SKC PowerFlex Series User manual

PowerFlex Battery Charging System
Small and lightweight, the SKC PowerFlex®is an advanced charging system
designed for optimal charging of NiCad and NiMH baery packs for most SKC
personal air sampling pumps. Baeries for up to four different pump models
(excluding EX and ATEX models and models with lithium-ion [Li-Ion] baeries)
can be charged simultaneously on the five-station PowerFlex.
Pump-specific cables are used to connect baery packs to the PowerFlex so that
only one charger is needed for most SKC personal sample pumps. PowerFlex fully
charges baery packs in 6 to 8.5 hours, and then automatically switches to a safe
pulse trickle charge. Each aached baery pack runs through an independent
cycle. An LED at each port indicates baery charge status. Baery packs can be
charged aached to or detached from the pump.
Performance Profile*
Dimensions: 4.4 x 5.5 x 1.4 in (11.1 x 14 x 3.5 cm)
Weight: 1.1 lbs (0.5 kg)
Charging time‡:6 to 8.5 hrs
Status LED: Steady Red = Charging
Steady Green = Trickle charge
Input voltage: 100-240 V
Intrinsic safety: Not intended for use in explosive or hazardous
locations
Approvals: Power supply is for electrical safety and
is CE marked.
* For U.S.-produced pump models only. Not compatible with Ex or ATEX-approved models.
‡ Typical charging times vary with model, baery capacity, and level of discharge.
Operating Instructions
863 Valley View Road, Eighty Four, PA 15330 USA
Tel: [phone] • www.skcinc.com

Operation
Procedure for PowerFlex Activation
To activate the PowerFlex charger, follow the steps below in the order indicated.
In particular, note that the power cord must be plugged into the electrical outlet
LAST.
1. Plug the switching power supply into the power jack on the back of the PowerFlex.
2. Plug the adapter end of the power cord into the jack on the switching power supply.
3. Plug the other end of the p
ower cord into the electrical outlet (100-240 V).
Failure to follow this sequence of steps will cause the charger to shut down due
to a protective mechanism in the electronics. If this occurs, unplug the power cord
from the electrical outlet and from the switching power supply, wait 2 minutes, and
then plug the adapter end of the power cord into the jack on the switching power
supply and the other end of the power cord into the electrical outlet.
If any LED lights red or green upon plugging the charger into the wall
outlet (no pump[s] aached), discontinue use of the charger and return it
to SKC for repair.
Procedure for Charging AirChek 2000 Pumps
Aention AirChek 2000 Users: To prevent baery damage, follow the steps below
in the order indicated.
1. Ensure the sample pump is off.
2. Open the protective cover on the pump charging port by turning the cover
90 degrees counter-clockwise.
3. Connect the charging plug end of the charging cable to
the charging jack on the AirChek 2000 with the keyed
edge facing down. Caution: Forcing the plug into the
pack with the keyed edge facing up will cause damage to the
baery pack.
4. Insert RJ-45 connector on the charging cable into the
PowerFlex charging port.
5. Allow up to 60 seconds for the LED indicator to
light red. If it does not light, see Troubleshooting, Step 1.
6. The baery is fully charged when the LED indicator lights green.
7. Disconnect the RJ-45 connector on the charging cable from the PowerFlex
charging port.
8. Disconnect the charging plug end of the cable from the charging jack on the
AirChek 2000 baery.
9. Close the protective cover on the pump charging port.
• PowerFlex line source is UL Listed for electrical safety, but the low-voltage
charger unit is not. Do not use PowerFlex in hazardous locations, in rain, or
in standing water. For indoor use only.
• Remove pump-specific cables from the charger when they are not in use
to avoid shorting.
• Do not obstruct the cooling fan vent.
Caution
3

Procedure for Charging Other SKC Pump Models
The following instructions apply to each charging port and sample pump used.
Each port operates independently.
1. Ensure the sample pump is off.
2. Select the appropriate pump-specific cable.
3. Insert the RJ-45 connector into a charging port on the PowerFlex. The connector
should slide easily into the port.
4. Insert the charging plug end of the cable into the charging jack on the appropriate
sample pump.
AirChek 52 Note: Plug the charging plug end of the cable into the jack on the
back of the baery pack.
5. The LED at the port containing the pump will light a steady red to indicate that
a charge sequence has been initiated. Baeries for up to four different pump models
can be charged simultaneously on the five-station PowerFlex.
If the LED does not light red within 60 seconds, see Troubleshooting, Step 1.
6. Once the baery pack is fully charged, the LED at the port will change to a
steady green to indicate that PowerFlex has switched to a trickle charge to keep
the baery at full charge.
7. The baery can be removed at any time after the LED turns green. Detach the
baery from the cable and remove the cable from the charger.
Important Note: Remove pump-specific cable from charger when not in
use to avoid shorting.
Important Note: Pumps may remain connected to the charger indefinitely
(without causing damage to the pump or charger).

Form 37783 Rev 2003
PowerFlex Charging System Cat. No.
PowerFlex 5-station Charger†includes power supply and cord.
Purchase pump-specific cables separately; choose from list below
100-240 V 223-1000
PowerFlex Single Charger†includes power supply. Purchase pump-
specific cables separately; choose from list below. 100-240 V 223-2000
PowerFlex Pump-specific Cables†Cat. No.
AirChek®2000 223-1001
Universal XR (5 cell) 223-1002
Universal XR (4 cell, MSHA) 223-1003
AirChek 52 223-1004
Accessory Cat. No.
Nylon Carry Case, for 5-station PowerFlex, includes
padded shoulder strap and compartment for cables 224-903
PowerFlex Technology
Charging NiCad/NiMH batteries is generally accomplished by applying constant current to the battery.
SKC PowerFlex Chargers use a technology that is new to industrial hygiene equipment batteries.
Reflex charging†delivers pulses of current instead of constant current to charge batteries. In between
pulses, PowerFlex applies short reverse pulses that discharge the battery slightly and short pauses.
This eases the battery into a full and uniform charge. It helps to prevent dramatic increases in internal
temperature and pressure that can damage the battery and shorten its life.
† Patented by Galaxy Power, Inc.
Note: Discharging the pump battery before charging is not necessary with this system
because the charging technology does not promote memory. However, if the user
desires to discharge before charging, simply run the pump until it stops, then
charge the battery.
SKC Limited Warranty and Return Policy
SKC products are subject to the SKC Limited Warranty and Return Policy, which provides SKC’s sole
liability and the buyer’s exclusive remedy. To view the complete SKC Limited Warranty and Return
Policy, go to hp://www.skcinc.com/warranty.
Troubleshooting
If the LED does not light when a baery pack is plugged into a port or the LED
does not turn offafter a baery pack is unplugged, follow the steps in the table.
Step Action No result, Action Yes result, Action
1 Keep the unit powered on. If the battery is deeply
discharged, the LED may take up to 30 minutes
to light or turn off.
Go to Step 2 Proceed with operation
2 Check fan. Is it running?
a. Check power to unit and/or
b. Move unit to a different wall outlet
Go to step 3 Proceed with operation
3 Move battery to different port Go to Step 4 Proceed with operation
4 Unplug charger from its power source for 20
seconds. Plug it back into power source.
Go to Step 5 Proceed with operation
5 Replace pump-specific cable Go to Step 6 Proceed with operation
6 Try a different battery pack Call SKC Proceed with operation —
previous battery pack may
be damaged; call SKC.
† For U.S.-produced pump models only. Not compatible with Ex or ATEX-approved models.