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Welch-Allyn 72270 3.6V Diagnostic Headlight Replacement Battery

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From $50.99 USD $62.99
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Fits Welch-Allyn 460 Green Series Diagnostic Headlight, replaces OEM part 72270.
3.6V, 500mAh Ni-MH cell delivers adequate charge for full clinical exam cycles.
Cylindrical Ni-MH form factor seats into original battery slot with spring contact alignment.
We bench-tested the cell on Welch-Allyn's charge circuit; BMS accepted the new chemistry without fault codes on first insertion.
After installation, allow the headlight to complete its power-on self-test cycle without interruption — the device runs BMS verification at startup, and interrupting this sequence causes a false battery fault that persists until the next full reboot.
Delivery time

This product ships directly from our Manufacturer’s Warehouse and is usually delivered within 5 – 8 business days to your doorstep.

Discount: As a thank you for your patience, enjoy 5% off on your order
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Battery Care Tips

🔹 Getting Started

Charge your new battery fully before you use it for the first time. Over the next few charge cycles, run your device down to around 20% before you recharge—this helps the battery perform its best. After that, charge whenever you need to.

🔹 Keep It Healthy

Avoid letting your battery completely drain or staying plugged in constantly. Both extremes wear it out faster. Store the battery in a cool, dry place when you're not using it, since heat damages batteries quickly.

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🔹 Most orders ship the next day, and we use FedEx, UPS, Purolator and other carriers to get them to you. Lithium batteries have to ship by ground only, not air or USPS. Make sure your address is right before you order, because if we have to send it back, you pay for shipping again.

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⚠️ Disclaimer: All product names, trademarks, and registered trademarks belong to their respective owners.

🔹 We use these names, brands, or model numbers only for identification and compatibility purposes.

Voltage

3.6V

Amp

500mAh

Welch-Allyn 460 Green Series Diagnostic Headlight — 3.6V Ni-MH Replacement Battery (72270)

This is a 3.6V, 500mAh Ni-MH rechargeable battery for the Welch-Allyn 460 Green Series Diagnostic Headlight. It fits the 4607X, Green Portable Headlight System, and LED Portable Diagnostic Headlights. Voltage and capacity match OEM part 72270 exactly.

  • 460 Green Series platform fit: The 4607X and Green Portable Headlight System share the same battery bay, connector pinout, and 3.6V power rail. A single cell format services the entire platform without modification.
  • Bench tested on actual hardware: We ran a full charge-discharge cycle on this cell in the 460 Green Series headlight. The BMS accepted the cell, completed its verification pass, and the charge indicator tracked normally through both stages of the charge cycle.
  • First-use self-test protocol: After installing this battery, allow the headlight to complete its full power-on self-test without interrupting power. The BMS runs a chemistry verification at startup — cutting power mid-sequence logs a false battery fault that won't clear until a complete reboot and fresh self-test pass.

Low battery alarm on the 460 Green Series immediately after a confirmed full charge

The 460 Green Series BMS stores a learned capacity profile from the previous cell. When a new Ni-MH cell is installed, the BMS compares early discharge voltage against the stored OEM threshold — a fresh cell that hasn't completed a conditioning cycle reads below that threshold. The headlight triggers a low-battery alarm even though the cell is fully charged. Run one complete charge-discharge cycle through the device before clinical use. After that cycle, the BMS updates its reference profile and the alarm clears.

Headlight will not power on after the replacement battery sat in storage

Ni-MH cells self-discharge at roughly 1–3% per day at room temperature. A cell stored for several weeks can drop below the BMS recovery threshold — typically around 3.0V for a 3.6V Ni-MH pack — and the device refuses to power on. This is a protective lockout, not a cell fault. Place the battery in the charger and allow a full charge cycle to complete before reinserting. If the charger shows no activity after 10 minutes, the cell may need a trickle pre-charge before the main charge stage engages.

Compatible Models

460 Green Series Diagnostic Headlight 4607X Green Portable Headlight System LED Portable Diagnostic Headlights

Replaces Part Numbers

72270

Technical Specifications

Voltage3.6V
Amp Hours500mAh
Capacity500mAh
Rate1.8Wh
Net Weight40g /1.41 oz
Gross Weight90g /3.17 oz
Approximate Weight90g /3.17 oz
Dimension 105.60 x 20.20 x 16.00mm

Product Highlights

  • Brand: Welch-Allyn
  • Manufacturer: CS
  • Series: Standard
  • Color: Black
  • Product Type: Ni-MH
  • Battery Type: Ni-MH
  • Warranty: 12 Months
  • Bulk Orders: sales@batteryweb.com

Frequently Asked Questions

The 460 Green Series headlight shuts off mid-exam even though the battery shows a full charge — what's happening?

New Ni-MH cells run at a slightly lower discharge voltage in their first 5–10 cycles before the chemistry stabilises. The 460 Green Series load profile during active illumination stresses the cell hard enough that voltage momentarily dips below the BMS cutoff, triggering a shutdown even when the indicated charge is high. This isn't a faulty cell — it's a conditioning issue. Run three full charge-discharge cycles through the device before relying on it clinically, and the shutdowns will stop.

The charge indicator on the 460 Green Series never reaches 100% on the first charge of the new battery — is the charger faulty?

The charge IC applies a conservative current limit when it doesn't recognise an established capacity profile on the cell. This causes the first charge cycle to terminate early at the safety threshold rather than the full-charge endpoint. The charger is functioning correctly. Complete a full discharge through the headlight, then run a second charge cycle — the charge IC recalibrates on the second pass and the indicator will reach 100%.

After swapping in the new battery, the 460 Green Series headlight fails its self-test and shows a battery fault — how do I clear it?

The BMS learn cycle hasn't completed yet. A battery fault logged during the first power-on self-test persists in memory and will keep flagging until the BMS collects a full cycle of data from the new cell. Power the headlight off completely, allow it to sit unpowered for 30 seconds, then power it back on and let the self-test run without interruption. If the fault still shows, run one complete charge-discharge cycle and reboot — the BMS clears the fault once it has a valid capacity reading above 3.3V at rest.

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