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Apeks THE FORCE 5000-5Lx5LDP Owner's Operation Manual

5000psi dual phase botanical oil extraction system
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THE FORCE™ 5000
B
OTANICAL
FAILURE TO FOLLOW THE SET UP AND OPERATION PROCEDURE
PROVIDED WITHIN THIS MANUAL MAY VOID THE EXTRACTION
SYSTEM'S WARRANTY
service@apekssupercritical.com
www.apekssupercritical.com
Updated 04/22/2019
O
O
'
WNER
S
Apeks Supercritical
150 Commerce Blvd.
Johnstown OH 43031
740-809-1160, option 2
DUAL PHASE
PSI
E
IL
XTRACTION
O
PERATION
WARNING
Scan this QR code to get the most
recent version of this manual!
S
YSTEM
M
ANUAL
©Apeks, LLC 2019

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Summary of Contents for Apeks THE FORCE 5000-5Lx5LDP

  • Page 1 PROVIDED WITHIN THIS MANUAL MAY VOID THE EXTRACTION SYSTEM’S WARRANTY Apeks Supercritical 150 Commerce Blvd. Johnstown OH 43031 740-809-1160, option 2 service@apekssupercritical.com www.apekssupercritical.com Scan this QR code to get the most recent version of this manual! Updated 04/22/2019 ©Apeks, LLC 2019...

  • Page 2: Table Of Contents

    The Force Dual Phase™ Operation Manual Table of Contents Page 1. Critical Safety Overview ........................3 2. System Operation ........................... 4 2.1. The Force™ Dual Phase 5000psi System Overview .............. 4 2.2. Automation Systems Overview ....................4 2.3. Screen Shots .......................... 6 2.4.

  • Page 3: Critical Safety Overview

    The Force Dual Phase™ 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 4: System Operation

    The Force Dual Phase™ Operation Manual 2. System Operation The following operating instructions are for The Force™ Dual Phase: 5000-5Lx5LDP, 20Lx20LDP and 40Lx40LDP, CO -based Botanical Oil Extraction systems. Instructions assume that chiller and Booster Pump are OEM (Original Equipment Manufacturer) supplied. Failure to follow the instructions provided below may void the warranty of the system.
  • Page 5 The Force Dual Phase™ Operation Manual 2.2.2.3.1. 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. 2.2.2.4. 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.

  • Page 6: Screen Shots

    The Force Dual Phase™ Operation Manual Flow Direction Flow Direction Figure 3. a) Valve 1 in the open position, b) Valve 1 in the closed position 2.3. Screen Shots Home Screen 2.3.1. The home screen is where all pressures, temperatures, run times, weight, and access 2.3.2.
  • Page 7 The Force Dual Phase™ Operation Manual Manual Screen 2.3.3. 2.3.3.1. 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 CO before the entered run time is complete, opening the Extractor Vessel or changing a CO bottle.
  • Page 8 The Force Dual Phase™ Operation Manual Maintenance Screen 2.3.4. 2.3.4.1. The Maintenance Screen is rarely used. The Maintenance screen is where you will go to monitor run times on your system and pump for scheduling maintenance. Figure 6. Maintenance Screen Logo Screen 2.3.5.
  • Page 9 The Force Dual Phase™ Operation Manual I/O (Input/Output) Status Screen 2.3.6. 2.3.6.1. The I/O Status Screen is 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.

  • Page 10: Pre-Cleaning

    2.4.2.1. Apeks takes great care to clean all systems prior to shipping. However, it is the user’s responsibility to ensure that the system meets the required level of cleanliness.

  • Page 11: Opening Extraction Vessel

    The Force Dual Phase™ Operation Manual 2.5. Opening Extraction Vessel 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 trying to open vessel. An Extractor Vessel can only be opened if it is not selected for use and the pressure 2.5.1.
  • Page 12 The Force Dual Phase™ Operation Manual Figure 12. Remove safety pin Rotate the plug inside the closure until the ears on the plug match up to the holes on the 2.5.6. nut, as shown below in Figure 13. Figure 13. Rotate the plug inside the closure until the ears on the plug match up to the holes on the nut Attach chain hoist to eyebolt and carefully raise plug out of the nut (see Figure 14).

  • Page 13: Loading Botanical Material

    The Force Dual Phase™ Operation Manual Figure 14. Removing extractor plug with hoist 2.6. Loading Botanical Material Material to be extracted is loaded directly into the extraction vessel. The supplied funnel 2.6.1. can be used to help minimize spillage. 2.6.1.1. Typically, botanicals perform best in CO extractions when ground to a particle size of about 200 µin, roughly the consistency of coffee grounds.

  • Page 14: Chiller Start Up

    The Force Dual Phase™ Operation Manual Close the vessel by placing the plug back into the nut and rotating until the safety 2.7.3. closure pinhole is in the correct location. Rotate 30 degrees until holes line up Figure 15. Closing Vessel Insert safety closure pin and reattach flexible CO hose, as shown in Figure 16.

  • Page 15: Evacuating The System

    The Force Dual Phase™ Operation Manual Verify coolant flow for both storage and water extractor loops on “I/O Screen.” One is 2.8.4. storage water flow and the other is extractor water flow. 2.9. Evacuating the System (Removing moisture and checking for leaks prior to extraction) Three separate types of evacuation can be performed: 2.9.1.

  • Page 16: Conducting An Extraction

    The Force Dual Phase™ Operation Manual vessel is not closed. Check all connections that have been opened since the last run before proceeding. Close Evacuation Valve. 2.9.10. Turn off the vacuum pump. 2.9.11. Disconnect the vacuum gauge, blue vacuum hose and pump. 2.9.12.
  • Page 17 The Force Dual Phase™ Operation Manual 2.10.7.2. Set the Phase 2 Extractor Target Pressure (between 900psi and 4800psi). This is the pressure that the system will try to achieve while flowing through the other Separator not chosen in Phase 1. 2.10.7.3.

  • Page 18: Automatic Or Manual Flow Reversal

    The Force Dual Phase™ Operation Manual 2.10.13.1. Close the CO cylinder. 2.10.13.2. Open Valve 10A and Valve 10B. Once the operator acknowledges that the CO cylinder is closed and Valve 10A and 2.10.14. Valve 10B are open, the system will open all Valves except 22, 23, 17, 30A, and 30B, vent any trapped CO and wait for the next command.

  • Page 19: Removing Oil From Collection Cup (End Of Run)

    The Force Dual Phase™ Operation Manual 2.14. Removing Oil from Collection Cup (End of Run) 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. Verify that all Separator Vessel gauges and the Separator pressure on the Home 2.14.1.
  • Page 20 The Force Dual Phase™ Operation Manual Figure 20. Illustration of using two wrenches to remove flexible metal lines Remove the yellow wire connected to the Separator #1 and 2 thermocouples. 2.14.3. Use the ″ ratchet wrench to remove the high-pressure sanitary clamps from the top 2.14.4.

  • Page 21: Removing Oil From Collection Cup (During Run)

    The Force Dual Phase™ Operation Manual 2.15. Removing Oil from Collection Cup (During Run) 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. With the three-Separator arrangement, collection and servicing can be done on a 2.15.1.

  • Page 22: Performing Maintenance Between Runs

    The Force Dual Phase™ Operation Manual WARNING Failure to remove hose completely could cause damage or injury if system loses power or air pressure. Use two wrenches to remove hoses, as shown in Figure 20, to prevent tubes from 2.15.5. twisting.
  • Page 23 The Force Dual Phase™ Operation Manual Figure 22. Location of separator line cleanout valve 2.16.3.3. Close Valve 10A and Valve 10B. 2.16.3.4. Go to the “Manual Screen” and select “Clean Sep 1 Tubing” or “Clean Sep 2 Tubing” (both will need to be done). 2.16.3.5.
  • Page 24 The Force Dual Phase™ Operation Manual Clean CO return line to Diaphragm Compressor. 2.16.4. 2.16.4.1. Ensure Valve 11 is open. 2.16.4.2. If Valve 11 isn’t open, then go to the Manual Screen and hit Evacuate. This will open Valve 11 (Evacuate will not appear on "Manual Screen" if any pressure is present in the extraction system.

  • Page 25: Recommended Operating Parameters

    The Force Dual Phase™ Operation Manual 2.16.4.5. Inspect filter element for clogging or wear and replace as necessary. 2.16.4.6. Pour alcohol into the Separator outlet line until the solvent is colorless coming out of the filter. Then, use compressed air to blow out the line, ensuring that no residual alcohol remains in the line between the Separator and the pump.

  • Page 26: System Maintenance

    • Run the system “empty of plant material” for 1 hour to clean the high- Hours pressure side of the system and extraction vessel(s). Yearly • Check torque on all screws in electrical panels (see Appendix G). Apeks online store: http://apeksonlinestore.com/ Resource Revision Date: 4/22/2019...

  • Page 27: Diaphragm Compressor Maintenance

    The Force Dual Phase™ Operation Manual 3.3. Diaphragm Compressor Maintenance See Diaphragm Compressor Manual for specific instructions on maintenance items. Below is general system information. Frequency Maintenance Item • Check oil level. • Check oil pressure. Daily • Listen for abnormal noise or vibration. •...

  • Page 28: Troubleshooting

    • Vent Storage Tanks and Clean (Recommended to vent and clean tanks Yearly anytime run material is changed to prevent cross-contamination) • Check torque on all screws in electrical panels (see Appendix DG). Apeks Online Store Resource http://apeksonlinestore.com/ 4. Troubleshooting 4.1.

  • Page 29: Extractor Overpressure

    The Force Dual Phase™ Operation Manual correct orifice is in the selected Separator and verify that both pumps are functioning correctly. The orifice can be checked by going to the “Manual Screen,” selecting “Service Separator” and following the instructions below: From the Home Screen, press the Manual Screen button.

  • Page 30: High Separator 1 Or 2 Pressure

    The Force Dual Phase™ Operation Manual 4.5. High Separator 1 or 2 Pressure (>350psi) and Low Separator #3 Pressure High Separator 1 or Separator 2 pressure can be cause by excess oil, dry ice or a valve not functioning correctly. Follow the steps below to clean lines between the Separators: From the Home Screen, press the Manual Screen button.

  • Page 31: References

    The Force Dual Phase™ Operation Manual 5. References YouTube Instructional Videos https://www.youtube.com/user/ApeksSupercritical Apeks online store (740) 809-1160 option 2 http://apeksonlinestore.com/ Software Updates and E-mail Alerts (740) 809-1160 option 2 http://www.apekssupercritical.com/service/ Revision Date: 4/22/2019...

  • Page 32: Appendices

    The Force Dual Phase™ Operation Manual 6. Appendices 6.1. Appendix A - Belt Tension Testing/Adjustment Refer to our YouTube video: https://youtu.be/JUTNsP8vows 6.1.1. Remove belt guard. Figure A1: Belt Guard Check belt(s) tension with belt tension tester. PDC-4 belts should be tensioned to 10 6.1.2.
  • Page 33 The Force Dual Phase™ Operation Manual Figure A3: Bolts holding the motor to the base Before moving the motor, retighten the bolts to finger tight (this keeps the motor from 6.1.4. lifting up on one side during adjusting due to the belt tension) See Figure A3. Alter the adjustment bolts on the motor base in or out to tighten or loosen the bolt as 6.1.5.
  • Page 34 The Force Dual Phase™ Operation Manual Be sure to check motor shaft alignment (Note: There can be up to ″ difference from 6.1.6. side-to-side). Figure A5: Check motor shaft alignment Retighten motor bolts. 6.1.7. Rotate belt by hand around one turn (failure to do so could result in incorrect reading). 6.1.8.

  • Page 35: B: Diaphragm Pump Priming

    The Force Dual Phase™ Operation Manual 6.2. Appendix B - Diaphragm Pump Priming Figure B1. Open the over pump bypass valve Open the over pump bypass valve (see Figure B1) by turning counterclockwise until it 6.2.1. stops. Go to the Manual Screen on the HMI and hit the “Start Prime Compressor” button. 6.2.2.

  • Page 36: C: Check Valve Cleaning

    Do not clean the poppet (brown donut) in the ultrasonic cleaner. If poppet is beyond cleaning or damaged contact Apeks for a replacement. Reassemble checks when cleaned and assemble in pump.
  • Page 37 The Force Dual Phase™ Operation Manual Poppet Springs Figure C2. Components of check valve Figure C3. Suction check valve Revision Date: 4/22/2019...
  • Page 38 The Force Dual Phase™ Operation Manual Figure C4. Discharge check valve Revision Date: 4/22/2019...

  • Page 39: D: Piping And Instrumentation Diagrams

    The Force Dual Phase™ Operation Manual 6.4. Appendix D – Piping and Instrumentation Diagrams Revision Date: 4/22/2019...

  • Page 40: E: Co 2 Phase Diagram

    The Force Dual Phase™ Operation Manual 6.5. Appendix E – CO2 Phase Diagram Revision Date: 4/22/2019...

  • Page 41: 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 42 The Force Dual Phase™ Operation Manual o Future maintenance will require: Shop vacuum with a long, slim nozzle for removing material from extractor. Pencil Type Belt Tension Tester: http://apeksonlinestore.com/product/tension-tester/ 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 43: G: Electrical Screw Torque Requirements

    The Force Dual Phase™ Operation Manual 6.7. 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.

This manual is also suitable for:

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