CO2 REFILL STATION
OPERATION MANUAL
Version 1.0-0712
© 2014 by VirTra Inc. All Rights Reserved. VirTra, the VirTra logo are either registered trademarks or trademarks of VirTra in the
United States and/or other countries.
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VirTra Inc.
DISCLAIMER
This manual is intended to be used as a practical and informative guide only and is not to be used as legal authority
for any purpose. Specific legal authority comes exclusively from statute and case law. VirTra Inc. shall not be liable
for any incidental or consequential damage resulting from the performance or use of this product. In the interest of
continued product improvement, we reserve the right to revise, modify or alter the contents of this manual at any
time without notice and without obligation to notify any person of such revision or changes.
TRADEMARKS
VirTra, the VirTra logo are either registered trademarks or trademarks of VirTra in the United States and/or other
countries. Product names used in this manual are ascribed to their respective owners and acknowledged.
HOW TO USE THE MANUAL
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C02 Refill Station Version 1.0-0712
Author: Robert Dowling
Editor: Brent Barcena
Layout/Design: Brent Barcena
TABLE OF CONTENT
I.OPERATIONS
II.
III.
1.1
Safety Notices
1.2Requirements
4
4
SYSTEM OVERVIEW
5
2.1
5
Powering on the CO2 Refill Station
ISSUES
4.1
4.2
V.
Main System Components
OPERATION INSTRUCTIONS
3.1
IV.
4
Repair Disclaimer
Nozzle Seal Service
CONTACT VIRTRA
6
6
10
10
10
12
TABLE OF CONTENTS
I.OPERATIONS
1.1
Safety Notices
CAUTION: Carbon Dioxide (CO2) can be fatal if ingested or inhaled in abnormally high concentrations. The procedures
outlined below should ALWAYS be performed in a large, well ventilated room in which dispelling CO2 does not have a
significant impact upon the overall air quality.
AC Power:
100-240V AC, 50-60Hz.
1.2Requirements
Power Outlet: 100-240V @ 50-60 Hz (clean power requested - no power spikes or brown-outs)
Temperature:
Humidity:
Storage:
CO2 Tank:
77 – 85 F° ( 25-30 C° ) indoors temperature.
Less than 90% relative.
Well ventilated room.
CO2 tank with siphon tube.
NOTE: As per the Compressed Gas Association standard CGA G-6—2009, Chapter 8: Storage and handling of carbon
dioxide, Section 8.1: Uninsulated cylinders, Subsection 8.1.1: Storage precautions. “Cylinders should never be subjected to
temperatures in excess of 125 F° ( 51.7 C° ) because of the excessive pressure that will occur. Cylinders should never be stored
in direct sunlight, near furnaces, radiators, or any other sources of heat.”
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II.
SYSTEM OVERVIEW
2.1
Main System Components
The pictures below, Fig. 1 and Fig. 2, show an overview of the refill stations main components.
Actuating Cylinder
Power Push Button
Fig. 1: CO2 Refill Station (Front View)
Low Pressure
Input Line
High Pressure
Input Line
Female Power
Receptical
Power Switch
High Pressure
Relief Valve
Fig. 2: CO2 Refill Station (Rear View)
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TABLE OF CONTENTS
III.
OPERATION INSTRUCTIONS
3.1
Powering on the CO2 Refill Station
1. Plug in the female end of a UL-listed 3-prong power cable into the power receptacle on the CO2 refill station, as shown
below. Then plug the male end of the power cord into a wall power outlet. See Fig. 3 below.
Plug in female end of
power cable here.
Fig. 3: Insert Power Cable
2. Flip power switch to on by toggling rocker switch towards the bottom of the unit, see Fig. 4. One can ensure that the
power is on by lifting up the lid which should trigger a blue light to switch on. If the blue light does not come on while the
lid is raised and the power is on, then double check that the power cable is plugged into a live power outlet.
Toggle rocker switch
towards bottom of
unit as shown here.
Fig. 4: Switch on Power
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3. Attach the high pressure hose (braided steel line) to the high pressure inlet of the refill station, as shown on Fig. 5 below.
Snuggly tighten down the high pressure line with a 5/8” open end wrench.
Attach high
pressure line here
and snug secure
with 5/8” wrench.
Fig. 5: Attach High Pressure Line
4. Attach the low pressure (1/4” OD, black nylon) hose to the push-to-connect fitting shown below, Fig. 5.
Connect low pressure
line here by pushing
nylon tube into here.
Fig. 6: Attach Low Pressure Line
5. Slowly open the CO2 valve on the CO2 tank to release liquid CO2 into the system. The gauge pressure on the high
pressure line should read approximately 1,000 psi.
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6. Open the high pressure relief valve to bleed off any air in the lines. It should only be necessary to have the bleed valve
Turn handle on bleed
valve until it hits stop
block.
Fig. 7: Bleed Air
open for approximately 1 second until liquid CO2 begins to spray out. See Fig. 7 at the top of the next page.
7. By this step the pump should have activated but should have stopped pumping by now. Open the lid to ensure that the
blue light activates.
8. Place the magazine, which may or may not contain an empty CO2 canister still secured in place, into a corresponding
Fig. 8: Insert mag into adapter plate
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adapter plate, see Fig.8 below.
9. Open lid (the blue light should illuminate),
place the adapter plate containing the
magazine in between the guide rails and
push the adapter plate all the way forward
until contact is made with the block switch, as
shown below. Once the guide block has been
pushed into the correct position the blue light
Push guide block until contact
is made with switch.
Guide Rails
Fig. 9: Insert mag guide block
will turn off and a green light will illuminate.
10. Close the lid, both the blue and green lights should illuminate. Push and release the start button once, which will activate
the cylinder, push the block forward into the nozzle, and pump liquid CO2 into the magazine. See Fig.10 below.
11. While the magazine is filling the user should hear a few cycles of the pump and then the process will end in which the
cylinder retracts. Open the lid, remove the magazine adapter plate, then remove the magazine from the adapter plate
and begin normal use of the CO2 recoil kit.
12. Repeat steps 8-11 to continue refilling exhausted CO2 magazines. NOTE: the user must wait approximately 30 seconds
from the end of one refill cycle to the beginning of another refill cycle. This was done to help eliminate the internal
components from freezing.
13. When use of the refill station is done for the day a few simple steps should be taken to properly shut down the CO2 refill
station.
• Close off the CO2 supply by tightening down the valve on the CO2 tank.
• Open the pressure relief valve on the CO2 refill station to bleed off any remaining CO2 left in the system.
• Flip the power switch up to turn off the power.
Both BLUE and GREEN
lights should be illuinated.
Push start button to
activate filling process.
CO2 REFILL STATION OPERATION MANUAL
Fig. 10: Start Process
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IV.
ISSUES
4.1
Repair Disclaimer
READ CAREFULLY: The following repairs are the only repairs suggested by VirTra. Any other repairs or modifications of
this kit could void any warranties implied or in writing.
4.2
Nozzle Seal Service
If the nozzle on the refill station leaks upon refilling or after refilling a magazine then it might be time to replace the seal
housed within. This can be completed in a few simple steps as outlined below. NOTE: The top cover assembly has been
removed from the computer model however, all the below tasks should still be able to be accomplished with the lid simply
resting in the open position.
1. Switch off the refill station
2. Unplug the power cord from the refill station.
3. CAUTION: ENSURE THAT THE VALVE ON THE CO2 SOURCE IS CLOSED AND USE THE BLEED VALVE (FIG. 7) TO
BLEED OFF ANY REMAINING CO2.
4. Disconnect the low pressure line from the refill station with your hands and unscrew the high pressure line from the refill
station with a crescent wrench. In order to disconnect the low pressure line, one must push in on the outer ring of the
quick-disconnect fitting with one hand, then pull the nylon hose out with the other hand. See Fig. 11 below for clarification.
Disconnect nylon
hose from this
quick-disconnect
fitting.
Unscrew high
pressure hose from
this connection.
Fig 11: Disconnect pressure lines
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5. Using a 9mm open end wrench, unscrew the nozzle from the nozzle housing. See Fig. 12 and Fig. 13 on the following
page for instructions.
CAUTION: Nozzle is under spring pressure so extra caution should be taken when nozzle is almost completely unscrewed.
Place wrench on flats
that have been cut
into the nozzle.
Place wrench over
flats shown here.
Fig. 13: Nozzle close up
Fig. 12: Remove nozzle
6. Remove all parts from the nozzle assembly, as shown below, except for the spring that rests behind the ball bearing
(not shown). NOTE: One will most likely have to use a straightened paper clip or something similar in size to remove the
rubber washer cup from the nozzle housing. See Fig. 14 on following page.
Nozzle
Housing
3/16” Ball
Bearing
Rubber
Washer
Nozzle
Nozzle
Retainer
Rubber
Washer
Cup
Nozzle
Spring
Fig. 14: Nozzle assembly
7. Replace the rubber washer (shown above in Fig. 14) with a replacement supplied by VirTra.
8. With the replacement rubber washer in the rubber washer cup, replace the ball bearing, then place the rubber washer
(installed in the rubber washer cup) over the ball bearing.
9. Put the nozzle spring over the nozzle and into the nozzle retainer.
10. Screw the nozzle retainer into the nozzle housing to capture all of the above pictured parts.
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TABLE OF CONTENTS
V.
CONTACT VIRTRA
If you have any questions or issues with any part of this manual, please see contact below:
VirTra Service Department
7970 S. Kyrene Road
Tempe, AZ 85284 USA
Office: 480.968.1488 x 5029
Mobile: 602.616.7504
Email: [email protected]
To download an electronic copy of this manual, please scan the QR code below with
your smartphone device or click the link below:
www.virtra.com/PDF/Manuals/Engineering/RefillStation.pdf
CO2 REFILL STATION OPERATION MANUAL
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