Apeks 2000PSI THE DUPLEX Installation Manual

©Apeks, LLC 2019 THE DUPLEX TM 2000PSI 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 740-809-1160 [email protected] www.apekssupercritical.com Scan this QR code to get the most recent version of the installation instructions.

2 Revision Date 04/11/2019 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 ............................................................................................................. 5 2.1.2. Extractor Vessel Stand ............................................................................................................... 6 2.1.3. Separator Vessel/Control Stand ................................................................................................. 7 2.2. General System Specifications ............................................................................................................. 8 2.3. Electrical Requirements ....................................................................................................................... 8 2.4. Facility Requirements ......................................................................................................................... 10 3. When the System Arrives .......................................................................................................................... 10 3.1. Receiving the Crates .......................................................................................................................... 10 3.2. Unpacking Instructions ........................................................................................................................ 11 3.3. Set Up and Assembly ......................................................................................................................... 15 3.3.1. Layout/Footprint ...................................................................................................................... 15 3.3.2. Coolant Line and Chiller Setup ................................................................................................. 15 3.3.3. CO2 Connections ...................................................................................................................... 16 3.3.4. CO2 Vent Connections .............................................................................................................. 18 3.3.5. Air Connection ......................................................................................................................... 18 3.3.6. Electrical Connections .............................................................................................................. 20 3.3.7. Chillers ..................................................................................................................................... 21 3.3.8. Email Alerts and Software Updates .......................................................................................... 22 4. Pre-Training Checklist................................................................................................................................ 23 5. References ............................................................................................................................................... 24 6. Appendices ................................................................................................................................................ 25 6.1. System Layouts .................................................................................................................................. 25 6.2. Torque Requirements ......................................................................................................................... 29

3 Revision Date 04/11/2019 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 CO2, potentially causing equipment damage or harm to workers. WARNING Subcritical and Supercritical CO2 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 CO2 systems use large amounts of CO2 during operation. Ensure that the system is installed in a well-ventilated area to prevent buildup of CO2, which can cause asphyxiation. Always use a CO2 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 CO2 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 CO2 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 weigh 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.

4 Revision Date 04/11/2019 2. Before the System Arrives 2.1. System Overview Duplex Diaphragm Compressor Separator Chiller Extractor Chiller Extractor Vessel Stand Separator Vessel Stand Figure 1: Overhead view of standard layout (Duplex 2000-20Lx20LDU)

5 Revision Date 04/11/2019 2.1.1. Diaphragm Compressor Main Control Enclosure HMI CO2 Outlet CO2 Inlet Junction Box Regenerative Heat Exchangers Fork Pockets Figure 2: Front view of standard layout (Duplex 2000-20Lx20LDU) Figure 3: Diaphragm Compressor

6 Revision Date 04/11/2019 2.1.2. Extractor Vessel Stand Extractor B Extractor A Temperature Control Heat Exchanger Flow Switch Figure 4: Extraction Vessels on Extraction Stand

7 Revision Date 04/11/2019 2.1.3. Separator Vessel/Control Stand Bank 1 Bank 2 E-Stop Evacuation Valve Vent Valve Flow Switch Collection Cup Water Valves Cup Lift Control Panel Mount Figure 5: Extraction Vessels and Control Panel

8 Revision Date 04/11/2019 2.2. General System Specifications Extraction Stand Separation/ Control Stand Diaphragm Compressor Extractor Chiller Separator Chiller Air Compressor Max Pressure (psi) 2000psi 2000psi 2000psi 100psi 100psi 125psi Operating Temperature (°F) 40°F - 160°F 40°F - 160°F 75°F - 250°F 20°F - 150°F 20°F - 150°F 60°F - 80°F Dimensions (in) WxDxH 58x42x77 53x36x84 74x37x68 25x34x53 19x30x39 14x24x18 Weight (lbs) 1000 lbs 750 lbs 4500 lbs 500 lbs 450 lbs 80 lbs 2.3. Electrical Requirements Figure 6: Electrical Requirements for Duplex with two Indoor Chillers

9 Revision Date 04/11/2019 WARNING Do not Modify Power Connections Figure 7: Electrical Requirements for Duplex with one Outdoor Chillers

10 Revision Date 04/11/2019 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 – The system 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. Modulation – Apeks Duplex systems are designed to be able to be located in different rooms or area to isolate different portion of the process. This modulation should be stated during the purchase process or additional costs and delays may occur. 2.4.5. CO2 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. ⅜" x.035 or ½" x.049 stainless steel tubing recommended. Contact Apeks for part recommendation if necessary.) 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 tampering. See Figure 1. Note: If no sticker is found, open crate to verify no damage has occurred during shipping. Figure 1: Shipping Label

11 Revision Date 04/11/2019 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. 3.2. Unpacking Instructions WARNING Heavy Components. Do not attempt to lift without the proper equipment. 3.2.1. Uncrating the Extractor Stand and Separator/Control Stand 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. Figure 2: TiltWatch Label

12 Revision Date 04/11/2019 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

13 Revision Date 04/11/2019 3.2.2. Uncrating the Diaphragm Compressor 3.2.2.1. Remove the sides and top of the shipping crate. See Figure 5. 3.2.2.2. Remove lag screw/bolts that keep the pump attached to the skid. 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 Figure 6: Vibration Dampening Feet

14 Revision Date 04/11/2019 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.

15 Revision Date 04/11/2019 3.3. Set Up and Assembly 3.3.1. Standard Layout/Footprint with Indoor Chiller 3.3.2. Coolant Line and Chiller Set Up 3.3.2.1. Separator Coolant Loop – The separator coolant loop will incorporate the Separator Chiller, the diaphragm compressor and the Separator Vessel/Control Stand. 3.3.2.1.1. Chiller Outlet to Diaphragm Compressor – The hose on the chiller outlet will connect to the oil heat exchanger on the diaphragm pump. 3.3.2.1.2. Diaphragm Compressor to Separator Stand – The hose coming from the brass tee on the diaphragm compressor will connect to the water valve with the flow switch on the separator stand. 3.3.2.1.3. Separator Stand to Chiller Inlet – The hose on the chiller outlet will connect to the water valve without the flow switch on the separator stand. 3.3.2.2. Extractor Coolant Loop – The extractor coolant loop will incorporate the Extractor Chiller and the Extractor Vessel Stand. 3.3.2.2.1. Chiller Outlet to Extractor Stand – The hose on the chiller outlet will connect to the temperature control heat exchanger on the extractor stand. 3.3.2.2.2. Extractor Stand to Chiller Inlet – The hose on the chiller inlet will connect to the flow switch on the extractor stand. 3.3.2.3. 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, page 21.) Figure 7: Standard Layout/Footprint with Indoor Chiller

16 Revision Date 04/11/2019 3.3.2.3.1. Once the water line connections and electrical connections have been made, fill the chiller reservoir with 95/5 mix of water/propylene glycol. 3.3.2.3.2. From the manual screen, start the desired chiller. 3.3.2.3.3. Continue to fill the chiller reservoir with the same fluid mix as the chiller pump fills the system with fluid. 3.3.2.3.4. Once the reservoir has stopped receding, top off reservoir and allow the chiller to continue to run as the chiller pump primes. 3.3.2.3.5. This priming should continue until the pressure in the chiller reaches operational level: 45psi for the extractor chiller, 78psi for the separator chiller. Note: if chiller over pressurizes, partially close the ball valve on the back of the chiller to reduce pressure to the operating pressure. 3.3.2.3.6. As the pressure increases the reservoir level may decrease so top off as necessary. 3.3.2.3.7. Once the chillers are up to pressure, the extractor chiller is ready to run and can be turned off. 3.3.2.3.8. The separator chiller loop will need separator bank 2 filled with fluid 3.3.2.3.8.1. Go to the manual screen and click the “Fill Separator Bank 2 WATER” button. Note: If this button does not appear on the screen click on the “Manual Mode” button. 3.3.2.3.8.2. As the pump fills the second separator bank the reservoir will need to be filled again and the pump may need to re-primed if the pressure drops. 3.3.3. CO2 Connections – There are four CO2 lines to be connected on the Duplex system, two between the Extractor and Separator Stands and one each between those stands and the Diaphragm Compressor. 3.3.3.1. Separator Vessel Stand to Diaphragm Compressor – This connection is a 36" long stainless steel braided flexible line with ¾" compression fittings. Figure 8: Separator Stand to Compressor

17 Revision Date 04/11/2019 3.3.3.2. Diaphragm Compressor to Extractor Vessel Stand – This connection is a 36" long black nylon flexible line with ½" compression fittings. 3.3.3.3. Extractor Vessel Stand to Separator Vessel Stand – These connections are 18" long stainless steel braided flexible lines with 3/8" compression fittings. Connect 1 and 2 on the extractor stand to 1 and 2 on the separator stand respectively. 1 2 Figure 9: Diaphragm Compressor to Extraction Vessel Figure 10: Extraction Vessel Stand to Separator Vessel

18 Revision Date 04/11/2019 3.3.4. CO2 Vent Connection – Apeks extraction systems come with rigid vent tubing all connected to one outlet located near Valve 0 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 (3/8" x.035 or ½ " x.049 stainless steel tubing recommended). Connection is a 3/8" Swagelok compression fitting. 3.3.5. Air Connections – There are over twenty-five air operated ball valves that are used to control the CO2 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. See Figure 12. 1 2 Figure 11: Vent Connection Figure 12: Manifold Air ouputs

19 Revision Date 04/11/2019 3.3.5.2. Separator Vessel Stand to Extractor Vessel Stand – There are thirteen ¼" red airlines that run between the separator and extractor stand. These lines are connected with a push-to-connect coupling and labeled on both sides. Fully insert the tubing into the coupling to connect. See Figure 13. 3.3.5.3. Separator Vessel Stand to Diaphragm Compressor – There is one ¼" red airline that runs between the separator stand and the diaphragm compressor. This line is connected with a push-to-connect coupling and labeled on both sides. Fully insert the tubing into the coupling to connect. See Figure 14. Figure 13: Airline connections Figure 14: Airline connection to Compressor

20 Revision Date 04/11/2019 3.3.6. Electrical Connections 3.3.6.1. Harting Connector – This connector carries all the signals from the pressure transducers, flow switches, etc. back the main control enclosure (excluding the thermocouples). These are quick connecting electrical connections that plug in and are secured with snaps on each side as seen in Figure 15. 3.3.6.2. Thermocouple Connector – This connector carries the signal from the thermocouples back the main control enclosure. This connector is a plug style connection as seen in Figure 16. 3.3.6.3. Separator Vessel Stand to Extractor Vessel Stand 3.3.6.3.1. Junction Box 3 (Extractor B Side) 3.3.6.3.1.1. Harting Connector #1214CBL1. 3.3.6.3.1.2. Thermocouple Connector #1709CBL1. 3.3.6.3.1.3. Thermocouple Connector #1809CBL1. 3.3.6.3.2. Junction Box 2 (Extractor A Side) 3.3.6.3.2.1. Harting Connector #1511CBL2. 3.3.6.3.2.2. Thermocouple Connector #1805CBL1. 3.3.6.4. Separator Vessel Stand to Diaphragm Compressor (Junction Box 1) 3.3.6.4.1. Harting Connector #1209CBL1. 3.3.6.4.2. Thermocouple Connector #1705CBL1. Figure 15: Harting Connector Figure 16: Thermocouple Connector

21 Revision Date 04/11/2019 3.3.6.5. Diaphragm Compressor Motor Wiring – The wiring for the motor on the diaphragm compressor terminates in the bottom of the motor starter shown in Figure 17. These three wires should be labeled T1, T2 and T3 and should be terminated in the respective locations. The wiring coming from the top of the motor starter will be terminated to the facility power. 3.3.7. Chillers 3.3.7.1. Communication Cable – Each chiller is connected to the main control enclosure by a 15- pin connector shown in Figure 18. The cable will be labeled EXT Chiller or SEP Chiller. 3.3.7.2. Power – The chiller is terminated to the facility power by customer supplied wiring, terminated to the chiller power box on the back-left hand side of the chiller. See Figure 19. Figure 17: Motor Starter on Control Panel Figure 18: Communication Cable

22 Revision Date 04/11/2019 3.3.8. Email Alerts and Software Updates 3.3.8.1. The Apeks systems should be connected to the internet via an Ethernet cable. Connecting the Apeks system to the internet allows for software updates, and email alerts. 3.3.8.2. Attach an Ethernet cable to the Ethernet connection located on the side of the electrical control box. 3.3.8.3. For email alerts, setup a designated email to be used only for the Apeks system. The Apeks system will then send messages to a designated email, and then this email will send messages to any person’s phone numbers you decide to forward messages to. 3.3.8.4. After connecting the system to the internet via an Ethernet cable, and after the designated email for the system has been set up, please go to http://www.apekssupercritical.com/customer-support/service-request/ and submit a ticket with the systems information and an Apeks representative will be in touch. 3.3.8.5. After setting up the system for email alerts, the operator can then decide what notifications to receive. 3.3.8.5.1. Click on the “Message Screen.” See Figure 20. 3.3.8.5.2. From this screen choose the messages to receive. Power Box Figure 19: Chiller Figure 20: Message Selection Screen

23 Revision Date 04/11/2019 4. Pre-Training Checklist In preparation for training, please refer to the installation manual for unpacking and set up instructions. Below is a checklist of what needs to be purchased or completed BEFORE scheduling your onsite training. Onsite training is a four hour block of instruction that is NOT designed to include unpacking and set up. Incomplete items at the time of onsite training will result in incomplete training or additional charges for rescheduling. Our training process is as follows: 1. Customers to reference the installation manual for instructions on un-crating and system set up. 2. Customer to complete entire Pre-Training Checklist. 3. A FaceTime or Skype session is required (when available) to ensure checklist is complete, set up is correct and to cover basic operation and cleaning of the system. 4. After 1 through 3 are complete, onsite training can be scheduled. There will be a 2-3 week lead time. Pre-Training Checklist: Below is a checklist of what needs to be purchased or completed BEFORE scheduling your onsite training. o Must be complete before scheduling training: Print complete operational 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 its location of operation. Refer to unpacking instructions in the installation manual. o Must be complete before scheduling training: See installation manual for electrical requirements of your system. All electrical connections are to be completed before onsite training is scheduled. o Must be complete before scheduling training: Purchase and have on site for training: o Bottles of CO2, gas feed, check valve free, food grade or better. Minimum requirements are: o (4) 75 lb. bottles for 20Lx20LD o 4x20LD – to be determined o Distilled water and Propylene glycol 95/5 mix; Propylene Glycol - 1 Gallon o Total Gallons of mixture needed for system: o 9 gal for indoor chiller o Minimum of 55 gallon barrel for outdoor chiller – check with the service department: (740) 809-1160 option 2 o 190 or higher proof ethanol 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 CO2 Monitor; Amprobe CO2 100

24 Revision Date 04/11/2019 o Material to be extracted must be very dry and ground to the consistence of coffee grounds. Have ready the day of training. o After completing the pre-training checklist, request scheduling of onsite training via our website: http://www.apekssupercritical.com/training/ o Onsite training is generally a four hour block of instruction that will go into detail the fundamentals of operation and maintenance of each component of the system. 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/

25 Revision Date 04/11/2019 6. Appendices 6.1. Appendix A – System Layouts The Duplex™ – 2000-20Lx20LDU: Standard Layout

26 Revision Date 04/11/2019 The Duplex™ – 2000-20Lx20LDU: CGMP Layout

27 Revision Date 04/11/2019 The Duplex™ – 2000-4x20LDU: Standard Layout

28 Revision Date 04/11/2019 The Duplex™ – 2000-4x20LDU: with External Chiller Layout

29 Revision Date 04/11/2019 6.2. Appendix B – 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. Ground Block Middle Screw (1492-JG4) = 7.1 lb-in 6. JG10 Large Ground Blocks (1492-JG10) = 20.4 lb-in 7. JG10 Large Ground Block Middle Screw (1492-JG10) = 8.9 lb-in 8. Small Motor Contactor Phillip Screws (100-C55D10) = 31 lb-in 9. Small Motor Contactor (43-44) Phillip Screws = 13 lb-in 10. Overload Relay (T1/T2/T3) Phillip Screws = 22 lb-in 11. Overload Relay (95-98) Phillip Screws = 5 lb-in 12. Large Motor Contactor Allen Screws (100-C72D10) = 53 lb-in 13. Large Motor Contactor Phillips Screws (100-C72D10) = 13 lb-in 14. Overload Relay Allen Screws (193-EEGE) = 40 lb-in 15. Overload Relay Phillips Screws (192-EEGE) = 5 lb-in 16. Micro 850 Power Supply = 4.4 lb-in 17. Micro 850 Terminal Strip = 4.4 lb-in 18. 2080 TC2 = 2.21 lb-in 19. 2080 IF4 = 2.21 lb-in 20. 2080 IF2 = 2.21 lb-in 21. HMI = 5 lb-in 22. Yellow Terminal Jumpers = 7.1 lb-in 23. Estop Contact (800F-X01) = 8 lb-in 24. Relay Base Screws (700-HN153) = 7 lb-in 25. IF8 = 5.3 lb-in 26. Relay Output Module = 5.3 lb-in 27. 10A Circuit Breaker (18 AWG) = 13.3 lb-in 28. 10A Circuit Breaker (14 AWG) = 17.7 lb-in 29. 10A Circuit Breaker (8 AWG) = 39.9 lb-in 30. Ewon Flexy Power Connector = 7 lb-in 31. Ewon Cosy Power Connector = 7 lb-in 32. 125V Plug = 12 lb-in