Battery Education & Training

Because your two-way radio batteries are vital to your radio’s operation, we have developed our Battery Education Series to provide essential information to assist you in understanding how to get the most from your equipment.

Lithium-based Batteries

Your two-way radios were designed to be used reliably every day for many years. The usefulness of your portable two-way radios depends largely on its battery. Lithium-Ion (Li-Ion) chemistry batteries are the choice for most two-way radio applications because they are powerful, long-lasting, lightweight, and cost-effective.

Useful Life

Li-Ion batteries for portable two-way radios typically have useful service life of 2 to 3 years under normal usage conditions. The Li-Ion cells are rated to operate properly for 300 – 500 charging cycles and often times work well for up to a maximum of 1,000 charging cycles. There are factors of duty cycle, temperature conditions, and proper charging schedule that play significant roles in their overall performance.

How Two-way Radios Differ from Other Electronics

Lots of electronic devices these days use Li-Ion batteries. Chances are you use them every day. Portable two-way radios differ from most other battery-operated electronics in their high demand for proper voltage while transmitting. Radios that are in the on position or “standby” mode use very little battery voltage. Radios that are actively receiving a transmission are also using very little battery voltage. It’s when the radio is transmitting that the highest demand for power is placed on the battery. The proper voltage is crucial to provide full radio output power and therefore proper operation. Underperforming batteries are the #1 cause of poor two-way radio operation.

Chargers

The chargers for your portable two-way radios are specifically designed to charge at the optimal rate for the ideal combination of maximum capacity (runtime), optimal output (voltage), battery longevity, fast charging times and safety.

Warranty

All of the Li-Ion batteries Eagle Communications sells from all brands offered include a minimum one-year manufacturer’s warranty from the date of purchase. They all are warranted to be free from defects due to materials or workmanship. Should an issue arise, please let us know and we’ll do our best to take care of it right away.

Discover what the battery user can do to prolong its life.

As a battery care-giver, you have choices in how to prolong battery life. A battery may fail prematurely due to heavy use, unfavorable temperature conditions, improper charging, or physical damage or abuse.

Environmental conditions, as well as charge cycling govern the longevity and useful output of lithium-ion batteries. The worst situation is keeping a fully charged battery at elevated temperatures. Battery packs do not die suddenly, but the runtime and output voltage gradually shortens as the capacity fades.

Some Do’s & Don’ts

Do Charge using only the recommended charger AND using only the supplied charger power supply.

Do Charge the battery before it’s completely run out. The “low battery indication” from your radio is the easiest way to know it’s time. Partial and random charge is fine; Lithium-Ion batteries do not need full  charge every time.

Do Keep batteries at normal room temperatures, especially when charging.

Don’t expose Li-Ion batteries to excessive heat.

Do Charge the battery with the radio in the OFF position.

Don’t use the charger as a radio stand while the radio is ON

Do Follow all guidelines and regulations when transporting or shipping. Check with your shipping service provider for up-to-date requirements and regulations.

Do Store batteries at ideally 40% charged. Apply some charge after a full discharge to keep the protection circuit alive.

Do Recycle your batteries properly. Eagle Communications is committed to environmental responsibility! We offer free recycling of two-way radio batteries for all our customers.

How to Spot Battery Problems

Your two-way radios were designed to be used reliably every day for many years. The usefulness of your portable two-way radios depends largely on its battery. The two factors that affect the proper operation of your portable two-way radio batteries are (1) output voltage (powerfulness) and (2) Capacity (runtime).

• Output voltage – Portable two-way radios differ from most other battery-operated electronics in their high demand for proper voltage while transmitting. Radios that are in the on position or “standby” mode use very little battery voltage. Radios that are actively receiving a transmission are also using very little battery voltage. It’s when the radio is transmitting that the highest demand for power is placed on the battery. The proper voltage is crucial to provide full radio output power and therefore proper operation. Voltage decreases are difficult for the radio user to notice as they usually degrade slowly over time.

• Capacity – Radio batteries with standard capacity ratings are designed to last an 8-10 hour shift. Batteries with extended capacity ratings may last up to 16 hour shifts. New batteries tend to last longer during the first few months, but generally fall into the rated capacity timeframes in the 4 – 24 month range. It’s easy to tell when the battery capacity is diminished, the radio does not last throughout the day as long as it used to. Diminished capacity is also invariably a sign of diminished output voltage.

Physical Damage

Let’s face it. Sometimes we can be a little rough with our two-way radios. They are built to be durable, but even when someone takes personal care of a radio, inevitably they’ll take a few bumps and bruises. Add the factors of the demanding jobs of maintenance or construction, security personnel, or other industrial occupations, and the likelihood of damage occurring increases. Also, when radios are passed amongst staff members, less care of equipment usually occurs. Troubling to even think about the abuse a radio might endure in the hands of a careless or malicious employee. Unseen damage can occur to the battery’s cells or circuitry. Oftentimes the damage isn’t “fatal” to the battery, but results in degraded output voltage which causes poor radio operation.

Additionally, batteries may incur cracks or breaks to the exterior housing due to falls or abuse. If a battery is found to have cracks or missing sections in the housing, its use should be discontinued immediately to prevent injury from unstable or leaking cells and to prevent the possibility of explosion or fire while charging.

If you find that your equipment is in need of repair, you can use our handy Repair Service Form on our website, along with the address of our service facility.  We’ll always do our best to fix them right and get them back to you promptly. 

Avoid False Radio Repairs due to Faulty Batteries

As we discussed before in How to spot battery problems, the two factors that affect the proper operation of your portable two-way radios are (1) output voltageand (2) Capacity (runtime). A faulty or underperforming battery affects all aspects of a portable radio’s operation and can often be the root cause of a radio complaint by a staff member.

Underperforming batteries are the #1 cause of poor two-way radio operation!

Radio repair facilities take in numerous radios each year. As a business that uses radios, there are expenses involved with processing a radio for repair. Typically, a staff member must bring a suspected radio issue to their manager or other staff member who is assigned to processing repairs. Besides the shipping costs involved, there is the downtime of radio use while that repair process is being fulfilled, and the repair charges themselves. About half of the time this can be avoided. An industry-wide audit of radio repair facilities found that an average of 46% of all radios turned in for a repair had only one significant problem: a faulty battery.

Significant time and expense can be saved by ensuring that all your radios are using well performing batteries that are within the battery’s useful life. In fact, most customers are able to replace their fleet of aging batteries with the cost savings and gained productivity of avoiding sending radios in for “repair” when a fresh new battery solved what were thought to be radio problems.

If You Need a Radio Repair

All equipment, especially electronics, needs to be serviced periodically to keep them running in top condition. Portable two-way radios are most often used all day long and this continuous duty cycle can place a strain on the internal components. All two-way radios operate on frequencies expressed in megahertz (MHz). 1 megahertz is equal to 1,000,000 cycles per second. Chances are that your equipment is operating in the 450 – 470 MHz band, or 450,000,000 – 470,000,000. That’s a lot of cycles! The point is that even a slight “drift” off your proper frequencies can make a big difference in sending clear transmissions. This is why occasional tuning and alignment is necessary to keep things running smoothly.

Of course, individual components like the on/off/volume control, push-to-talk switch (PTT), channel selectors, buttons or keypads, and LCD displays can become worn or faulty over time due to use or abuse. Radios that get their share of bumps and bruises can end up with a broken antenna or antenna jack, a broken display, a cracked housing, or missing knobs or other parts.

Is Now the Time to Budget?

Replacing your fleet of aging batteries (every 2-3 years) is one of the best things you can do to maximize the longevity and usefulness of your two-way radio system. New batteries provide the energy that allows your portable radios to communicate well and perform at their best. New batteries also help to avoid false repairs due to faulty batteries, and keep any worries about battery safety concerns due to old worn out batteries from affecting your business.

As most business expenses require planning, perhaps now is the best time to budget for an upcoming purchase of new batteries before your current batteries reach the end of their useful life.  If you’d like a proposal for budgeting, please Contact Us.

For financing options, like Leasing, of your two-way radio equipment, please Contact Us.

What Causes Lithium-ion to Age?

Environmental conditions, as well as charge cycling govern the longevity and useful output of lithium-ion batteries. The worst situation is keeping a fully charged battery at elevated temperatures. Battery packs do not die suddenly, but the runtime and output voltage gradually shortens as the capacity fades.

All batteries achieve optimum service life if used at 68°F (20°C) or slightly below. If, for example, a battery operates at 86°F (30°C) instead of a more moderate lower room temperature, the cycle life is reduced by 20 percent. At 104°F (40°C), the loss jumps to a whopping 40 percent, and if charged and discharged at 113°F (45°C), the cycle life is only half of what can be expected if used at 68°F (20°C). As the temperature conditions you operate your two-way radios likely differ from these ideal conditions, chances are your batteries will need to be replaced sooner rather than later.

The lithium-ion battery works on ion movement between the positive and negative electrodes. In theory such a mechanism could work forever, but cycling, elevated temperature and aging decrease the performance over time. Radio manufacturers specify the life of Li-ion batteries as being between 300 and 500 discharge/charge cycles, with a typical outside maximum of 1,000 charging cycles. In most business two-way radio applications, that equates to a 2-3 year useful life.

Similar to a mechanical device that wears out faster with heavy use, the depth of discharge (DoD) determines the cycle count of the battery. The smaller the discharge (low DoD), the longer the battery will last. If at all possible, avoid full discharges and charge the battery more often between uses. Partial discharge on Li-ion is fine. There is no memory and the battery does not need periodic full discharge cycles to prolong life.

For safety reasons, lithium-ion batteries should never be charged with excessive voltage. While a higher voltage boosts charging time, exceeding the voltage shortens service life and compromises safety.

Battery Safety

Most countries label batteries as hazardous material, and with good reason. The greatest problem is short circuiting. Aging, unstable or damaged cells can cause an electrical short which can create a chain reaction releasing a large amount of energy. This release of energy causes heat which causes fires.

Batteries can be a health hazard if not handled properly. Batteries are safe, but caution is necessary when touching damaged cells. Lithium-ion is benign — the battery contains little toxic material. Nevertheless, caution is required when working with a damaged battery. Use gloves when handling a suspected damaged battery; do not touch your mouth, nose or eyes. Wash your hands thoroughly.

Travel / Transportation

Since 2008, lithium batteries can no longer be placed in checked baggage; they must be carried onboard. Air travelers are reminded of how many batteries they can carry with a portable device and as spares

All lithium batteries are considered to be dangerous goods and transporting them requires compliance with Class 9 directives.

Safety is an ongoing concern. In 2016, the FAA has banned shipments of lithium batteries on passenger aircraft. Lithium batteries are now shipped in cargo airplanes only. Lithium batteries can only be transported after passing UN 38.3 testing requirements. In spite of these precautions, the U.S. Federal Aviation Administration (FAA) recorded 138 airport and air incidents between 1991 and 2016 involving lithium batteries.

Unresolved airplane crashes that were likely caused by batteries catching fire onboard during flight include the Asiana Airlines 747 near South Korea in July 2011, a UPS 747 in Dubai, UAE in September 2010 and a UPS DC-8 in Philadelphia, PA in February 2006. These events prompted authorities to tighten the rules when transporting batteries

Shipping Li-Ion Batteries

Rules for shipping batteries evolve every year. Remember to follow all guidelines and regulations when transporting or shipping. Check with your shipping service provider for up-to-date requirements and regulations.

Know the hazardous material rules when carrying or shipping batteries.

How Do I Choose Right Battery?

Radio manufacturers advise customers to use only approved battery brands that include only the highest quality suppliers who produce batteries that are well built, safe and have received approval by the governing safety agencies. In the search for possible cost savings, consumers may inadvertently purchase poor quality batteries that can be unsafe. Sometimes lower quality batteries are used by consumers for more casual applications, but for businesses, liability issues could counter any savings gained. Quality options are available from manufacturers dedicated to the radio battery industry.

Battery Composition

Two-way radio batteries are comprised of (A) an array of individual battery cells, (B) circuitry for connection of the cells, charging terminals, and power terminals, and (C) poly-carbonate housings designed specifically for given radio models. All of these components should be of the highest quality materials, and made with exacting design to ensure proper fit, charging, and safety compliance.

Quality Battery Cells

At the heart of every two-way radio battery is the quality and composition of the individual battery cells. Two companies have been making the actual cells that are the benchmark for quality in the industry: Panasonic & Sanyo. Both companies are dedicated to using the highest quality raw materials, and have set the standard for the highest quality workmanship. Cells from Panasonic or Sanyo are commonly referred to as “Japanese cells”. Other companies make battery cells, but few can match the standards they set for quality and purity of materials which produces the safest and most reliable battery cells available.

Intrinsically Safe Batteries

People who work in flammable and potentially explosive conditions must take extra safety precautions. The electronic equipment they use requires specific safety standards and must be certified intrinsically safe (I.S.). The International Electrotechnical Commission (IEC) standard 60079-11 dictates that to be considered “intrinsically safe” such components, including batteries, should not produce sparks or release electrical or thermal energy that could cause ignition of flammable or combustible atmospheres, even under abusive conditions. This certification is a guarantee of safety in hazardous conditions and only the largest and most respected battery manufactures have the standards and abilities to produce batteries that carry an intrinsically safe certification.

We hope you have found our Battery Education Series Training to be worthwhile and informative. Our goal is to provide our customers with valuable facts about two-way radio batteries in an educational & fun format, allowing you to make informed choices and enabling you to get the most value from your two-way radio system.

When you are approaching the end of the 36-month useful life of the batteries from your original purchase, please contact us to discuss your replacement battery needs.  You’ll be glad you did. 

Eagle Communications
“Now You’re Talkin’!”
1-800-600-EAGLE