Nordisch BCS 5400 basic User manual

Operating Manual
(V. 1.7d)
BCS 5400/5401 (m) +
BCS 5400/5401 basic

2]
Technical details:
Cell detection: NiCd and NiMh batteries automatically up to 14 cells, Li-Ion
batteries automatically up to 7 cells, special types able to be
programmed via update.
Charge: Microprocessor-controlled electronic charge based on precise
impedance measurement at the electrode-electrolyte
transition.
Charging current: up to max. 5 amperes (effective)
Capacities (battery): 0.1 to > 100 Ah.
Battery voltage: NiCd and NiMh to 16.8 V (optionally higher)
Li-Ion up to 36 V
Connection: EU: 230 V - 50 Hz (mains fuse 3.15 A)
US: 110 V - 60Hz (mains fuse 6.30 A)
Mains connection via cooling device plug connector
Cooling: Thermo-management: Charge-independent ventilation
with cooling automation.
Dimensions: W x H x D in cm weight in Kg
BCS 5400 (m) + 49.5 x 20.0 x 30.5 8.8
BCS 5401 (m) + 30.0 x 32.5 x 30.5 8.8
(Technical changes reserved!)

3]
Foreword:
About the charging process
The applied charging process is patented worldwide and has received innovation
awards. Starting with series BCS 5400/5401 (m) +, we are working with a new and
unique technology for charging batteries, especially for detecting the causal 100%
charge level of a battery. Analogous to the current process, fully new methods are
applied to charge batteries. This enables the 100% full charge level to be specified for
batteries featuring different types of technology (NC, NMH, LiIon, Pb, and more). This
was possible because an alternating current equivalent circuit diagram has been used
for the first time to calculate the process inside the cell (interior impedance at the
electrode-electrolyte transition). Originally used for applications with maximum
reliability requirements, e.g. involving medical technology like life-support systems, and
this technology is also found in other applications like safety equipment, UPS systems,
electrical vehicles, radio stations, data collection devices, mobile telephones, laptops,
and specific applications in the automotive industry.
Thank you for choosing this Nordisch charging station, which is a highly developed
charging device. Our customers’ requirements for protection against overheating,
modularity, operation and service-friendliness have motivated us to develop the type
BCS-5400 (m) + multiple charging system. By charging your industrial tool batteries
regularly using this station, you can increase their tool life between 2000 and 5000
charging cycles (NiMh and NiCd batteries)!

4]
Special properties of the BCS-5400 (m) +:
- Independent of battery type (Li-Ion/lead acid/NiCd/NiMh, etc.)
- Precision: exact full charge possible.
- Long lifespan of battery combined with simultaneous fast charging
- Micro-computer controlled, automatic charging
- Independent of battery capacity and cell quantity
- No memory effect, no gases
- Micro-processor controlled charging
- Automatic battery and voltage detection
- Automatic transition to conservation mode (after full charging)
- Error analysis and indication via LED signal encoding.
- Charging possible for extremely low batteries
- Optional programming for individual charging parameters (e.g. for
regions with other climatic conditions).
- Automatic configuration of charging rates via processor in the adapter.
- “Deep sleep” mode possible (Li-Ion).
- Update possible via external interface.
- Selectable as individual or cabinet system.

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First steps:
(1) Remove the device from the packaging and place it on a stable underlay.
(2) Connect the device to a protective contact plug socket (a matching mains cable
is provided in the packaging).
(3) Slide the corresponding charging adapter and the required intermediate adapter
as needed (accessory) into the charging slots (figure 1). Do not use force, since
the adapter will snap into the insert with slight pressure. If used, ensure that the
arrow on the intermediate adapter faces upwardsand that the connectorlocated
on the adapter points to the left side of the charging slot. The system is not
compatible with other similar charging adapters (with 8-pin contact connectors)
from other manufacturers. (If you want to use these, please contact us.)
(4) Switch on: After you have inserted all necessary adapters, switch on the device
with the main switch (rear side). After switching on, all optical signal lamps glow
in sequence to check the functionality (LEDs) for approx. 0.5 seconds, and then
the red and blue signal maps (LEDs) go out, while the green signal lamps
indicate that the charging slots are ready for operation.
-The charging station is now ready for operation! –
Charging slot
O
Direct connector plug
O
Adapter
(Opening for battery)
O
Status LEDs
Functional principle: Insert adapter

6]
Notice:
If a charging adapter is not inserted correctly or is not inserted at all, activation will
issue a signal (optically and acoustically) via the red LED. The red LED flashes until
an adapter has been inserted correctly or until the parameter sets of the adapter have
been imported for the charging circuit board.
Do not use force to insert the charging adapter. If the adapter is inserted in the correct
direction in the adapter mount, use soft pressure to slide the last 5 mm up to the end
stop in the connector device. Never hammer the charging adapter into the mount!

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Charging slot description:
The charging slot is the receptacle for the charging adapter (types, see separate
adapter list) and indicates all of the necessary information to the userfor the respective
device or the battery level in this slot.
Figure, charging slot (front view):
4 fastening screws of the
charging slot.
Battery technologies
that can be charged.
Charging slot voltage range
(min./max.)
Charging slot number
Function LED:
Green: Chargingfunction(ready/complete)
Blue: Notice
Red: Charging or errors &
messages in
combination with red or blue.

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Interface/rear side of device:
The BCS 5400 (m) + has been future-proofed thanks to its freely programmable
structure. Battery technologies that are not yet used and batteries that will be only be
used years from now may be used by individually adjusting the parameter sets to suit
future, unknown requirements. The properties on the chip of the adapter or on the main
circuit board that are relevant are updated to the
state of the art via the charging strip up to the adapter
using a software update. An update is possible using a
conventional USB cable and a PC including user
software. The combination of rotary switch (left in the figure), USB (3.0) interface
(centre of figure), and the network connection provide the system maximum flexibility.
The network interface (right in the figure) is provided for the network connection of the
AM 5400 battery management system and is not important for normal charging.
Notice:
Programming the device and parameter sets in the adapter may only be completed by
trained technical personnel. In case of doubt, ask us directly.

9]
Additional battery information:
The design of a battery is different according to the manufacturer. Make sure that the
battery you use
a) matches the adapter mechanically
b) matches the internal contact arrangement
in the adapter
It is possible that the battery in fact matches the shape of the adapter you wish to use,
but the connection contacts inside the adapter still do not match those of the battery.
Or, the arrangement of the contacts matches, but the configuration of the contacts is
different. (figure 2).
Figure: Contacting principle (front view):
For this reason, always ensure that the battery type is pressed on to the adapter
properly. If you observe the previously indicated points and the adapter type matches
the battery, then you can slide the battery into the corresponding charging slot.
Nevertheless, if an acoustic signal sounds, please compare the contact configuration
of the battery with that of the adapter again. The BCS-5400/5401 (m) + is fully
compatible with the adapters of the previous series of our charging stations, i.e. all
adapters with the older design (8-pin connector) match the new charging station, and
in case older adapters are used, the BCS-5400/5401 (m) + works in compatibility
mode. For safety reasons, batteries after the year 2011 may only still be charged with
the new one-wire chip adapter, which may be recognised by its 10-pin connector plug.
We can convert older adapters for you after checking them.
In case of doubt,please read the troubleshooting chapter, contactthe technical service
department, or talk with us directly.

10]
Charging:
After you have slid the battery into the charging slot, the system checks the battery
briefly, the green signal lamp goes out, and the red signal lamps start to glow. The
automatic charging process has now started.
During the charging process, the internal temperature of the battery is monitored
continuously. If the temperature exceeds its threshold value during the charging
process, this will stop immediately. If anoverheated battery is inserted into the charging
slot, the charging process only begins after the battery has cooled off. This may extend
the charging time accordingly.
In order to start the charging process directly, do not insert overheated batteries into
the charging device (e.g. batteries that were previously
discharged under extreme conditions).
During charging, voltage & current are regularly monitored. Upon reaching its
maximum capacity, the battery is immediately disconnected from the charging current.
The measurement applied in the device for internal impedance detection therefore
rules out overcharging. Therefore, a charged battery does not need to be removed
from the charging slot, but instead remains full thanks to the automatically activated
conservation mode (this compensates the self-discharge caused by the battery’s
interior resistance). The battery is therefore always available in an optimal state. Li-Ion
batteries are charged directly in dialogue with the battery, and the final shut-off and
charge conservation is completed in dialogue with the battery or the adapter chip.
The flashing green LED indicates the availability of the battery.
This signals that:
- the battery in the battery is fully charged
- conservation mode is active
If you possess a battery management system (AM 5400), the blue LED indicates
instructions for use of the battery in the device. Additional detailed information is
provided in the separate use instructions.

11]
Notice:
If you insert older batteries in this device (basically NiCd or NiMh) that were charged
previously in a conventional charging device, these could nevertheless possess less
capacity in spite of complete charging.
This so-called “memory effect” results from the different charging processes. After
charging this battery multiple times with the BCS-5400 (m), this effect should be
completely corrected again (provided the battery is not yet damaged).

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LED signal description:
GREEN glowing - the charging slot is ready
GREEN flashing - fully charged &
conservation charge
RED glowing - BATTERY charging
RED flashing - ERROR MESSAGE
(for details, see the error codes chapter)
BLUE glowing - NOTICE - battery cooling off
Automatic charging only continues
after cooling.
The description of the signal encoding is also provided on an included sticker. This
may be attached to the device as required.
Messages/error codes
The BCS 5400/5401 (m) + is equipped with numerous extensive self-monitoring and
analysis functions. The goal is to examine the individual charging requirements of the
battery manufacturer to achieve the max. life cycle of the battery. If a battery or system
function deviates from the specified criteria during the charging cycle, an optical and
acoustic signal message will be provided to the user. The optical signal message takes
place during registration via the attached LED together with an acoustic signal. The
LED flashes again during the signal tone after the process has been completed. If the
battery is removed from the charging adapter, the signal tone repeats and provides
information about the situation. The meaning of the signal tones differs according to
the frequency of the repetitions. The colours of the diodes differ according to:
RED &GREEN
Status message (uncritical situation - battery should be evaluated or tested manually. E.g. overloading, over-temperature, etc.
BLUE
Information: The charging process has been interrupted temporarily by the cooling phase, will start after cooling automatically.

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After removing the battery, the type of error is indicated to the user by an acoustic
signal. The error codes indicated below describe the errors that occurred:
(please also see: “Technical service information for software version XX”)
The exact importance of the notice/warning message and the error codes are included
with the respective testing documents for the device and correspond with the newest
version. If you receive a software update, then ask for an updated version of the
documents in case of doubt.
Security system:
The device is equipped with a regular security query.
After the supply voltage switches on, the charging device electronics are checked for
any possible errors by a self-test. If the detected parameters do not match the saved
ones, this is indicated to the user by a message.
These system checks take place as described above and during battery charging. If
errors occur in this case that could endanger the battery, then the message indicated
above will be displayed and the affected charging slot will be switched off.

14]
Safety instructions/disposal:
● Note the voltage supply!
The device may only be connected to the following alternating current mains:
a) 230 V/50 Hz (EU version) or
b) 110 V/50-60 Hz (US version)
● Only batteries marked NiCd (nickel cadmium), NiMh (nickel metal hydride), and Li or Li-
Ion (lithium ions are charged with the adapters provided for this. Other battery types
permitted only if authorised by the manufacturer.
● In commercial institutions, the accident prevention regulations of the Association of
Commercial Trade Associations for electrical systems (BGV-A3) must be observed.
● Adapters are subject to wear. The BCS-5400/5401 (m)+ itself is maintenance-free.
Nevertheless,
if faults occur that require an alteration in the device required, then this
may only be completed by trained technical personnel.
● Defective safeguards on the device may only be replaced with equivalent designs.
●The BCS-5400/5401 (m) + may only be operated in dry rooms.
●Ensure sufficient ventilation! The ventilation slits on the respective device may never be
covered during operation to prevent possible heat accumulation.In spite of the innovative,
sophisticated cooling concept, the worst case could result in damage to individual
electronic components!
● In case of transport from a cold into a warm environment, wait until the BCS-5400/5401
(m)+ has reached room temperature before switching it on.
●Damaged batteries and charging systems are able to be recycled or must be disposed of
correctly as special waste. Provide these to your dealer accordingly. Your dealer is
obligated to accept them free of charge.

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Troubleshooting:
Error
Cause
Remedy
After switching on,
not all prepared displays
glow
The device is defective
Contact
our customer service
After inserting the
battery, an acoustic
warning signal sounds
The adapter used
is not compatible with the
battery type
Use an adapter
that matches the
corresponding battery
The inserted battery
is defective
Replace the
defective battery
After inserting the
battery, the red
Signal lamp flashes
The adapter used
is not compatible with the
battery type
No adapter inserted.
Use an adapter
that matches the
corresponding battery
and insert it correctly.
The thermo-element in
the
battery is defective
Replace the
defective battery
After approx. 100 min,
The signal lamps flash
The maximum charging
time
has been exceeded
Replace the
defective battery
The battery does not
provide power in spite of
a full charge
One or more cells
in the battery are
defective
Replace the
defective battery
Charging adapter for 1.2 V-36 V:
NiCd and NiMh batteries: Bosch
Atlas Copco
Dewalt
Cooper (Cleco)
Fein
Uruy
Makita
Gesipa
Panasonic
Hitachi
Li-Ion batteries: Bosch
Atlas Copco
Makita
Panasonic
Cooper (Cleco)
Desoutter
HST, AMT
POP
Milwaukee
Additional adapters and testing devices upon request.

16]
Declaration of conformity with ES standards
The signing party,
Nordisch GmbH, Carsten-Dressler-Str. 10, Germany,
hereby declares that the following industrial charging devices:
Model: BCS-5400 (m) + and BCS 5401 (m) +
(serial no.: serial production)
According to the guidelines 2004/108/EC (ex 89/336/ECC), guideline 2006/95/EC (ex
73/23/ECC) and guideline 2006/42/EC for safe & fault-free operation matching the
following standards or standard documents:
EN 60065, EN 55014, EN 55011, EN 61000-3-2, EN 61000-6-2
Bremen, 01.05.2014
Dipl. –Wirtsch.- Ing. (FH)
Marcus Runge
-Geschäftsführung / Chief Executive Officer-
WEEE-Reg.-Nr. DE 50982548