LPG-Refiller-Guide

TapRack™ – Professional Refiller Instructions

System Overview

  • TapRack connects up to four (4) 15.5 oz refillable propane cylinders
  • Designed for professional refilling using standard LPG equipment
  • Maximum total system fill: 0.89 gallons (≈ 3.4 lbs propane)
  • Maximum individual bottle weight: ~2.67 lbs (1.21 kg)
  • Each bottle includes:
    • Pressure Relief Valve (PRV): 300–375 psig
    • Bleeder valve for fill indication

⚠️ Critical Safety Principles

  • All bottles must be empty or at equal fill level before refilling
  • Weight is the primary method to verify safe fill
  • Bleeder valves indicate fill progress, NOT final fill level
  • Meter readings are a guide only — NOT a final control
  • Never exceed 80–85% liquid capacity

1. Pre-Fill Inspection

  1. Verify all cylinders are:
    • DOT / TC approved and properly marked
    • Free from damage, dents, corrosion, or leaks
  2. Confirm starting condition:
    • All bottles must be empty (recommended method)
    • If not empty → bottles must be at equal fill level
  3. Position TapRack:
    • Keep system upright and stable during filling

2. Connect Filling Equipment

  1. Attach LPG fill hose to TapRack main valve
  2. Ensure secure connection (no leaks)
  3. Purge air from fill line if required

3. Open System for Filling

  1. Open TapRack main valve
  2. Open ALL bleeder valves on connected bottles
    • Use flathead screwdriver
    • Leave open throughout filling

4. Begin Filling

  1. Slowly open bulk tank / start pump
  2. Liquid propane flows into all bottles simultaneously

During Filling:

  • Bleeder valves will pulse vapor initially
  • As bottles fill, vapor flow becomes steady

5. Monitor Fill (Meter = Guide Only)

  • Filling may approach 0.89 gallons total (as guide only)
  • Do NOT rely on meter alone to determine fill completion

👉 When bleeders show steady vapor across bottles:

  • System is nearing full condition

6. Shut Down Filling

  1. Turn off filler pump / close bulk tank valve
  2. Close TapRack main valve
  3. Allow residual vapor to vent
  4. Close all bleeder valves
  5. Bleed pressure from fill hose
  6. Disconnect fill hose

🔴 7. VERIFY FILL BY WEIGHT (REQUIRED)

Final fill MUST be verified by weight. This is the primary safety control.

Step 7A – Remove and Weigh

  1. Remove each bottle individually from TapRack
  2. Place on scale and record weight

Step 7B – Confirm Weight Limits

  • Compare against stamped tare weight (TW)

Maximum allowed:

  • Total bottle weight ≤ 2.67 lbs (1.21 kg)

Step 7C – Correct Overfill (If Needed)

If bottle exceeds max weight:

  1. Hold bottle upright
  2. Slowly open bleeder valve
    • Vent small, controlled amounts of propane
  3. Close bleeder
  4. Re-weigh bottle
  5. Repeat until within specification

Step 7D – Final Check

  • Ensure ALL bottles:
    • Are within weight specification
    • Have closed valves
    • Show no leaks (soap test recommended)

⚠️ Important Refiller Notes

  • Do NOT rely on dispenser meter alone
  • Bleeder valves indicate fill progress — NOT compliance
  • Overfilled cylinders can create hazardous pressure conditions
  • Always verify each cylinder individually

Advanced Filling (Uneven Bottles)

If bottles are not empty:

  1. Open all bleeders
  2. Begin fill
  3. When a bottle shows steady bleed:
    • Stop fill
    • Close its bleeder
    • Remove bottle
  4. Continue filling remaining bottles
  5. Repeat until all bottles are filled
  6. Perform full weight verification process

Pressure Reference

Condition

Pressure

Normal Fill

110–200 psig

Max Fill Pressure

≤ 250 psig

PRV Activation

300–375 psig

No cylinder may be returned to the customer without weight verification.

WARNING: FINAL FILL MUST BE VERIFIED BY WEIGHT
Meter readings and bleeder output alone do not ensure safe fill levels.
Each cylinder must be weighed and adjusted if necessary.

The TapRack Refill Hang Tag Information (attached to production units):