XpressFill XF4100 User manual
XpressFill XF4100 / XF2100
Congratulations on the purchase of your XpressFill Bottle filling machine.
Thank you for choosing our handcrafted bottle filler as the technology to bottle your passion. We look forward to
assisting you in experiencing the best performance from your filler.
This manual is written with your safety and convenience in mind. We highly recommend reading the manual before
using your filler for the first time.
If you have any questions or comments, please do not hesitate to contact us.
XpressFill Systems LLC
265 Prado Road, Suite 1
San Luis Obispo, CA 93401
US
805.541.0100
Toll free 844.361.2750
www.xpressfill.com
Important Safety Instructions
Misuse of the bottle-filling machine can result in serious injury or death. Do not use the machine in any way not
covered in this manual or for any purpose other than those explained in the following pages.
Severe product damage and/or injury could result from the use of unqualified Service Technicians or non-original
replacement parts. All repairs must be performed by a qualified Service Technician or with the approval from an
XpressFill Technician. Only original factory replacement parts should be used.
Electrical shock or fi re could result if the electrical supply for the bottle filler covered in this manual is not correctly
installed or if the bottle filler has been improperly grounded. Do not use the bottle filler covered in this manual
unless you are certain the electrical supply has been correctly installed and the bottle filler has been properly
grounded.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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Safety Warnings
Table of Contents
1Introduction
2Set Up Your Filler
3Options
4Troubleshooting
5Cleaning Your Filler
6Additional Information
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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1
Introduction
XpressFill Product Guarantee
We guarantee our products to be free of defects in materials and workmanship. The filler will be repaired or replaced
if, upon inspection at the factory, the filler is found to be defective in materials or workmanship.
This guarantee does not apply to damage resulting from normal wear and tear, accident, abuse, negligence or
shipping. The guarantee may be rendered invalid if the customer has made repairs or alteration to the machine
without first consulting XpressFill Systems LLC.
2
Set Up Your Filler
The level filler uses a self-priming pump. Due to small flow passages and precision components in the filler, it is
important to filter your product so you do not introduce particulates into the machine. Failure to filter your product
can result in damage to your bottle filling machine. In most cases, the filler can be cleaned by the customer.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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Unscrew the adjustable knobs holding the shelf to the
machine. Plug the shelf’s electrical connector into the side
of the filler (shown with optional gas sparge above the shelf
connector).
Unpack the filler from the box. Place is on a flat surface where
you plan to bottle.
Tip: To get familiar with your filler, you may want to initially
test it with water.
Plug the filler into a wall outlet. Turn on the Power
Switch. DO NOT turn on the Pump Switch at this time.
To set the fill height of your machine, you will need to
fill one bottle by hand to your desired level.
NOTE: If your machine has the gas sparge option, make
sure the gas supply is turned off as you adjust the shelf.
•Slide the filled bottle onto any of the four spouts and
place the bottle on the shelf if equipped with the gas
option. The green light will take a few seconds to
illuminate as the purge cycles operates without gas
connected.
•While holding the shelf, loosen the adjustable knobs
on either side so the shelf moves freely.
•Slowly raise the shelf until the green light goes off.
Once that light goes off, you know you have found
the height to set the shelf for bottling.
•Note which holes on the side of the machine are
aligned between the filler body and the adjustable
shelf. Install the knobs to hold the shelf in place.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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Snap the transfer kit onto the machine with the quick
connector after lightly lubricating the connector with
water. Place the free end of the hose/rod into your
product. The pump is self-priming so it will begin
drawing your product into the filler with both the
Power Switch and the Pump Switch are turned on.
Note: To make sure there is minimal air in the flow
path, turn the inline strainer upside down while the
pump is running with four bottles in place. This
ensures that the air bubbles in the strainer housing
mostly dissolve, although a little air bubble in the
strainer is normal.
You are now ready to begin filling. Place an empty
bottle under each spout. Turn on the Pump Switch.
The filling process will start and stop automatically.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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Gas Sparge
If your filler has the gas sparge option, first make sure you have the hose going into the filler safely connected to
your gas tank and regulator. The barb fitting on your unit is ¼″, use ¼″tubing, braided for strength, and good hose
clamps. The recommended pressure is 20-30 psi. The gas purge is automatic, it will purge the bottle once the bottle
is placed on the shelf, then it will start the liquid filling cycle.
Variable Flow Control
The four white valves on top of your unit are for flow control. Each valve controls the spout in which it is aligned.
The valves functions are to increase or decrease flow per spout. Usually if foaming is occurring in your product,
decreasing flow and or slowing down your flow will eliminate this problem.
To Decrease flow: Turn the knob Clockwise until desired flow is achieved.
To Increase flow: Turn the knob Counterclockwise until desired flow is achieved.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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3
Options
Before calling the factory, please read through the Troubleshooting Guide.
Bottle Filler Is Not Priming
The XF4100/2100 Bottle Filler is equipped with a diaphragm pump. Over time the valve kit for the pump,
depending on the age and use, might lose some of its effectiveness. This is an easily exchangeable part. The
indication that the valve kit has failed is that you hear the pump running, but the pump does not prime.
Dripping Spouts
Sometimes dripping occurs after a fill cycle for different reasons. One could be a particulate caught in the solenoid
valve. Simply run your fill cycle a couple of times with warm water or your cleaning solution. If the problem
persists contact XpressFill for assistance.
Fill Cycle Will Not Begin
If the green light does not turn on (or flickers momentarily) and the fill cycle does not start, it is typically a case of
moisture between the spout and sensor tube. This can corrected by drying the entire area with a dry cloth or towel in
between the two stainless steel sprouts as well as the nylon spacer holding them in place. If the problem persists,
please contact XpressFill for assistance.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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4
Troubleshooting
Premature Shut-Off
The XF4100/2100 is a Level Fill machine, meaning that
the flow of product will automatically shut off when
liquid touches the exposed metal of the CO2 and
beverage-fill spouts simultaneously. If moisture is
allowed to collect between the two spouts, the filler will
prematurely shut off, stopping the fill or not allowing the
fill to begin at all. The machine senses that it has a full
can at the point there is contact between the spouts.
To correct this problem, dry the spouts thoroughly.
Once completely dry, filling should resume.
Please note: You are responsible to ensure that your filler is clean and does not contaminate your product. We
recommend a thorough cleaning before and after your bottling run.
Cleaning your XpressFill is quick and easy, and is the single most important maintenance you can perform to
ensure long life and efficient performance from your filler. Please use caution when using any cleaning product.
For general cleaning, we highly recommend a product called PBW by Five Star Chemicals. It is safe, fast,
effective and our customers have been happy with the results. To clean your XpressFill, begin by flushing your filler
with 2 gallons of plain warm water. Follow the warm water flush with a mixture of 2 ounces of PBW cleaner
dissolved in 2 gallons of water. Allow the PBW to soak inside your filler for a few minutes. When using PBW in
food processing areas, the equipment that has been cleaned must be rinsed with potable water.
After cleaning with PBW, the manufacturer recommends sanitizing prior to the next use. Saniclean, also from
Five Star Chemicals, is highly effective and completely food grade if diluted correctly per the manufacturer's
instructions. Use 1 once of the sanitizer in 3 gallons of water, and follow the steps according to the manufacturer's
instructions.
Before storing your XpressFill, flush your filler with 2 gallons of warm water. Be sure you get all water out of
the flow path. This is done by continuing to run the pump until it runs dry with bottles in place.
DANGER:Read and follow all manufacturers’ instructions.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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5
Cleaning & Sanitizing
Cleaning the Shelf
When cleaning and wiping the shelf, be sure to wipe from left to right in order to avoid damage to the shelf and
switches.
6
Additional Information
Collet Release Tool
Our fillers use “Push-to-Connect” type connectors which are standard in the beverage industry. Installation simply
requires pushing a hose into the fitting and pulling lightly to check that the connection is secure. Removal requires
using the collet release tool to firmly push the collet and remove the tube. A tool is included with the filler and can
be found inside the filler.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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Push collet in with tool to remove hosing
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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Spare O-Rings
There is an O-ring on the transfer kit coupler. During cleaning it can be lost and causing lose of suction during
filling. Spares are offered and located inside the filler.
Spare Fuse
There is a spare fuse in the power cord receptacle. Unplug the machine and set a screwdriver on the notch (do not
remove screws) and pop the spare fuse holder toward you, then replace the fuse. XpressFill Part No. 200002 –
Bussmann Series by Eaton, Model BK/GDB-2A, 250V Fast Acting, 5mm x20mm.
The exposed fuse in the clip is the active fuse. The fuse stored in the box holder is the spare.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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CO2 Purge Solenoid Valve Deep-Cleaning Instructions
Remove the solenoid valve from the filler. Use the
release tool provided to disconnect the push-to-connect
fittings from the tubes.
Slide off the clip from the top of the coil assembly.
Remove the coil assembly off the center shaft. Unscrew
the shaft from the stainless steel base. It is not necessary
to unscrew the tubing adaptors from the stainless steel
base.
Now rinse out all the openings inside and outside of the
solenoid valve, removing any particulates and
stickiness that may have accumulated.
Reassemble and replace in the filler.
Stainless steel valve body is marked #1 for input,
#2 for output. Note: Valve may leak if installed back-
wards.
Note: This maintenance is needed only when the filler is not performing properly.
265 Prado Road, Suite 1 | San Luis Obispo, CA 93401 | 805.541.0100 | xpressfill.com | [email protected]
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Delay-Timer Adjustment
Accessory Kit
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