Intermec CA54200-0090 Antares 2420 Replacement Battery 7.4V

Intermec Antares 2420 / 2425 — 7.4V Li-ion Replacement Battery (CA54200-0090)

This 7.4V, 2200mAh Li-ion battery replaces the CA54200-0090 (also listed as FMWBP4) in the Intermec Antares 2420, Antares 2425, and 5020 DCPC handheld barcode scanner family. These are portable data collection devices used in warehouse picking, retail stockrooms, and logistics workflows. The pack slots directly into the battery compartment and communicates with the onboard BMS before the unit will power on.

• Antares 2420 / 2425 and 5020 series compatibility: These models share the same 7.4V dual-cell configuration, identical connector pinout, and the same BMS handshake protocol — the scanner queries the pack for cell chemistry and voltage state before enabling the scan trigger. One battery fits all of them without modification.
• Bench tested on actual hardware: We ran this pack through full charge cycles and monitored the BMS negotiation sequence. The protection circuit responded correctly to charge termination, over-discharge cutoff, and the inrush spike that occurs when the laser or imager fires on the first scan after power-on.
• First-install cradle protocol: After fitting this pack, place the scanner in its charging cradle for a complete charge cycle before starting a shift. The scan trigger inrush current is highest when the cell is near minimum — a fully charged pack prevents false BMS trips when the imager fires for the first time under load.

Cradle showing a charging error on a brand-new pack

Charging docks on the Antares series read pack voltage through pogo-pin contacts on the base of the battery. If those contacts have oxidation or debris from a previous worn-out pack, the dock registers a high-resistance connection and throws a charge fault — even though the new battery is fine. Wipe the contacts on both the pack and the dock with a dry cloth, then reseat the scanner firmly. The charge indicator should switch to normal within 30 seconds of a clean contact.

Scanner losing wireless connection during rapid scan bursts

On the 2420 and 2425, the radio module and the imager draw current simultaneously during fast barcode capture — each scan trigger fires the imager while the radio is mid-transmission sending the previous scan result. This combined inrush can sag cell voltage below the BMS's low-voltage floor on a degraded or deeply discharged pack, causing the radio to drop its connection to the host. The fix is to ensure the pack is above 7.0V before a high-frequency picking session — check the battery indicator on the scanner before the shift starts.