About this replacement
Honeywell CW45 — 3.7V Li-ion Replacement Battery (CW45-BAT-EX)
This is a 3.7V, 6800mAh Li-ion replacement battery for the Honeywell CW45 rugged mobile computer. It fits the CW45 handheld directly, using the same OEM part number CW45-BAT-EX. Capacity figures are sourced from the product specification — 25.16Wh total energy.
- CW45 platform fit: The CW45 uses a single-cell 3.7V Li-ion pack with a proprietary latch and BMS handshake. This pack matches that voltage rail and connector geometry exactly — the BMS negotiates charge state with the cradle the same way the original does.
- Bench tested on actual hardware: We ran this pack through charge and discharge cycles on a CW45 unit. The BMS reported state-of-charge accurately at all stages and the cradle accepted the pack without a fault code. Scan trigger and wireless radio draw both behaved normally during load testing.
- First-shift preparation for pick-and-pack: After installing this pack, seat the CW45 in its charging cradle and complete a full charge cycle before deploying it on the floor. The scan trigger inrush current is highest when the cell is near minimum charge — a fully charged cell prevents false BMS trips when the first shift starts heavy scanning.
Cradle showing a charging error after fitting a new pack
The CW45 cradle reads battery data through gold contact pins on the base of the pack. If those contacts have residue, oxidation, or are slightly misaligned, the cradle throws a charging fault even though the pack itself is fine. Wipe both the pack contacts and the cradle contacts with a dry lint-free cloth, then reseat the device firmly until the latch clicks. If the fault clears, the issue was contact resistance — not the battery. A persistent fault after reseating points to cradle pin damage, not the pack.
Scanner losing wireless connection during rapid scan bursts
During a fast scan burst, the CW45 draws current from both the imager and the wireless radio simultaneously. If the cell voltage sags below the radio module's minimum operating threshold under that combined load, the radio drops out briefly — it looks like a connection loss but it is actually a voltage sag event. A new pack with full charge holds the voltage rail steady through those dual-draw peaks. Charge the pack fully before the shift and confirm cell voltage is above 3.6V before starting high-frequency scan runs.