How to Refill Sail Air Safely: Step-by-Step Guide

Refilling your Sail Air should feel simple and stress-free, not confusing or risky. 

When it is done the right way, you get a system that is ready when you need it and performs exactly as it should. When it is done wrong, even small errors can affect safety and reliability.

This guide will walk you through the correct way to refill Sail Air so you can do it with confidence every time and keep your system in proper working condition.

What is Sail Air

Sail Air is a compact, refillable air system made for short-term breathing support underwater. It is smaller and easier to use than traditional scuba gear, which makes it practical for quick underwater tasks without the need for full dive equipment.

It is designed for simple jobs like retrieving something that fell overboard, clearing debris from the hull, or checking your propeller. With Sail Air, you can access breathing air directly from your boat, without depending on shore-based facilities.

Things to Keep in Mind Before Refilling Sail Air

Before refilling your Sail Air, always start with a basic safety check over the entire system. If anything appears worn, loose, or abnormal, do not proceed with the refill.

Safety reminders before you begin:

1. Never overfill the cylinder beyond 207 bar.
2. Do not fill or use the system if it has been exposed to extreme heat above 40°C or to open flame.
3. Do not stand directly over the product during filling.
4. Carefully inspect your device for damage, leakage, or poor performance before every refill.
5. Always remove the dust cap and inspect the threads on both the first-stage regulator and the cylinder for damage.
6. Make sure the main valve turns smoothly before continuing.

These checks will reduce avoidable risks and help keep your Sail Air safe, dependable, and ready for use.

Method 1: Refilling with a SCUBA Tank (Decanting)

This method uses a full standard SCUBA tank and a refill adapter to transfer air into your Sail Air cylinder. It is a simple and direct way to refill, as long as each step is followed in the correct order and the pressure limit is respected.

Step-by-step filling process:

1. Connect the refill adapter to a full 3000 psi / 200 bar standard scuba tank.
2. Tighten the pressure relief valve on the refill adapter.
3. Connect the refill adapter to the Sail Air cylinder.
4. Slowly open the scuba tank valve to begin filling and stop when the pressure reaches 3000 psi / 207 bar.
5. After filling, close the scuba tank valve and open the pressure relief valve to release the pressure inside the adapter.
6. Disconnect the refill adapter to complete the filling process.

Once the adapter has been fully depressurized and disconnected, your Sail Air is ready for use or safe storage according to the recommended guidelines.

Method 2: Refilling with a High-Pressure Manual Pump

This method allows you to refill your Sail Air using a dedicated high-pressure manual pump connected directly to the quick-coupling filling port. It is important to follow the correct order and stop filling once the pressure limit is reached.

Step-by-step filling process:

1. Connect the high-pressure manual filling pump to the quick coupling filling port.
2. Close the hand pump pressure relief valve.
3. Start pumping and stop when the pressure reaches 3000 psi / 207 bar.
4. Open the pressure relief valve.
5. Disconnect the pump from the quick coupling filling port.
6. Replace the filter material after 5 fillings or once each year.

Once the line has been depressurized and the pump disconnected, your Sail Air is ready for use or can be stored safely.

Essential Rules for Sail Air Maintenance

Regular care and proper handling are key to keeping your Sail Air safe, reliable, and ready for use. Simple habits like cleaning after use, correct storage, and scheduled servicing all play a major role in extending the life of the system and preventing avoidable failures.

Some maintenance rules to follow:

• Wash the cylinder with fresh water and dry it after every use.
• Store Sail Air in a cool place with a remaining pressure of 30 bar.
• NEVER use hydrocarbon-based oils, such as household oil or motor oil.

  • If there is any damage, wear, suspicion of leaks, or missing parts, do not use the system.

• Do NOT attempt to repair Sail Air yourself.

  • Sail Air should be serviced annually by an authorized Sail Air dealer or NRC International to assure proper performance and safety measure.

• The cylinder must be inspected internally and externally for corrosion, dents, cracks, or other damage every 2 and 4 years.
• The Sail Air pump must also be serviced yearly by an authorized dealer or NRC International.

By following these maintenance rules, you help ensure that your Sail Air stays in a safe working condition and continues to perform as intended whenever it is needed.

Refill with Confidence, Stay Ready on the Water

Knowing how to refill your Sail Air properly means you are never caught unprepared when something needs attention below the surface. With the right steps, the right pressure, and simple routine checks, refilling becomes a quick and reliable part of your normal onboard routine.

Whether you are clearing debris, checking your hull, or responding to an unexpected situation, having a properly filled and well-maintained air system gives you peace of mind. Sail Air keeps your next underwater task simple, controlled, and within reach.

And if you ever need guidance along the way, our team is ready to help you keep everything running smoothly. Contact us today if you have any questions about your Sail Air!