service manual

Airflo Plus & Mk3

Simple solutions for everyday independence

 Part 1 Service Schedule

Introduction
The Airflo Plus battery operated compressor is supplied with a removable battery pack containing two 12v
rechargeable VRLA batteries. The Airflo Mk3 compressor contains one fixed12v rechargeable VRLA battery.
Air output of 5psi is produced from a diaphragm air compressor.
The Mk3 compressor (and earlier Airflo Plus) has a motorised dump valve which contains a pressure chamber
linked to a pressure switch. The air outlet socket contains a shut off valve which seals the outlet when an inflatable
product is not connected.
The Airflo Plus compressor does not have a motorised dump facility but does contain a pressure chamber linked to
a pressure switch. The air outlet socket contains a shut off valve which seals the outlet when an inflatable product
is not connected.
The Airflo Plus has a pneumatic 4-Way hand control which distributes the air between the air outlet and pneumatic
product.
The Mk3 is operated by a two button 12V DC hand control.
Electronic control and monitoring is managed through a PCB mounted micro processor.

Contents Page
Part 1 Service Schedule 2
Part 2 Service And Repair 4
2.1 Battery 4
2.2 Air Filter 4
2.3 Cover 5
2.4 Control PCB 5
2.5 Switch Label 6
2.6 Carrying Handle 6
2.7 Side Feet 6
2.8 Motorised Valve 7
2.9 Compressor 8
2.10 Pressure Relief Valve 8
Part 3 Fault Finding 9
3.1 Wiring Diagram 12
Parts List 14
Specifications 15

Service Schedule
Check with user for any known problems.

Function Test
Momentarily press the ‘Power’ button (Plus) or connect the 2 button hand control and momentarily press
either the ‘Up’ or ‘Down’ button (Mk3) to activate the battery status LED and check the battery state.
NOTE: If the battery pack has been removed and reinserted on the Airflo Plus, the indicator light will show
Steady Green for approximately 16 secs before showing the true battery state as follows:
Steady Green = Fully charged.
Flashing Green = Recharge soon.
Steady Red = Recharge immediately

2
 Part 1 Service Schedule

• On earlier models of the Plus which have a 2-button hand control socket, connect a 2-Way hand control and
operate the down button three times to check operation of dump valve and to ensure that the valve is fully
closed.
• Press and hold the ‘Power’ button to activate the ‘Auto’ function, the compressor will run until the internal pressure
switch is activated. Leave on ‘Auto’ function for approximately 15 seconds, in which time the compressor should
not run. If it does, leave for a further 15 seconds and if it runs again within the time, investigate the cause of the
leak.
• Momentarily press the ‘Power’ button to deactivate the ‘Auto’ function and depress the air outlet non return
valve to depressurise the unit.

(Mk3)
• Connect the two button hand control and press the Inflate button. Check unit runs momentarily and stops
when pressurised.

• Press the inflate button again for 2 or 3 seconds with the air outlet non-return valve depressed so as to allow
the compressor to run freely.

• Press the deflate button. Listen for the valve opening and closing. Check there is no unusual “clicking” at the
end of valve closure. Any “clicking” may be an indication that the motor is over running allowing the teeth to
jump.

Battery Charging (Plus & Mk3)

• Check condition of charger lead.
• Connect the battery charger and switch on. The battery status LED on the Airflo should flash green. The LED
will flash green while the batteries are charging and go to steady green when charged.
• Carry out an Insulation Resistance test on the battery charger as follows: Connect the charger power supply to
the PAT equipment and ensure that the power supply switch (if fitted) is switched ‘ON’ before carrying out the
test. Insulation Resistance @ 500vDC: Select either 500vDC Megohms/Insulation as appropriate. Press the
Test Button and check the insulation reading:

Reading ∞ (infinity) Ohms

Air Filter
• Remove the air filter from the underside of the Airflo and check it for cleanliness. If necessary, fit a new filter.

Casings
• Inspect the Airflo and hand control casings for signs of damage.
• Check the security of all screws on the lower case.
• Check the security and condition of labels and replace if necessary.
• Check the security and condition of the handle.

Pressure and Flow Test

Using a Mangar pressure/flow test kit (part No.CA0210), test the Airflo for minimum pressure and air flow rates as
follows:

Depending on battery charge state: – 90 l/min @ 3.0 psi. (minimum) (Plus)

50 l/min @ 2.0 psi. (minimum) (Mk3)

Simple solutions for everyday independence 3

 Part 2 Service and Repair

2.1 Battery
The Airflo Plus is fitted with a quick release battery
pack. The batteries can either be re-charged whilst in A
the Airflo Plus or easily removed and re-charged in the
optional charging cradle.

2.1.1 Turn the Airflo Plus upside down and remove the
battery pack by pulling the handle (A fig.1).

2.1.2 Fit the replacement battery pack, ensuring that it

‘clicks’ into place and is held by the four catches
(B). B
NOTE: If the battery pack has been removed and
reinserted, the indicator light will show Steady
Green for approximately 16 secs before showing
the true battery state.
Fig. 1 F
The Airflo Mk3 battery is supplied mounted to a rigid
plastic sheet which ensures correct orientation and
positioning during fitting to the Airflo. This is located in
the base of the Airflo (C fig.2).

2.1.3 Turn the Airflo upside down and remove the

two screws (D) from each of the two retaining
plates (E) and rubber pads. Turn the Airflo
the right way up to remove the battery.

2.1.4 On refitting, orientate the replacement battery C

pack to ensure that the two battery contacts align
with the two contacts in the housing. E
2.1.5 Refit the rubber pads, retaining plates (E) and
screws (D).

NOTE: When replacing the battery, always replace with

the same type. D

2.2 Air Filter

The air inlet filter is located in the base of the Airflo.

Fig. 2 F
2.2.1 Remove the screw (F figs.1&2) followed by the
filter cover.

2.2.2 Replace the air filter (Kit part No. CA0074).

4
 Part 2 Service and Repair

2.3 Cover

The cover is secured to the base by seven self tapping

screws. The control PCB is secured to the inside of the
cover and is attached to the wiring loom by means of five
connector plugs and to the motorised valve pressure
chamber, by a silicone hose.

2.3.1 Remove the battery pack (Section 2.1).

2.3.2 Remove the seven self tapping screws which

secure the cover.

2.3.3 Turn the Airflo the right way up and carefully lift
the cover away from the base, at the same time,
turning the cover over so as to expose the PCB
(fig.3). Disconnect the pressure sensing hose
and connector plugs from the PCB.
A
2.3.4 Inspect the condition of the gasket (A fig.3)
Fig. 3 and replace if necessary. Refit the cover in the
reverse order.

NOTE: When refitting the cover, ensure that the wires and
pressure sensing hose do not become trapped
between the mating surfaces, particularly at the
screw fixing locations. Ensure that the pressure
sensing hose does not become kinked as this
will interfere with the operation of the pressure
switch.

2.4 Control PCB

A
2.4.1 Remove the cover and disconnect the five
connector plugs and pressure sensing hose
(Section 2.3).

2.4.2 Remove the four screws (A fig.4) and lift the

PCB clear of the cover.

NOTE: The software version number should be printed

on the white label in the corner of the board.

Fig. 4

Simple solutions for everyday independence 5

 Part 2 Service and Repair

2.5 Switch Label

2.5.1 Peel the label and remove any surplus adhesive

from the cover (fig.5).

2.5.3 Carefully fit the new label so that the clear windows
align with the indicator light holes (A fig.5).
NOTE: The Mk3 label does not contain the ‘Auto’
function indicator light window.

2.6 Carrying Handle

The carrying handle is secured in a slot within the cover

by two self-adhesive pads and has a small lug at each
A
Fig. 5
end (A fig.6), which becomes locked in place when the
cover is refitted to the base.

2.6.1 Remove the cover and disconnect the wires and

pressure sensing hose from the PCB (Section
2.3). A
2.6.2 Insert a small flat bladed screw driver between
the handle and cover, as indicated (fig.7) and
carefully prise the handle away from the cover
to break the adhesion of the two pads. Pull the
handle clear of the cover.
Fig.6
2.6.3 Fit a new handle by fully inserting it into the slot,
as far as the two lugs (A fig.6). Press the back of
the handle to secure the self adhesive pads. Refit
the cover.

2.7 Side Feet

Fig.7
2.7.1 Remove the cover and disconnect the wires and
pressure sensing hose from the PCB (Section
2.3). The feet in both the cover and base (A
fig.8) can be removed and refitted without further
dismantling.

2.7.2 Remove the side feet by easing them out from the
outside of the cover and base.

2.7.3 Replace the feet by adding a little lubricant to A

each foot and manipulating it into its locating hole
from the outside of the cover and base.

Fig.8

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 Part 2 Service and Repair

2.8 Motorised Valve

If a fault develops, the motorised valve assembly (A fig.9)
D will need to be replaced. NOTE: The latest version of the
Airflo Plus valve does not have a motor, dump mechanism
or hand control socket. The illustrations show the Airflo Mk3
C valve.
Removing
2.8.1 Remove the battery pack (Section 2.1). Remove
the cover and disconnect the wires and pressure
sensing hose (Section 2.3).
2.8.2 Remove the outlet port label and remove the two
valve fixing screws (B fig.9).
A
B Fig.9 2.8.3 (Airflo Mk3 only) - Insert a narrow bladed
screwdriver as indicated (inset fig. 9) and lever the
clip (C) on the plastic shield away from the valve
arm stop. Place a finger under the shield and lift it
clear.
2.8.4 On the Airflo Plus, remove the screw and compressor
inlet filter (not shown) located at the compressor air
inlet (D fig.9).
2.8.5 Disconnect each of the four rubber mounts by
inserting a pair of long nose pliers under the
Fig.10 compressor foot and levering the compressor up
whilst pushing the mount down through the hole with
a flat bladed screw driver (fig.10).
2.8.6 To remove the motorised valve and compressor,
press on the valve air outlet socket to push the valve
body into the base, whilst tilting and lifting both the
compressor and valve together (fig. 11).
2.8.7 Remove the clip (A fig.12) and disconnect the
motorised valve from the compressor outlet hose.
A
Refitting
2.8.8 Reconnect the compressor outlet hose and clip to
the valve inlet socket (A fig.12).
2.8.9 Fit a foam gasket (A fig.11) to the valve face.
Relocate the valve in the mounting holes in the base.
Fig.11
Secure the valve with the two screws (B
fig.9).
2.8.10 Re-attach the four compressor rubber mounts by
pulling them up through the mounting foot holes with
a pair of long nose pliers.
2.8.11 Refit the plastic shield (Airflo Mk3 only).
2.8.12 Refit the compressor inlet filter (D fig.9) Airflo Plus
A only.
Fig.12 2.8.13 Replace the outlet port label and refit the cover
(Section 2.3).

Simple solutions for everyday independence 7

 Part 2 Service and Repair

2.9 Compressor

The compressor is driven by a DC motor. The compressor

contains no serviceable parts, If a fault is diagnosed,
the compressor will need to be replaced.

Removing
2.9.1 Remove the compressor and motorised valve
from the base. (Section 2.8 - Removing).
Remove the motorised valve from the
compressor.

2.9.2 Remove the clip (A fig.13) and disconnect the

outlet hose from the compressor.

Refitting

2.9.3 Fit the motorised valve to the compressor and

secure the hose with a nylon hose clip. Refit the Fig.13
compressor and motorised valve to the base
(Section 2.8 – Refitting).

2.10 Pressure Relief Valve

Pressure build up within the compressor is regulated by
a relief valve (A fig.14).
A
To adjust:

2.10.1 Remove the cover (Section 2.3). Leave the

wires connected to the PCB but disconnect the
pressure sensing hose.

2.10.2 Connect a pressure gauge to the air outlet

socket. Run the compressor and using a 5mm
nut driver, adjust the PRV until the pressure
shown on the pressure gauge is between
5.5 (min) - 6.0 (max) PSI.

Note: Remove the nut driver from the PRV before

checking the gauge reading.
Fig.14

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 Part 3 Fault Finding
Possible Cause
1. Poor connection at charging
socket.
• The battery status indicator 2. Faulty connections at battery
light does not light up when terminals or PCB connector.
connected to the battery
charger. 3. Faulty battery charger.
4. Faulty control PCB.
Possible Cause
1. Wire disconnected at rear of
• Compressor and/or dump hand control socket or poor
valve fail to work when the connection at control PCB
hand control buttons are connector.
pressed.
2. Faulty hand control.
Possible Cause
1. Flat batteries.
2. Over/under bent contacts on
batteries or contacts on inside
of battery housing.
• Compressor and Dump Valve 3. Faulty connections at battery
not working and no lights. housing terminals or PCB
connector.
4. Bad connection/fault in wiring.
5. Faulty control PCB.
Simple solutions for everyday independence
Action
1. Make good connection.
2. Repair connections
3. Replace charger.
4. Replace PCB.
Action
1. Re-solder, make good
connection or replace
Motorised Valve.
2. Replace hand control.
Action
1. Charge/replace batteries as
appropriate.
2. Re-bend/align contacts.
3. Repair connections.
4. Make good connection/fault.
5. Replace PCB.
9
 Part 3 Fault Finding
• Compressor stops running
but dump valve works.
• Dump valve does not work.
• Compressor runs
continuously or intermittently
(with air outlet closed).
10
Possible Cause Action
1. Motor wire disconnected or 1. Make good connection.
poor connection.
2. Temperature sensor has tripped 2. Leave Airflo to cool for 60-90
(flashing red battery status). minutes to cool.
3. Current overload cut-out 3. Leave for 3 seconds to self
(flashing red/green battery reset.
status)
4. Faulty temperature sensor 4. Replace compressor assembly.
(flashing red battery status).
5. Faulty PCB. 5. Replace PCB.
Possible Cause Action
1. Motor wire disconnected or 1. Make good connection.
poor connection.
2. Faulty motor. 2. Replace the motorised valve.
3. Stiff/jammed flap valve 3. Replace the motorised valve.
mechanism.
4. Faulty PCB. 4. Replace PCB.
Possible Cause Action
1. Dump Valve not sealing or leak 1. Investigate cause and rectify or
through valve body joint. replace the Motorised Valve.
2. Compressor outlet hose leaking/ 2. Refit/replace hose.
disconnected.
3. Compressor pressure relief 3. Adjust pressure relief valve.
valve out of adjustment.
4. Pressure sensing hose leaking/ 4. Refit/replace hose.
disconnected.
5. Low air output from compressor. 5. Replace compressor.
6. Faulty PCB. 6. Replace PCB.
 Part 3 Fault Finding

Possible Cause Action

1. Kinks in air hose to product. 1. Remove kinks from hose.
2. Pressure relief valve on 2. Adjust pressure relief valve.
• Compressor keeps cutting compressor not opening.
out when inflating product.
3. Pressure cut-out setting on PCB 3. Replace PCB.
set too low.

Possible Cause Action

1. Battery voltage too low. 1. Check charging regime with
client and if the batteries are
• Airflo drops out of ‘Auto’ and
not retaining a charge and
stops running (battery status
indictor shows red). frequently need recharging,
replace batteries.

Possible Cause Action

1. Water within bathing product or 1. Investigate/repair cause
• Moisture within Airflo casing. air hose. of water ingress. Replace
damaged Airflo components.

Simple solutions for everyday independence 11

 Part 3 Fault Finding

3.1 Airflo Plus Wiring diagram (with and without Dump Valve and Hand Control Socket)

100nF Charging Hand Control

socket socket
Up

Motorised Valve Motor Com

Down

Air
Outlet

1
2
3
1 4
5
2
5 4 3

Ribbon cable
Ribbon cable

Red Red
2
1
Black Black 6

2
1

6 Ribbon cable

Temp sensor

Motor
Black

Red

Compressor Assy
Pressure Switch

Brown

Blue
PCB Assy
Red

Brown

Blue

Battery 1 Battery 2

Red
Yellow -

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 Part 3 Fault Finding

3.2 Airflo Mk3 Wiring diagram

Motorised Valve

100nF Charging Hand Control

socket socket
Up

Motor Com
Down

Air
Outlet

1
2
3
1 4
5
2
5 4 3

Ribbon cable

Ribbon cable

Red Red
2
1
Black Black
6

2 Ribbon cable
1
6

Temp sensor

Motor
Black

Pressure Switch
Red

Compressor Assy

PCB Assy

Brown Blue

Blue

Battery

Brown -

Simple solutions for everyday independence 13

 Parts List

4&5
6
11

12
1&2 10

13

3 9 8
(Prt of 1 & 2)
7

14

15

No. Part Number Description No. Part Number Description

1 CA0376 Motorised Valve - Kit (Airflo Plus) 9 CA0167 Handle Assembly (Airflo Mk3)
2 CB0409 Motorised Valve - Kit (Airflo Mk3) 10 CA0074 Inlet Filter - Kit
3 - Outlet Port Label (Prt of CA0376 & CB0409) 11 CA0311 Removable Battery Pack, Airflo Plus
4 CA0380 PCB & Pressure Switch (Airflo Plus) 12 CB0405 Replacement Battery Assy, Airflo Mk3
5 CB0414 PCB & Pressure Switch (Airflo Mk3) 13 CA0165 Replacement Foot & Mounting - Kit
6 CA0379 Pump assembly Plus/Mk3 - Kit 14 CA0431 Charging Power Supply (Airrflo Plus)
7 CA0396 Label, Front Panel, Airflo Plus 15 CB0117 Charging Power Supply (Airrflo Mk3)
8 CA0398 Handle Assembly (Airflo Plus)

14
 Specifications

Airflo Plus Airflo Mk3

Weight: 5.7Kg (12½ lbs)
Output pressure: 0.35 bar (5 psi)
Flow (at 5psi): 150L/min
Batteries: 2 x 12v - 2.3Ah (VRLA)
Environmental protection: IP51
Type BF equipment
Charger
Input: AC 100v - 230v, 50-60Hz, 0.3A
Output: DC 30v, 350mA
Double insulated Class II equipment
Weight: 4.6Kg (10 lbs)
Output pressure: 0.35 bar (5 psi)
Flow (at 5psi): 100L/min
Batteries: 1 x 12v - 2.3Ah (VRLA)
Environmental protection: IP51
Type BF equipment
Charger
Input: AC 100v - 230v, 50-60Hz, 500mA
Output: DC 15v, 350mA
Double insulated Class II equipment

This equipment has been tested and meets the requirements of current EMC legislation.

Mangar International reserves the right to alter product specifications and/or any of the information contained within this document without notice.

Simple solutions for everyday independence 15

Simple solutions for everyday independence

Mangar International
Presteigne, Powys, Wales, LD8 2UF
United Kingdom
tel: +44 (0)1544 267674
fax: +44 (0)1544 260287
e-mail: sales@mangar.co.uk
www.mangar.co.uk
www.mangarhealth.com MI0338 issue 3
(12/14)