Apeks TRANSFORMER 2000PSI Installation guide

Revision date: 04/09/2019 © Apeks LLC 2019

THE TRANSFORMER

TM

2000PSI

THE BAMBINO

TM

i2000PSI

BOTANICAL OIL EXTRACTION SYSTEM

INSTALLATION MANUAL

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

844-446-4262, option 2

service@apekssupercritical.com

www.apekssupercritical.com

Scan this QR code to get

the most recent version of

the installation instructions.

Installation Manual: The Bambino™ and The Transformer™

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Revision Date 4/9/2019

Table of Contents

Section Page #

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

2. Before the System Arrives ........................................................................................................................... 4

2.1. System Overview .................................................................................................................................. 4

2.1.1. Diaphragm Compressor ............................................................................................................. 6

2.1.2. Extraction System ...................................................................................................................... 7

2.2. General System Specifications ............................................................................................................. 9

2.3. Electrical Requirements ....................................................................................................................... 9

2.4. Facility Requirements ......................................................................................................................... 10

2.4.1. Temperature ............................................................................................................................ 10

2.4.2. Ventilation and Dust Control .................................................................................................... 10

2.4.3. Foundation .............................................................................................................................. 10

2.4.4. CO

2

Vent ................................................................................................................................. 10

3. When the System Arrives .......................................................................................................................... 11

3.1. Receiving the Crates .......................................................................................................................... 11

3.1.1. Apeks Labelling ....................................................................................................................... 11

3.1.2. TiltWatch ................................................................................................................................. 11

3.1.3. Inspecting Crates for Damage ................................................................................................. 11

3.2. Unpacking Instructions ........................................................................................................................ 12

3.2.1. Uncrating Extraction System .................................................................................................... 12

3.2.2. Uncrating Diaphragm Compressor ........................................................................................... 13

3.2.3. Uncrating the Chillers ............................................................................................................... 14

3.2.4. Verifying Apeks Shipper ........................................................................................................... 14

3.3. System Set Up .................................................................................................................................... 15

3.3.1. Layout/Footprint ...................................................................................................................... 15

3.3.2. Coolant Line and Chiller Setup ................................................................................................. 16

3.3.3. CO

2

Connections ...................................................................................................................... 16

3.3.4. CO

2

Vent Connections .............................................................................................................. 18

3.3.5. Air Connection ......................................................................................................................... 18

3.3.6. Electrical Connections .............................................................................................................. 19

3.3.7. Email Alerts and Software Updates .......................................................................................... 21

4. Pre-Training Checklist................................................................................................................................ 24

5. References ............................................................................................................................................... 25

6. Appendices ............................................................................................................................................... 26

6.1. Appendix A – System Layouts ........................................................................................................... 26

6.2. Appendix B – Torque Requirements .................................................................................................. 32

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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

2

, potentially causing

equipment damage or harm to workers.

WARNING

Subcritical and Supercritical CO

2

systems operate under high pressure. Operators must be fully trained and

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

injury.

WARNING

Subcritical and Supercritical CO

2

systems use large amounts of CO

2

during operation. Ensure that the system

is installed in a well-ventilated area to prevent buildup of CO

2

, which can cause asphyxiation. Always use a CO

2

monitor to ensure safe operations.

WARNING

Opening a vessel under pressure can result in a rapid release of pressure and ejection of material from 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 gauge reads zero prior to loosening the vessel closure.

WARNING

Subcritical and Supercritical CO

2

systems are designed to operate indoors, in a temperature-controlled

environment. Extreme temperatures (below 60°F and above 80°F) will negatively impact the functionality of the

system. The environmental temperature range applies to the system, chiller, pump and CO

2

bottles.

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

Extraction system components can weight in excess of 2000lbs and need to be moved carefully. Never attempt

to move system pieces without the proper equipment, failure to do so could result in serious injury or death.

WARNING

Always wear safety glasses when operating and servicing the system.

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2. Before the System Arrives

2.1. System Overview

Diaphragm Compressor

Chiller

Extraction System

Figure 1: Overhead view of standard layout

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Main Control

Enclosure

HMI

Fork Pockets

Bottle Stand

Figure 2: Front view of standard layout

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2.1.1. Diaphragm Compressor

CO

2

Outlet

CO

2

Inlet

Junction Box

Regenerative

Heat

Exchanger

Leak Detect

Oil Heat

Exchanger

Pump Motor

Oil Pressure

and Filter

Figure 3: Diaphragm compressor

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2.1.2. Extraction System

Extractor

B

Extractor

A

Temperature

Control Heat

Exchanger

Flow Switch

Separator

1 2

E-Stop

Evacuation Valve

Collection Cup

Control Panel Mount

Bottle

Connection 2

Figure 4: Extraction vessels, separation vessels, and control panel

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Vent Valve

Separator Filter

Extractor Filter

CO

2

Inlet

CO

2

Outlet

Bottle

Connection 1

Motor Starter

Enclosure Mount

Air Manifold

Mount

Air Inlet

Connection

Figure 5: Rear view of standard layout

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2.2. General System Specifications

Extraction

Stand

Diaphragm

Compressor

Separator

Chiller

Air

Compressor

Max

Pressure

(psi)

2000psi 2000psi 100psi 125psi

Operating

Temperature

(°F)

40°F - 160°F 75°F - 250°F 20°F - 150°F 60°F - 80°F

Dimensions

(in)

WxDxH

68x42x78 50x33x62 19x30x39 14x24x18

Weight (lbs)

1250lbs

2750lbs

450lbs

80lbs

NOTE: Weights and Dimensions are for largest system. See Appendix A for specific system dimensions.

2.3. Electrical Requirements

The Bambino™

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The Transformer™

WARNING

Do not Modify Power Connections

2.4. Facility Requirements

2.4.1. Temperature – The system is designed to run in a climate-controlled facility, where the

temperature is maintained between 60°F and 80°F.

2.4.2. Ventilation and Dust Control – Apeks systems should be placed in a well-ventilated

environment that is free from excess dust from other manufacturing operations.

2.4.3. Foundation – Apeks systems are designed to be installed on a concrete (or similarly stable) flat

floor.

2.4.4. CO

2

Vent – Customer is responsible for running rigid tubing from system outlet to a safe vent

location. (NOTE: Vent lines should be rated to the pressure of the system. 3/8" x.035 or

1/2" x.049 stainless steel tubing recommended. Contact Apeks for part recommendation if

necessary.)

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3. When the System Arrives

3.1. Receiving the Crates

3.1.1. Apeks Labeling – Look for an Apeks sticker on the outside of each crate to verify it came

directly from Apeks without being tampered with. See Figure 1. Note: If no sticker is found, open

crate to verify no damage has occurred during shipping.

3.1.2. TiltWatch – Locate the TiltWatch Plus sensors on the outside of the crate, as shown in Figure

2. 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 (740) 809-1160.

3.1.3. Inspecting Crates for Damage – Prior to opening the crate(s), verify that there is no external

damage. If damage is found, do not accept delivery from the shipping company without noting

any damage on Proof of Delivery. In addition, call Apeks at (740) 809-1160 to report damage

and start the reporting process with the shipping company.

Figure 1: Shipping label

Figure 2: TiltWatch label

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3.2. Unpacking Instructions

WARNING

Heavy Components. Do not attempt to lift without the proper equipment.

3.2.1. Uncrating the Extraction System

3.2.1.1. Tools Needed: Drill with Philips head bit, pry bar and hammer.

3.2.1.2. Remove the sides and top of the shipping crate.

3.2.1.3. Remove the wooden tie downs that keep the system attached to the skid. See Figure 3.

3.2.1.4. Carefully use a forklift to remove the stand from the skid and attach the four leveling feet to

each stand. See Figure 4.

3.2.1.5. Once the system is on the ground use these feet to get the system level and then snug the

jam nut against the stand to secure the feet.

Wood Tie-Downs

Jam Nut

Figure 3: Wood Tie-Downs

Figure 4: Leveling Feet

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3.2.2. Uncrating the Diaphragm Compressor

3.2.2.1. Remove the sides and top of the shipping crate.

3.2.2.2. Remove lag screw/bolts that keep the pump attached to the skid. See Figure 5.

3.2.2.3. Carefully use a forklift to remove the pump from the skid and attach the four rubber

vibration dampening feet to the four corners of the pump. See Figure 6.

Figure 5:

Diaphragm pump on skid

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3.2.3. Uncrating the Chillers

3.2.3.1. Remove the sides and top of the shipping crate.

3.2.3.2. Remove the wooden blocks holding the chiller to the base.

3.2.3.3. Use a forklift or the provided ramp to remove the chiller from the base.

3.2.3.4. When chiller is in final location, lock the wheels.

3.2.4. Verifying Apeks Shipper – Every Apeks machine is sent with a shipper that will contain quality

control checklist and a packing slip. Verify that all items on the packing slip (example below)

have been received. Contact Apeks if there are items missing.

Figure 6:

Vibration Dampening Feet

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3.3. Set Up and Assembly

3.3.1. Layout/Footprint – For specific model footprint see Appendix A.

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3.3.2. Coolant Line and Chiller Set Up

3.3.2.1. Coolant Loop Set Up – The coolant loop incorporates all components of the system and

is used to transfer or remove heat from the system. Coolant flow is always from the bottom

of a vessel to the top of a vessel.

3.3.2.1.1. Chiller Outlet to Regenerative Heat Exchanger – Connect the hose attached to

the regenerative heat exchanger to the chiller outlet.

3.3.2.1.2. Flow Switch to Oil Heat Exchanger – Connect the hose attached to the Flow

switch at the top of the extractor vessel (extractor vessel a on two extractor systems)

to the oil heat exchanger on the diaphragm compressor.

3.3.2.1.3. Diaphragm Compressor to Separator Cup – Connect the hose attached to the

regenerative heat exchanger to the hose coming from the bottom of the collection

cup (should be a quick connector).

3.3.2.1.4. Separator #2 to Chiller Inlet – Connect the hose coming from the top of separator

#2 to the chiller inlet.

3.3.2.2. Initial Fill – This step will need to be performed after the chillers electrical connection has

been made and the chiller is connected to the main control enclosure. (See Electrical

Requirements section 2.3.)

3.3.2.2.1. Once the water line connections and electrical connections have been made, fill the

chiller reservoir with 95/5 mix of water/propylene glycol.

3.3.2.2.2. Start the chiller.

3.3.2.2.3. Continue to fill the chiller reservoir with the same fluid mix as the chiller pump fills the

system with fluid.

3.3.2.2.4. Once the reservoir has stopped receding, top off reservoir and allow the chiller to

continue to run checking its level for the first five to ten minutes.

3.3.2.2.5. Once the chiller has run for this time, the chiller is ready to run and can be turned off

until the system is ready to run.

WARNING

CO

2

in the system or bottles is under high pressure. Use proper handling and storage as well as

making sure all connections are tight before running the system to avoid damage or severe injury.

3.3.3. CO

2

Connections – There are three CO

2

lines to be connected on the system, two between the

extraction stand and the diaphragm compressor and the bottle connections.

3.3.3.1. Extraction Stand to Diaphragm Compressor – These connections are two 36" long

black nylon flexible line with ½" compression fittings on either end. One hose will have

female connections and the other will have male connections. Refer to the images in

section 2.1 and match the extraction systems CO

2

out let to the diaphragm pumps CO

2

inlet and vice versa. See Figure 7.

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3.3.3.2. CO

2

Bottle Connections – There are two different sets of CO

2

bottle connections. One set

(consisting of two bottle connections) is used to both supply CO

2

to the system and are

intended to be recovered back into. The other set (one bottle connection) is intended only

to supply the system with any additional CO

2

needed, no CO

2

will be recovered into this

bottle. Supplied hoses should be connected directly to the CO

2

cylinder valves. No

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

between the hose and the CO

2

cylinder. See Figure 8.

PUMP

INLET

PUMP

OUTLET

Figure 7: Extraction Stand to Diaphragm Compressor hook up

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3.3.3.2.1. CO

2

Supply and Recovery Bottles (Bottle Connection 1)– The connection for

these bottles is located underneath the main control enclosure towards the back of

the systems as seen in Figure 8. This is a double hose connection shipped with the

extra system material.

3.3.3.2.2. CO

2

Supply Bottle Only (Bottle Connection 2) – The connection for this bottle is

located on the diagonal support as seen in Figure 8. This is a single hose connection

shipped with the extra system material.

3.3.3.2.3. CO

2

Bottles – CO

2

used with the Apeks systems should be 99% purity or better

(Medical, Food or Instrument grade typically suffice), gas feed (not liquid feed/dip

tube), 50lb, 75lb or 100lb high pressure cylinders.

3.3.4. CO

2

Vent Connection – Apeks extraction systems come with rigid vent tubing all connected to

one outlet located near underneath the Motor Starter Enclosure. The customer is responsible for

running this vent line to desire location in build and should use material rated to the pressure of

the system (⅜" x.035 or ½" x.049 stainless steel tubing recommended). Connection is a ⅜"

Swagelok compression fitting.

3.3.5. Air Connections – There are air operated ball valves that are used to control the CO

2

flow path

throughout the system. These valves are controlled by an air manifold on the back of the control

panel mount.

3.3.5.1. Air Manifold – The air manifold receives electrical signals from the controller and uses

compressed air to open valves.

3.3.5.2. Supply Air from Compressor – Each system comes with a small air compressor used to

supply the approximately 120psi needed to control the air operated ball valves, cup lifts

and air nozzle used for cleaning. This air compressor is connected with a

5

/

16

" red air line

four feet long which is supplied in the accessories box. The connection on the system is

located between the motor starter enclosure and bottle mount. See Figure 9.

Bottle

Connection 1

Bottle

Connection 2

Separators

Figure 8: CO

2

bottle connections

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3.3.6. Electrical Connections

3.3.6.1. Connection between Motor and Motor Starter Enclosure – Connect the diaphragm

compressor motor wires to the motor enclosure on the back of the Apeks system as shown

in Figure 11 by inserting labeled wire T1 to the bottom T1 of the motor starter, T3 to T3,

and ground wire to the ground terminal on the din rail immediately to the left of the motor

starter. NOTE: 3 Phase motors require a wire termination in T2 as well. Refer to Appendix

B for torque requirements.

Figure 9: Air line connection

Figure 10:

Electrical connection panel

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3.3.6.2. Connection between Diaphragm Junction Box and Motor Starter Enclosure – Insert

the conduit coming from the junction box on the pump into the receptacle on the left of the

motor enclosure on the back of the system. Terminate the wires in the bundle that are

labeled into the terminal block opposite of the wires with the same number as seen in

Figure 12 .

Figure 11:

Motor starter enclosure

Figure 12:

Electrical panel

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