™ 2-Stage Operation Manual 2.2.9.4. PLC Analog Outputs Revision Date 4/23/2019...
  • Page 23 The Force™ 2-Stage Operation Manual 2.2.9.5. I/O – Motor Starter Monitor 2.2.9.6. I/O – Temp Control Units Revision Date 4/23/2019...

  • Page 24: Alarm History Screen

    The Force™ 2-Stage Operation Manual 2.2.10. Alarm History Screen – This screen holds all the information about past alarms on the system. See the Troubleshooting Section 5 on page 36 for information about specific alarms. 2.2.11. Pop Up Screens – These screens will either appear to prompt the operator to enter additional information or will be called up by the operator to view or change parameters.
  • Page 25 The Force™ 2-Stage Operation Manual 2.2.11.3. Elapsed Time Setting – This Screen can be called up from the bottom middle of the main screen and allows the operator to change/monitor time settings. In continuous batch mode the operator will need to go to this screen to verify that extractors are ready to come online.

  • Page 26: Running Modes

    The Force™ 2-Stage Operation Manual 2.2.11.6. Master Reset Confirm – This window will pop up when a master reset is selected to make sure it is not done accidently. 2.3. Running Modes 2.3.1. Single Extractor – In this run mode, the system will run only one extractor (selected by the operator) for the duration of the cycle time and will then recover the CO .

  • Page 27: Continuous Batch

    The Force™ 2-Stage Operation Manual 2.3.3. Continuous Batch – In this run mode, the system will bring both extractors online and offline automatically based on parameters selected by the operator. The operator will have the option to start with one vessel, or both, and will control the amount of time each extractor will be run. The operator will also have the option to select two different cycle parameters, which separator bank to use for each set of parameters, and how long between transitions between separators as well.

  • Page 28: System Operation

    The Force™ 2-Stage Operation Manual 3. System Operation 3.1. Before the Cycle 3.1.1. Loading and Closing Extractor 3.1.1.1. CAUTION: Extractor plugs and nuts can weigh up to 50 lbs and care should be given to avoid damage and injury. 3.1.1.2. NOTE: Use appropriate tools to open and close vessels.

  • Page 29: Prepping And Securing Separators

    The Force™ 2-Stage Operation Manual 3.1.1.4. Before loading the extractor visually inspect the metal filters on either end of the vessel for any signs of clogs or damage. 3.1.1.5. Use the supplied metal funnel to help load the extraction vessel. Vessels should be loaded in stages using gentle packing in between to increase the amount of material able to be loaded into the vessel.

  • Page 30: Evacuating System

    The Force™ 2-Stage Operation Manual 3.1.2.4. Close Valve 10 and the Evacuation Valve. 3.1.2.5. Open the Vessel Isolation Valves once vessel is secure. 3.1.3. Evacuating System 3.1.3.1. From the manual screen press “Evacuate”. 3.1.3.2. Open the evacuation valve on the separator bank that will be online first and attach the vacuum pump to the bottom of the evacuation valve with the supplied hose and gauge.

  • Page 31: System Response On Startup

    The Force™ 2-Stage Operation Manual 3.2.2.2. If the “Cycle Parameters” button on the main screen is not green then the cycle parameters are not fully established and need attention. Return to the cycle parameters screen to fully set all the parameters. 3.2.2.3.

  • Page 32: Cleaning Out Extractor In Continuous Batch Mode

    The Force™ 2-Stage Operation Manual 3.4.1.7. Using supplied squeeze bottle, flush cleaning agent through the second separator (smaller separator in the bank) outlet down to the filter housing until the agent runs clear. 3.4.1.8. Use compressed air to blow any residual cleaning agent out of CO line and reassemble filter.

  • Page 33: Operator Maintenance

    The Force™ 2-Stage Operation Manual 3.5.2. Operator Maintenance 3.5.2.1. When the pressure of the extractor has been vented, the extractor is safe to open by using the rubber mallet to loosen the top nut, and then swing out of the way for storage. 3.5.2.2.

  • Page 34: System Preventive Maintenance

    The Force™ 2-Stage Operation Manual 4. System Preventive Maintenance For Apeks System Manuals and Other Component Manuals visit http://www.apekssupercritical.com/apeks- supercritical-operation-manuals/ Included with each system is a small squeeze bottle to help with proper maintenance and cleaning of your systems CO lines.

  • Page 35: Chiller Maintenance

    The Force™ 2-Stage Operation Manual • Replace diaphragms and O-rings in process head. • Clean and inspect oil inlet check valve. Every 4000 • Clean and inspect oil relief valve. Hours • Inspect crankcase assembly. • Inspect compressor lower head. •...

  • Page 36: Troubleshooting

    400psi with target pressure not reached check the following. Prime pump for ten minutes, check/clean check valves on diaphragm pump, and contact Apeks about other options. 5.1.5. Diaphragm pump pressure switch tripped – See Diaphragm Rupture Shutdown Alarm in Section 5.2.11.

  • Page 37: Code Needed Alarm

    Vent pressure if still present and check for oil. If oil is present, call Apeks (740-809-1160 option 2) about replacing diaphragms. If no oil is present, reset alarm on the manual screen, restart system and monitor the leak detect gauge for pressure.

  • Page 38: Oil Pressure Lost Alarm

    5.2.31. Valve Fault Alarm – The air valve manifold has faulted. Check the manifold for fault code and then try unplugging the yellow cord and plugging it back in. If fault continues contact Apeks (740-809-1160 option 2).

  • Page 39: References

    The Force™ 2-Stage Operation Manual 6. References YouTube Instructional Videos https://www.youtube.com/user/ApeksSupercritical Apeks online store http://apeksonlinestore.com/ Software Updates and E-mail Alerts (740) 809-1160 option 2 http://www.apekssupercritical.com/service/ Revision Date 4/23/2019...

  • Page 40: Appendices

    The Force™ 2-Stage Operation Manual Appendices 7.1. Appendix A. Belt Tension Testing/Adjustment. 7.1.1. Remove the belt guard. 7.1.2. Check belt(s) tension with belt tension tester. 7.1.2.1. Belts should be tensioned to 10 lbs. 7.1.2.2. If you need help using your tension tester tool please view the following video: https://www.youtube.com/watch?v=bYEHvfo8t6A 7.1.3.

  • Page 41: B – Diaphragm Pump Priming

    The Force™ 2-Stage Operation Manual 7.2. Appendix B. Diaphragm Pump Priming 7.2.1. Open BOTH of the Oil Bypass Valves (one on each head), see figure below, by turning counterclockwise until it stops. Oil Bypass Valve 7.2.2. Go to the “Manual Screen” on the HMI and hit the “Start Prime Compressor” button. 7.2.3.

  • Page 42: C – Check Valve Cleaning

    7.3.4. Dissemble check and clean thoroughly with alcohol or acetone. For heavily soiled valves use an ultrasonic cleaner on metal pieces to help remove soil. Do not clean the poppet (brown donut) in the ultrasonic cleaner. If poppet is beyond cleaning or damaged contact Apeks for a replacement.
  • Page 43 The Force™ 2-Stage Operation Manual Poppet Springs Suction Check Valve Revision Date 4/23/2019...
  • Page 44 The Force™ 2-Stage Operation Manual Discharge Check Valve 7.3.5. Reassemble checks when cleaned and assemble in pump. 7.3.6. Torque the retaining bolts to 15 ft-lbs after reassembly. Revision Date 4/23/2019...

  • Page 45: D – Piping And Instrumentation Diagram

    The Force™ 2-Stage Operation Manual 7.4. Appendix D. Piping and Instrumentation Diagram Revision Date 4/23/2019...
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  • Page 48 The Force™ 2-Stage Operation Manual 7.5. Appendix E. CO Phase Diagram Revision Date 4/23/2019...

  • Page 49: F – Pre-Training Checklist

    Must be complete before scheduling training: Print complete operation manual and have on site the day of training, along with the chiller manual. o Must be complete before scheduling training: Apeks system and diaphragm compressor are unpacked and set up in location of operation. Refer to unpacking instructions in the installation manual.
  • Page 50 The Force™ 2-Stage Operation Manual o Future maintenance will require: o Shop vacuum with a long, slim nozzle for removing material from extractor. o Pencil Type Belt Tension Tester: http://apeksonlinestore.com/product/tension-tester/ o CO Monitor; Amprobe CO o Material to be extracted must be very dry and ground to the consistency of coffee grounds. Have ready the day of training.
  • Page 51 The Force™ 2-Stage Operation Manual 7.7. Appendix G. Electrical Screw Torque Requirements 1. Fuse Holders (1492-H6) = 7.1 lb-in 2. Power Supply (1606-XLE120E) – 7 lb-in 3. Terminal Blocks (1492-J4) = 9 lb-in 4. Ground Blocks (1492-JG4) = 9 lb-in 5.
  • Page 52 The Force™ 2-Stage Operation Manual Appendix H: Apeks Automatic Machine Fault Troubleshooting Guide 7.8. Revision Date 4/23/2019...
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