Honeywell ScanPal 5100 Replacement Battery BP06-00028A 3.7V 3300mAh

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

This is a 3.7V, 3300mAh Li-ion cell that fits the Honeywell ScanPal 5100, Dolphin 6500, Dolphin 6110, and Dolphin 6100 handheld barcode scanners. It replaces OEM part numbers BP06-00028A, BP06-00029A, 6000-TESC, and 6000-BTSC. If your scanner is shutting down mid-shift or failing to hold a charge, this pack restores full operating capacity.

• ScanPal 5100 and Dolphin 6100 series compatibility: These models share a common battery bay footprint, connector pin-out, and BMS handshake protocol. The same 3.7V cell services the entire group without any firmware or hardware modification.
• Bench tested on actual hardware: We cycled this pack through full charge-discharge sequences on a ScanPal 5100 unit. The BMS responded correctly at low-voltage cutoff and accepted charge without error flags on the first cycle.
• First-shift cradle protocol: After installing this pack, seat the scanner in its charging cradle and complete one full charge cycle before running it in a pick-and-pack environment. The scan trigger inrush current is highest when the cell sits near minimum charge, and a fully pre-charged cell prevents false BMS trips during your first high-frequency scanning shift.

Cradle charging error on a new pack in the Dolphin 6100 dock

The Dolphin 6100 dock reads battery state through spring-loaded contacts on the base of the scanner. If those contacts have oxidation or debris from a previous battery, the dock misreads the new pack and flags a charging error. This is a contact resistance issue, not a pack fault. Wipe the gold contacts on both the scanner base and the dock with a dry lint-free cloth, then firmly reseat the unit. The charging LED should switch to solid amber within 10 seconds.

Scanner losing wireless connection during rapid scan bursts

During a rapid scan sequence, the ScanPal 5100 draws current simultaneously from the imager, the processor, and the wireless radio. If the cell voltage sags under this combined load, the radio stack loses its minimum operating voltage before the BMS trips, and the wireless link drops. This appears as a connection timeout rather than a power-off event, which makes it easy to misdiagnose as a network issue. If this happens with the existing battery, check resting voltage — anything below 3.5V under light load points to a degraded cell that can no longer sustain the inrush. A fresh pack at full charge resolves the sag.