The Tenergy 25.4V 3500mAh Li-ion Rechargeable Battery combines high energy density with industrial-grade durability, making it ideal for power tools, medical devices, and solar systems. Its 1000+ cycle life and built-in protection circuits ensure safe operation. This battery delivers 89.9Wh capacity while meeting UN38.3 safety standards, offering 30% longer runtime than comparable models.
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What Are the Key Specifications of the Tenergy 25.4V 3500mAh Battery?
The battery features a 25.2V nominal voltage (29.4V fully charged) with 3500mAh capacity. Its 18650 cells provide 15A continuous discharge, peaking at 20A. With dimensions of 7.1″x2.4″x3.9″ and 2.2lbs weight, it operates from -4°F to 140°F. The PCB protects against overcharge (4.25V±0.05V cutoff), over-discharge (2.5V±0.05V cutoff), and short circuits.
Which Devices Are Compatible With This Battery Pack?
Compatible with DeWalt 20V Max tools (via adapter), Black+Decker 20V systems, and Makita 18V LXT platforms. Widely used in:
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- Medical carts (Hill-Rom, Stryker)
- Robotic vacuums (iRobot 600-800 series)
- LED work lights
- Portable power stations
- Electric gardening tools
This battery’s adaptive voltage output makes it particularly suitable for hospital equipment like Hill-Rom’s Advanta 2 stretcher systems and Stryker’s MedSurg IV poles, where consistent power delivery is critical. Field tests show 18% fewer voltage drops during simultaneous device charging compared to standard 24V batteries. For power tool users, the pack maintains stable output under 15A loads – enough to drive DeWalt’s DCS570B circular saw through 2×4 lumber at 5 cuts per minute without sag.
| Device Type | Runtime Increase | Peak Power Support |
|---|---|---|
| Medical Carts | 42 minutes | 120W continuous |
| Robotic Vacuums | 1.8 cycles | 65W peak |
How Does Charging Performance Compare to Competitors?
Using a 29.4V 2A charger (sold separately), it achieves full charge in 2.5 hours vs. 4 hours for EBL’s equivalent model. The 4-stage charging (trickle/constant current/constant voltage/float) maintains cell balance within ±25mV. Testing shows 93% capacity retention after 500 cycles compared to 85% for generic Li-ion packs.
What Safety Certifications Does This Battery Have?
Certified to UL2054, IEC62133, and RoHS standards. The explosion-proof steel casing withstands 500N crush tests. Thermal sensors trigger shutdown at 158°F (70°C), with 0.08mm separator membranes between cells. Includes reverse polarity protection and automatic cell balancing every 5 charge cycles.
How Does Environmental Performance Impact Longevity?
In 85% humidity tests, the IP54-rated connectors showed 60% less corrosion than standard models after 200 hours. The nickel-plated terminals maintain <10mΩ resistance through 10,000 mating cycles. When stored at 40% charge, self-discharge is limited to 3% monthly vs. industry average 5%.
Accelerated aging tests at 113°F (45°C) demonstrate 72% capacity retention after 18 months of simulated daily use. The battery’s vented casing design reduces internal moisture accumulation by 40% compared to sealed units, particularly beneficial in marine applications. Field data from solar installations in Florida shows 98% performance consistency across wet/dry seasons when paired with proper weatherproof enclosures.
| Environmental Factor | Performance Metric | Tenergy Result |
|---|---|---|
| High Humidity | Terminal Resistance | 8.2mΩ after 500hrs |
| Thermal Cycling | Cell Expansion | 0.3mm max |
What Maintenance Optimizes Battery Lifespan?
Critical practices include:
- Store at 59°F (15°C) with 40-60% charge
- Deep cycle every 3 months (full discharge/recharge)
- Clean terminals monthly with 90% isopropyl alcohol
- Avoid partial charging – complete 0-100% cycles weekly
Implementing these protocols can extend cycle life by 300+ charges according to accelerated lab testing. The deep cycling process helps recalibrate the battery’s internal Coulomb counter, reducing capacity measurement errors to under 2%. For professional users, Tenergy recommends using their BT-7000 analyzer every 6 months to check individual cell voltages – imbalances over 0.15V indicate need for manual balancing.
What Warranty Protections Are Available?
Tenergy offers 3-year limited warranty covering capacity drops below 80% (500+ cycles). Includes free capacity testing through authorized service centers. Replacement program covers swollen batteries within 18 months. Pro users can upgrade to 5-year warranty with registration.
“The 25.4V architecture demonstrates smart engineering – it bridges 20V tool systems and 24V industrial needs without voltage conversion losses. The hybrid PCB design (analog protection + digital monitoring) is a game-changer, resolving 92% of premature failures in our field tests.”
Dr. Liam Chen, Power Systems Engineer at VoltaTech Solutions
FAQ
- Can this battery replace DeWalt 20V packs?
- Yes, using Tenergy’s DTAE20 adapter (sold separately), though runtime increases 22% due to higher capacity
- Is balancing required for storage?
- The auto-balancing circuit maintains ±5% cell variance during storage up to 18 months
- What indicates replacement need?
- 30% runtime reduction or battery swelling >1mm between cell seams