XpressFill XF2500 User manual
XpressFill XF2500 Counter Pressure Filler
Operating Instructions
ii | XPRESSFILL Systems LLC
Congratulations on the purchase of your XpressFill bottle lling machine.
ank 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.
is 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
USA
(805) 541-0100
sales@xpressll.com
www.xpressll.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 fire 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 or the bottle filler has been properly grounded.
XPRESSFILL Systems LLC | III
Table of Contents
1 Introduction iii
2 Know Your Filler iv
3 Set Up Your Filler 2
4 Operating Procedures 4
5 Trouble Shooting 6
6 Cleaning Your Filler 7
XpressFill Product Guarantee
We guarantee our products to be free of defects in materials and workmanship. e filler will
be repaired or replaced if, upon inspection at the factory, the filler is found to be defective in
materials or workmanship.
is guarantee does not apply to damage resulting from normal wear and tear, accident, abuse,
negligence or shipping. e guarantee will be rendered invalid if the customer has made repairs or
alteration to the machine without first consulting XpressFill Systems LLC.
1 Introduction
iv | XPRESSFILL Systems LLC
Bottle rest foot6.
Upper spout / product filling7.
Lower spout / pressurizing & release8.
Bottle neck filling stopper9.
Pneumatic ram10.
2 Know Your Filler
Bottle fill indicator light1.
Fill sequence start/stop switch2.
Quick pressure release button3.
Bottle interior pressure gauge4.
Bottle interior adjustment knob5.
1.
2.
3.
4.
5.
6
8.
7.
9.
10.
The below diagram highlights the important features on your filler, which will be referenced
throughout this manual. Being familiar with each of these and their functions will make your
filling experience easier.
XPRESSFILL Systems LLC | 1
1. Fill Indicator Light - is green light will
turn on while the liquid is flowing from the
spout.
2. Fill Switch - e fill switch turns the flow
of liquid on and off for each side. e flow is
off when the switch is in the down position.
It will glow red when the machine is plugged
in and turned on. e switch will glow green
once switched to the up position, indicating the
fill sequence has begun.
3. Pressure Release Button - is button will
manually release the pressure inside your bottle.
It will be used at the end of each fill sequence
or in case of emergency.
4. Bottle Pressure Gauge - is gauge displays
the pressure inside the bottle, which should
be lower than the pressure inside your keg or
liquid reservoir. (See our operating instructions
for our recommendations for what each of
these gauges should display).
5. Bottle Pressure Adjustment Knob -
is knob allows you to adjust the pressure
inside your bottle. Turning the knob
counterclockwise will lower the pressure, while
turning it clockwise will increase the pressure.
is will typically only need to be adjusted
when setting up your filler for the first time
with a new liquid.
6. Bottle Foot Rest - ese feet will hold your
bottle securely in place once the fill sequence is
started. Avoid putting your hands between the
bottle and the foot to prevent injury.
7. Upper Spout - is spout is used for the gas
flush and filling sequences.
8. Lower Spout - is spout is vented to
relieve the pressure in your bottle and acts as
the sensor for the automatic level filling system.
9. Stopper - e stopper seals your bottle and
helps to control the level your bottles is filled
to. While the stoppers are already set for the
level of a typical 12 oz. beer bottle, they can be
adjusted up and down on the spout to fill to
your own specifications.
10. Pneumatic Ram - e pneumatic ram
actuates the bottle and foot rest and are
activated when the filling sequence begins
2| XPRESSFILL Systems LLC
Required Equipment
XF2500 Bottle Filler1.
Pressurized CO2 Tank and Tubing2.
Air Compressor and Tubing (an additional3.
CO2 tank can be used or a ‘Y’ fitting from
your CO2 tank
Outlet Container and Tubing4.
Connect the air/CO2 and inlet from
the keg tubing to their respective
attachment points shown in Figure 1.
(Some air/CO2 and liquid will come
out of the vent in operation. e tube
labeled Vent leading to a catch container
should be connected at the Vent port to
collect any liquid.)
3 Setting Up Your Filler and Filling
Your First Bottle
Figure 1
Inlet Vent
Air CO2
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Air: 30 psi recommended
CO2: 30 psi recommended
Warning: Please follow the recommended
settings of the equipment you are using.
Exceeding manufacture recommended
settings may result in injury to self and
others, as well as damage and/or failure of
the machine.
Please see page 5, “Adjusting Pressures” to set
pressures outside the recommended settings.
Your filler is factory set for 30 psi keg
pressure and 25 psi bottle pressure.
e recommended operating pressures for
the CO2 and air compressor are listed to
the right. Please keep in mind that varying
temperatures and product properties will
mean that adjusting the pressures will
be necessary for your product. You are
encouraged to adjust these pressures carefully
until you find a combination that works for
your product and bottling environment.
Figure 2
Air Compressor1.
CO2 Tank2.
CO2 Regulator3.
CO2 Line to Keg Inlet4.
Pressurized Keg5.
Line to “Inlet” input on Filler6.
CO2 line to “CO2 input on Filler7.
Compressed are line to “Air” input on Filler8.
4| XPRESSFILL Systems LLC
the machine, flip all switches to their down
or off positions.
Plug the hose from your liquid container6.
into the port marked “Inlet” on the left side
of the machine using one of the provided
¼” barbed fittings. See “Adjusting Pressures”
on page 5.
Plug one end of the provided 4’ x ¼” tube7.
into the port marked “Vent” on the left side
of the machine, and place the other end
into your catch container.
Plug your air compressor into the port8.
marked “Air” on the left side of the machine
using one of the provided ¼” barbed
fittings. Your filler is factory set for 30 psi
keg pressure and 25 psi bottle pressure.
See “Adjusting Pressures” on page 5.
Plug your CO2 tank into the port marked9.
“CO2” on the left side of the machine using
one of the provided ¼” barbed fittings.
Once you are sure that all components10.
are plugged in correctly, you can open
the valves on your tanks and turn the air
compressor on.
Turn on your machine by flipping the11.
power switch on the right side of your
machine so that it is lit up. Your fill
switches should now glow red.
You are now ready to place a bottle on12.
your machine. Using your right hand, slide
a bottle up onto the stopper and hold in
place.
Step By Step
You will first want to unpack your filler1.
from the shipping box and spread the
components out on a large flat surface. You
will want to make sure that you also have
the following:
i. CO2 tank with regulator and connecting
tubes (we recommend a wye as well, see
setup diagram for details).
ii. Air compressor and hookup tubings
iii. A small (.5 liter or so) catch container
for collecting vented liquid
Place your filler on a flat surface where you2.
plan to bottle, ensuring that you have access
to a standard wall outlet or extension cord.
Place the liquid and CO2 tanks, as well as
the air compressor, nearby.
Begin by plugging the provided power cord3.
into your machine, and then plug it into the
wall. Now is a good time to make sure that
when you turn the machine on, the green
power switch lights up. e fill switches on
the front of the machine should glow red.
Toggle the fill switches and make sure that4.
they are red in the down position, and green
in the up position. Waiting a few seconds
after flipping the fill switch to the up
position should result in the green fill lights
also activating.
Once you are sure that you have power to5.
4 Operating Procedures
XPRESSFILL Systems LLC | 5
With your left hand, pull the bottle foot13.
rest up to the bottom of the bottle.
Still holding the bottle in your right hand,14.
take your left hand and flip the fill switch
to the left of your bottle to the on position
(it should light green). You should feel the
bottle foot rest engage, and it should now
be safe to release the bottle with your right
hand.
After a few seconds, you should see the fill15.
light activate and liquid will begin to flow.
Repeat steps 12-14 for the other spout.
Once the green fill light deactivates, firmly16.
grip the bottle in your right hand and press
it up against the stopper.
With your left hand, press and hold the17.
pressure release button to the left of the
bottle. You will see the pressure gauge drop
to zero. Once it has reached 0 psi, pull the
bottle off the stopper. A slight twisting
action may help with removing the bottle.
Congratulations, you have now filled18.
your first bottle using the XF2500 Filling
System!
Adjusting Pressures
Should your filler need to be adjusted from the preset recommended settings, follow the steps
listed below. Adjusting the pressure takes some coordination, so it is recommended that you read
through and understand all of the following steps before attempting this.
Follow steps 1-11 outlined in the setup instructions, setting the keg and CO2 pressures to1.
your required values rather than to the recommended settings.
Using two fingers, turn the bottle pressure adjustment knob counterclockwise until it becomes2.
difficult to turn. Using too much force may damage the valve.
Follow step 12-14 outlined in the setup instructions. Once the bottle foot rest is engaged,3.
quickly switch to turning the bottle pressure adjustment knob clockwise while watching the
bottle pressure gauge until the desired internal pressure is reached. e goal is to reach the
desired value before the purge process ends, see note below for details. is value should be
roughly 5 psi lower than the keg pressure, but the optimal value for your needs may vary.
NOTE: You will only have a few seconds to adjust the pressure during the gas purge process
before the liquid begins filling. It is more difficult to accurately adjust the machine once liquid
starts flowing, so it is recommended that you follow steps 16 and 17 in the setup instructions
to cancel the filling process, and repeat step 3 in this guide until the desired pressure is
reached.
Once you have reached the desired internal bottle pressure as indicated on the bottle pressure4.
gauge, it is recommended that you fill 1-3 test bottles to ensure the desired results have been
achieved. Small adjustments can be made using the same steps as above.
Repeat process on other spout.5.
6| XPRESSFILL Systems LLC
If at any time you have issues with the setup or adjustment of your XF2500 bottle filling machine,
or any other questions about filling your product, please contact us at the number listed at the
front of this manual. We are always happy to assist you.
Premature Shut O
e XF2500 is a Level Fill machine, meaning when liquid touches a spout and probe, it will
automatically shut off. If moisture is allowed to collect between the spout and the probe, the
filler will shut off prematurely, stopping the fill or not allowing the fill to begin at all, which is
characterized by the green LED fill indicator light to flash quickly and stay off as the machine
senses a full bottle is in place.
Dry the area between the spout and the probe with a clean towel or use the compressor to air dry.
Once completely dry, the fill will resume. Isopropyl Alcohol is very good for cleaning and is fast
drying.
Excessive Foaming
Excessive foaming is usually the result to the keg pressure not being high enough, or the indicated
pressure on the filler gauge is too low. e difference between the keg pressure and the counter
pressure indicated on the filler should be around 5 psi. e higher the pressure, the more the
CO2 will stay in solution.
5 Trouble Shooting
XPRESSFILL Systems LLC | 7
6 Cleaning
Cleaning your XpressFill is quick and easy, and is the single most important maintenance you can
administer to ensure long life and solid performance from your filler. Please use extreme caution
when using any cleaning product.
For general cleaning, we highly recommend a product called PBW by Five Star Chemicals. It
is safe, fast, and 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 (not boiling) water from a
pressurized keg, which is pressurized with air. Follow that with a 3-gallon mix of PBW cleaner,
and let the PBW sit inside your filler for a few minutes in order to do its cleaning job. Follow the
cleaning with a sanitizer.
For sanitizing, we recommend Saniclean, from the same manufacturer. Saniclean has low-
foaming characteristics, is highly effective, and completely food grade if diluted correctly per the
manufacturer’s instructions. Use the sanitizer with about 3 gallons of water, and follow the steps
according to the manufacturer’s instructions. After sanitizing, flush your filler with 2 gallons of
warm water. Before storing your XpressFill filler, make sure you get all water out of the flow path.
Allow to run until pressurized keg with cleaning solution is empty and runs dry, blowing the
remaining water out of the filler vent.
1. Cleaner to “Inlet” and “Sensor / Gas
Probes”
2 & 3. Tubing connecting to “Probes
and Vent”
4. Hose from Keg
5 & 6. Tubing connecting to “Spouts”
7. Tubing connecting to “Catch
Container”
8. Tubing from “Vent” to “Catch
Container”
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