service manual airflo plus & mk3 - shopify...2.5 switch label 2.5.1 peel the label and remove...

service manual

Airflo Plus & Mk3

Simple solutions for everyday independence

Simple solutions for everyday independence2 3

IntroductionThe 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 PagePart 1 Service Schedule 2Part 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 8Part 3 Fault Finding 9 3.1 Wiring Diagram 12Parts List 14Specifications 15

Service ScheduleCheck 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

Part 1 Service Schedule


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 TestUsing 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)


Part 2 Service and Repair

2.1 BatteryThe Airflo Plus is fitted with a quick release battery pack. The batteries can either be re-charged whilst in 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).

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.

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 pack to ensure that the two battery contacts align with the two contacts in the housing.

2.1.5 Refit the rubber pads, retaining plates (E) and screws (D).

NOTE: When replacing the battery, always replace with the same type.

2.2 Air Filter

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

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).

Fig. 1

A

B

F

Fig. 2

CE

D

F


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.

2.3.4 Inspect the condition of the gasket (A 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

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. 3

A

A

Fig. 4



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 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).

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.

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

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

Fig. 5

Fig.6

A

A

A

Fig.7

Fig.8



Fig.9B

D

A

Fig.10

A

Fig.11

Fig.12A

2.8 Motorised ValveIf a fault develops, the motorised valve assembly (A fig.9) 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 valve.Removing2.8.1 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).

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 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.

Refitting2.8.8 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. 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

only.2.8.13 Replace the outlet port label and refit the cover

(Section 2.3).

C



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 compressor and motorised valve to the base (Section 2.8 – Refitting).

2.10 Pressure Relief ValvePressure build up within the compressor is regulated by a relief valve (A fig.14).

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.13

Fig.14

A

A



Part 3 Fault Finding

• The battery status indicator light does not light up when connected to the battery charger.

1. Poor connection at charging socket.

2. Faulty connections at battery terminals or PCB connector.

3. Faulty battery charger.

4. Faulty control PCB.

1. Make good connection.

2. Repair connections

3. Replace charger.

4. Replace PCB.

Possible Cause Action

• Compressor and/or dump valve fail to work when the hand control buttons are pressed.

1. Wire disconnected at rear of hand control socket or poor connection at control PCB connector.

2. Faulty hand control.

1. Re-solder, make good connection or replace Motorised Valve.

2. Replace hand control.


• Compressor and Dump Valve not working and no lights.

1. Flat batteries.

2. Over/under bent contacts on batteries or contacts on inside of battery housing.

3. Faulty connections at battery housing terminals or PCB connector.

4. Bad connection/fault in wiring.

5. Faulty control PCB.

1. Charge/replace batteries as appropriate.

2. Re-bend/align contacts.

3. Repair connections.

4. Make good connection/fault.

5. Replace PCB.



• Compressor stops running but dump valve works.

1. Motor wire disconnected or poor connection.

2. Temperature sensor has tripped (flashing red battery status).

3. Current overload cut-out (flashing red/green battery status)

4. Faulty temperature sensor (flashing red battery status).

5. Faulty PCB.


2. Leave Airflo to cool for 60-90 minutes to cool.

3. Leave for 3 seconds to self reset.

4. Replace compressor assembly.

5. Replace PCB.


• Dump valve does not work.

1. Motor wire disconnected or poor connection.

2. Faulty motor.

3. Stiff/jammed flap valve mechanism.

4. Faulty PCB.


2. Replace the motorised valve.

3. Replace the motorised valve.

4. Replace PCB.


• Compressor runs continuously or intermittently (with air outlet closed).

1. Dump Valve not sealing or leak through valve body joint.

2. Compressor outlet hose leaking/disconnected.

3. Compressor pressure relief valve out of adjustment.

4. Pressure sensing hose leaking/disconnected.

5. Low air output from compressor.

6. Faulty PCB.

1. Investigate cause and rectify or replace the Motorised Valve.

2. Refit/replace hose.

3. Adjust pressure relief valve.

4. Refit/replace hose.

5. Replace compressor.

6. Replace PCB.




• Compressor keeps cutting out when inflating product.

1. Kinks in air hose to product.2. Pressure relief valve on

compressor not opening.

3. Pressure cut-out setting on PCB set too low.

1. Remove kinks from hose.2. Adjust pressure relief valve.

3. Replace PCB.


• Airflo drops out of ‘Auto’ and stops running (battery status indictor shows red).

1. Battery voltage too low. 1. Check charging regime with client and if the batteries are not retaining a charge and frequently need recharging, replace batteries.


• Moisture within Airflo casing.1. Water within bathing product or

air hose.1. Investigate/repair cause

of water ingress. Replace damaged Airflo components.




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

Motorised Valve

PCB Assy

Battery 2

-

Motor

Temp sensor

Motor

Charging socket

Hand Control socketUp

ComDown

100nF

54321

12

345Re

d

Red

Black

Red

Black

Ribbon cable

Blue

Compressor Assy

Brown

Ribbon cable

Ribbon cable

612

21

6

Blac

k

Pressure Switch

Blue

Brown

AirOutlet

Red

Red Yellow

Battery 1



Motorised Valve

PCB Assy

Battery

-

Motor

Temp sensor

Motor

Charging socket

Hand Control socket

Up

ComDown

100nF

54321

12

345

Red

Red

Black

Red

Black

Ribbon cable

Blue

Compressor Assy

3.2 Airflo Mk3 Wiring diagram

Brown

Ribbon cable

Ribbon cable

612

21

6

Blac

k

Pressure Switch

BlueBrown

AirOutlet



Parts List

No. Part Number Description No. Part Number Description1 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 Plus4 CA0380 PCB & Pressure Switch (Airflo Plus) 12 CB0405 Replacement Battery Assy, Airflo Mk35 CB0414 PCB & Pressure Switch (Airflo Mk3) 13 CA0165 Replacement Foot & Mounting - Kit6 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)

7

1 & 2

8

14

10

116

4 & 5

3(Prt of 1 & 2)

15

9

12

13


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

Airflo Plus Weight: 5.7Kg (12½ lbs)Output pressure: 0.35 bar (5 psi)Flow (at 5psi): 150L/minBatteries: 2 x 12v - 2.3Ah (VRLA)Environmental protection: IP51Type BF equipment

ChargerInput: AC 100v - 230v, 50-60Hz, 0.3AOutput: DC 30v, 350mADouble insulated Class II equipment

Specifications

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

Airflo Mk3 Weight: 4.6Kg (10 lbs)Output pressure: 0.35 bar (5 psi)Flow (at 5psi): 100L/minBatteries: 1 x 12v - 2.3Ah (VRLA)Environmental protection: IP51Type BF equipment

ChargerInput: AC 100v - 230v, 50-60Hz, 500mAOutput: DC 15v, 350mADouble insulated Class II equipment

Simple solutions for everyday independence

Mangar InternationalPresteigne, Powys, Wales, LD8 2UFUnited Kingdomtel: +44 (0)1544 267674 fax: +44 (0)1544 260287e-mail: [email protected] MI0338 issue 3

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service manual airflo plus & mk3 - shopify...2.5 switch label 2.5.1 peel the label and remove...

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