DUOFILLER Mono Automatic Bottle Filler User Manual

DUOFILLER Mono Automatic Bottle Filler

Duofiller Product Information

The Duofiller is a machine used for filling cans or bottles with beverages under pressure. It has the following specifications:

SPECIFICATION

• Dimensions 325mm172mm140mm
• Weight 2.6 kg
• Body material Stainless steel 304
• Operating temperature/humidity 0 – 35 °C / 20 – 80 % rH
• Power supply 12 V DC 2000ma, 5.5*2.1mm DC plug
• Working/max beverage pressure 2 bar (30 PSI) / 4 bar (60PSI)
• Max beverage temperature 60 °C (140F)
• Working/max purge gas (CO2) pressure 0.2 bar (3PSI) / 1 bar (15 PSI)
• Beer hose dimensions 4mm (5/32”) OD/2.5mm ID, length 2.5m
• CO2 connector 3/8” John Guest push fit / ¼” barb

Duofiller Product Usage Instructions

Before using the Duofiller, it is important to read and follow these instructions carefully:

Safety Precautions

• Avoid water splashes from any angle as it can cause damage to the machine and in the worst case, short circuit and damage to health, life or property.
• Always inspect hose and connections for damage before use. Use original connectors to prevent leakage or breakage.
• When using the filler with cleaning chemicals, use PPE as required by the chemical safety datasheet and always use safety goggles as a minimum.
• Do not open, modify, repair or otherwise interfere with the Duofiller power supply unit as it can be life-threatening or cause serious damage to health or property.
• Do not use the power supply unit if it or its cables are visibly damaged, exposed to moisture, show other signs of damage or of being defective. Always inspect the power supply unit and its cables before each use.
• Always unplug the unit while it’s not in use for safety reasons.

Package Contents

The Duofiller package includes:

• Beer hose (Note: The cornelius keg quick disconnect is not included!)
• Filter (to be used to prevent debris from getting stuck in the internal valves and which again may prevent the valve from closing properly)

1. Duofiller
2. 2.5 meter beer hose, 4mm (5/32”) OD / 2.5mm ID
3. Power supply 110-240 VAC to 12VDC, 2A. EU/US/UK/AU changeable plugs included.
4. ¼” MFL to 8mm (5/16”) push fitting
5. Filter strainer 8mm (5/16”) push fitting
6. 2pcs 8mm (5/16”) OD tubing
7. 2pcs 8mm (5/16”) OD to 4mm (5/32”) OD reducer
8. 8mm (5/16”) push-fitting Y-splitter
9. 9.5mm (⅜”) OD to ¼” barb fitting (CO2 connector)

Assembly

Beer hose:
Note: The cornelius keg quick disconnect is not included!

The filter should always be used, as this will prevent debris to get stuck in the internal valves and which again may prevent the valve from closing properly. The filter has a direction arrow. Keep the filter outlet high so that air/CO2 will always escape the filter.

Wall Mounting
Mounting screws are not included. The Duofiller also supports VESA 100 standard mounts (use M4*10mm screws to secure the VESA mount). VESA mount is not included.

Wall mounting the Duofiller:

Mounting screws are not included.
The filler also supports “VESA 100” standard mounts (use M4*10mm screws to secure the VESA mount). VESA mount is not included.

Connecting the Duofiller

The CO2 pressure connected to the Duofiller should not be higher than 3 PSI / 0.2 bar. Higher CO2 pressure can leak through the CO2 purge valve inside the filler and if so, it will cause unstable fill level measurement and/or excessive foaming. In worst case, it might also damage the fill sensors.
Always use a separate CO2 regulator, max 3 PSI.

Beer hose for left and right fill-head goes into the right and left most pushfit bulkhead CO2 is connected to the middle connector. Use the included ¼” barb to ⅜” OD pushfit adapter or ⅜” OD hose to connect CO2. CO2 hose is not included. Always use a separate regulator for the CO2 pressure. Start with the regulator on its lowest setting. Low CO2 pressure (< 3 PSI) will give the best purge/oxygen removal from the can as lower pressure causes less turbulence .

IMPORTANT:

• CO2 pressure connected to the Duofiller shall not be higher than 3 PSI / 0.2 bar
• Higher CO2 pressure can leak through the CO2 purge valve inside the filler and if so, it will cause unstable fill level measurement and/or excessive foaming. In worst case it might also damage the fill sensors.
• Always use a separate CO2 regulator, max 3 PSI.

Fill Level Programming

Before using the Duofiller for filling cans, it is important to prepare a keg with cold, clean water for first time test and fill level programming.
To start with the left-side filler:

1. Hold left button for 2-3 seconds and release to set it in manual mode/programming mode. Lamp shall light blue.
2. Put a can under the filler and press the left button one short press. The CO2 valve will open first to purge the can. After 6 seconds, the CO2 valve closes and the liquid valve opens. While filling liquid, the lamp shall light red.
3. When at desired fill level give the left button a short press. Filling stops and lamp glows green. Green light means that the fill level is stored and that it will automatically stop at the same level when it’s back in auto.
4. Repeat for the right-side filler
5. Return to auto mode by holding down either right or left button for 2-3 seconds and release. The lights should now go out. Start a filling and it should now stop at the same level as it was stopped in manual.

Filling can be stopped at any time by pressing the button while filling is in progress. If you stop while in programming mode, if it has detected level increase in the can by more than 1 cm, it will save it as a new fill level and the lamp will light green. If it has not registered an increase of more than 1 cm, the filling level is not stored and the lamp will light red. The filling level is stored in hard memory, i.e., it will be saved until a new filling level is stored.

A great way of fine-tuning or on-the-fly fill level adjustment is to loosen the tube clamp and adjust the height of the CO2 tube. Lift the tube to increase the fill level or down to lower it. The fill level is then raised / lowered by the same height as the height of the CO2 tube was adjusted. The CO2 tube is the closest to the center, i.e. the right tube on the left and the left tube on the right.

Purge time programming
Purge time can be adjusted between 0 and 10 seconds. It’s preset at 6 seconds which is recommended for carbonated beer. Purge time is adjusted by holding down one of the buttons for 6-7 seconds and release. The lamps now glow red. Press one of the buttons to increase purge time by 1 second. Press forward one and one seconds. When it reaches 10 seconds, it jumps back to 0 seconds, and when it is at 0 seconds, the lights are blue. Press once and one second again until both lamps light green, then the purge time is 5 seconds. One short press forward then it’s 6 seconds. Saving is done by holding down one of the buttons for 6-7 seconds, release and the lights should go out. The purge time is now stored and will be the same until new purge time is saved. It’s recommended to always use at least 1 second of purge time, this is to avoid getting liquid into the CO2 tube which can disturb the fill level sensor.

Cleaning

Before starting to use the filler with beer it’s mandatory to run a cleaner through the filler. The beer valves are made from machined stainless steel and in worst case they can have residues of machining oil that needs to be flushed out. We recommend using a TSP (Tri Sodium Phosphate cleaner), 5g pr liter in warm water (<50 °C) and run through. Repeat until the contact time is at least 10 minutes. Afterwards flush with warm water (<50 °C) at least for 10 minutes. Periodical in-line cleaning can be done with a suitable beer line cleaner as “Pipeline beer line cleaner”

Sanitizing
Use an acid-based sanitizer for beverage equipment (we recommend StarSan) at its recommended concentration. Run it through the filler (in-line) to ensure the recommended contact time is achieved.
Always sanitize the filler before and after each use.

Filling with beverage

First, make sure the beer is cold (4 degrees or colder) and that it is fully carbonated and has been at stable pressure and temperature for at least a week. This is because if the carbonation is in imbalance there is a much higher chance that you will have encounter excessive foaming.
For normally carbonated beers with refrigerator temperature (4C or lower) and stable pressure, there should normally be no foam problems.

It’s always best to use the pressure already in the keg as fill pressure and, do not change the pressure prior to filling. If it foams too much it helps to cool the beer down more. It may also be helpful to increase the pressure in the keg. Lowering the fill pressure is not recommended as it will usually make foaming worse.
It’s recommended to always put the can lid on foam to keep oxygen out of the can when the lid is pressed down. Seal the lid immediately. Done this way, even NEIPA will remain unoxidized for 1 year ++.

Always ensure that the beer in the keg is clear and that particles have properly settled and always check that the beer is clear by draining the initial deciliters before connecting the Duofiller. If you encounter that the filling speed is reduced while filling, this may be a sign of a clogged filter. Disconnect the hose from the keg, depressurize the hose and open the filter for inspection and possible cleaning. Please note that the filter is not designed to filter out a lot of particles, it should only stop individual particles that can get stuck in the valves inside the Duofiller. If the filter is clogged with hops or yeast particles, you must let the beer settle before filling continues. A clogged filter can cause the cartridge to collapse and this is not covered by the warranty.

After use

Run through warm water with detergent (PBW or similar is recommended) to flush out any leftover beer. Absolute maximum temperature is 60 degrees. Run through sanitizer after cleaning and then rinse with cold water. Cycle the liquid solenoid valves while cleaning, sanitizing and rinsing.
Drain the beer hoses after use. A good practice is to empty the beer hose with CO2. Change the quick disconnect on the beer hose with a grey CO2 type and connect it to the “Gas OUT” post on the keg and start a filling to displace the liquid in the tube with CO2. Disconnect the filter, take out the filter cartridge and flush it. The filter housing and the cartridge are dishwasher safe. Use a microfiber cloth and a glass cleaner to make the stainless housing shine.

Troubleshooting

If you find that there may be something wrong with your filler, contact us by phone, e-mail or the website ASAP and we’ll assist you at our best effort. Often, simple problems can be solved with a little support or with supply of spare parts.

The filler comes with 2-year warranty from purchase date.

If there is a problem with the filler, the lamps can be used to debug what’s wrong. Feel free to take a video of the issue before contacting us, and/or please describe the lamp status.
Examples of errors that may occur:

The can overflows:

• Pay attention to the red light in the switch while filling. If the red light goes out before the can overflows it means that the valve is not physically closing. It might be debris stuck in the valve. Contact us for guidance how to clean the valve. If red light while overflowing please verify CO2 pressure below 3 psi/0.2 bar and do a new fill level calibration.

No purging before filling:

• If no blue light in the lamp while purging: Purge time is set to 0 second, reprogram purge time.
• If blue light in the lamp: Check CO2 pressure or CO2 bottle is closed / empty.

Inconsistent fill level:

• Check CO2 pressure and if it’s leaking through the valves. Put a glass of water under the fill head and look for bubbles. Be sure that CO2 pressure is below 0.2 bar / 3 PSI.
• Power supply might be defect or caused by unoriginal power supply.

Leaking pushfit connectors:

• Inspect the tubing for damage. Cut off 15- 20mm of the tube and reinsert into the fitting.

Foaming

Normally foaming is not an issue but there are a few general rules to apply to ensure a good result.

1. Carbonation level is important. Know your carbonation level and ensure that carbonation process is finished before filling is attempted. Stable keg pressure and temperature for the last 7 days is normally required. If you use quick-carbonation methods please let the beer sit several days to stabilize before filling.
2. Beer temperature is key. The beer must be cold, 4°C or lower
3. Keg pressure matters. Do not change keg pressure prior to filling and never lower the keg pressure below carbonation pressure. Lowering the pressure will lead to foaming. Keg pressure can be increased to increase fill speed. However always verify filling at initial keg pressure before it’s increased. If you have lowered the keg pressure normally you have to increase pressure to the original pressure and let it sit a day or two to stabilise.
4. It’s normal to observe foam in the tubes on top of the Duofiller. It’s not normal to have foam in the clear tube downstream the filter. If there is, please check your carbonation level (is it over-carbonated?), temperature and pressure. Foaming downstream the filter may be a sign of over-carbonation, too warm keg or too low pressure in the keg. Try to increase the keg pressure to check if the foaming is reduced. If not, try to decrease keg temperature after the recipe below.

If you follow these guidelines and still have excessive foaming you can try to further cool your keg. Disconnect the CO2 from the keg and lower temperature further. It’s important to disconnect CO2 to not increase carbonation level while cooling. Keg pressure will decrease when the keg temperature is lowered and remember to adjust CO2 pressure lower when you are ready to fill. Start low and increase CO2 pressure gentle until you can hear CO2 entering the keg. You have now found the keg pressure and are ready to start filling. Sometimes it’s desired to increase foaming level to get a proper foam cap for the lid. First try to increase fill pressure. If foam level is still too low keg temperature can be increased. Remember to increase CO2 pressure prior to filling since higher temperature will lead to higher pressure in the keg.

Made in Norway

Contact us

• mail@duofiller.no
• https://www.facebook.com/Duofiller/
• +47 41 00 33 44
• https://duofiller.no
• Brewket AS, Dalavikvegen 93, 5574 SKJOLD, Norway

References

• Duofiller - automatisk boksfyller - Duofiller.no
• Duofiller - automatisk boksfyller - Duofiller.no

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>