Honeywell ScanPal 5100 Replacement Battery 3.7V 2200mAh

Honeywell ScanPal 5100 / Dolphin 6100 Series — 3.7V Li-ion Replacement Battery (BP06-00028A)

This 3.7V, 2200mAh Li-ion battery replaces the OEM pack in the Honeywell ScanPal 5100, Dolphin 6500, Dolphin 6110, and Dolphin 6100 handheld barcode scanners. These devices run in retail pick lines, warehouse inventory operations, and field data capture workflows where a dead battery means a stalled shift. The cell matches the original voltage rail and connector footprint across all four models.

• ScanPal 5100 and Dolphin 6100 series compatibility: All four models share the same 3.7V battery bay, connector pinout, and BMS handshake protocol — which is why one pack covers this entire scanner family without firmware conflict or charge-state reporting errors.
• Bench tested on actual hardware: We cycled this pack through repeated scan-burst sequences on the ScanPal 5100 and monitored BMS behaviour under combined wireless radio and imager draw. The protection circuit held voltage steady and did not false-trip at any point during the test sequence.
• First-shift pre-charge procedure: After installing this pack, seat the scanner in its cradle and run a full charge cycle before pulling it into active pick-and-pack. Scan trigger inrush is highest when the cell is near minimum charge — a pre-charged cell prevents the BMS from tripping on the first burst of the shift.

Cradle showing a charging error on a new pack

Honeywell cradle docks communicate with the battery pack through four contact points on the base of the scanner. If those contacts have dust, oxidation, or oil from handling, the dock reads elevated contact resistance and flags a charging fault rather than begin the charge cycle. Remove the scanner, wipe the battery contacts and cradle pins with a dry cloth, then reseat firmly. If the error clears within 30 seconds of reseating, contact resistance was the cause — not a fault with the pack itself.

Scanner losing wireless connection during rapid scan bursts

During a fast scan burst, the imager and the wireless radio fire near-simultaneously, creating a combined inrush current that momentarily sags the cell voltage. If the battery is below roughly 3.5V, that sag is enough for the radio module to drop its connection before recovering. This is not a pairing fault — it is a voltage-floor problem. Charge the pack to full before a high-throughput shift and the connection drops will stop.