About this replacement
Opticon OPN-4000i / OPN-4000n — 3.7V Li-Polymer Replacement Battery (SP622540)
This 3.7V 500mAh Li-Polymer cell replaces the original SP622540 / ET622538P pack in the Opticon OPN-4000i and OPN-4000n pocket barcode scanners. At 37.20 × 24.60 × 5.80mm, it matches the factory footprint and connector orientation. Capacity is 1.85Wh — identical to the original spec.
- OPN-4000i and OPN-4000n compatibility: Both models run the same 3.7V single-cell architecture with the same BMS handshake and connector pinout, so one part number covers both scanners without modification.
- Bench tested on actual hardware: We cycled this pack through charge and discharge on the OPN-4000 platform and confirmed the BMS accepted the cell without fault codes, voltage held steady under combined scan-trigger and wireless radio draw, and charge termination triggered correctly at full capacity.
- First-shift preparation for pick-and-pack use: After installing the new pack, seat the scanner in its cradle and let it complete a full charge cycle before the shift starts. Scan-trigger inrush current peaks when the cell is near minimum voltage — a fully charged pack prevents false BMS cutoffs during the first heavy scanning run.
Cradle showing a charging error on the new pack
The OPN-4000 cradle reads pack state through gold pogo pins on the scanner's base. Oxidation, dust, or residue on either the cradle contacts or the replacement pack's terminals raises contact resistance enough for the dock controller to flag a fault. Wipe the pack contacts and cradle pins with a dry lint-free cloth, then reseat the scanner firmly until it clicks. If the error clears within 30 seconds the contacts were the cause — if it persists, check cradle supply voltage at the USB or DC input, which should read 5V ±5%.
Scanner losing wireless connection during rapid scan bursts
The OPN-4000i transmits scanned data over Bluetooth while simultaneously firing the imager — both loads hit the cell at the same moment during a fast burst. When the pack is partially discharged, this combined inrush can pull cell voltage low enough for the radio module to reset, dropping the Bluetooth link. The BMS does not trip, so the scanner appears functional but stops sending data to the host. Keep the pack above 30% charge during heavy burst sessions — a cell voltage below approximately 3.5V under load is the threshold where the radio becomes unstable.