Lithium-Ion Battery Best Practices: The Do’s and Don’ts for Safe, Reliable Battery Performance
Lithium-ion batteries are essential to the performance of today’s portable equipment, from medical and industrial devices to scanners, communications equipment, and other battery-powered technologies. However, proper battery use, storage, charging, and maintenance are critical to maximizing battery life, safety, reliability, and performance.
A well-managed battery can deliver dependable power throughout its expected service life. Poor storage conditions, improper charging, physical damage, excessive heat, or the use of an unqualified battery or charger can reduce capacity and potentially create serious safety risks.
For organizations managing multiple battery-powered devices, implementing a Battery Management Program can help extend battery life, improve operational reliability, and identify batteries that should be removed from service.
Below are important lithium-ion battery do’s and don’tsto help you get the most from your battery investment.
1. Don’t Store Lithium-Ion Batteries Fully Charged
One of the most important considerations when storing a rechargeable lithium-ion battery is its state of charge (SOC).
Lithium-ion batteries can experience non-recoverable capacity loss when stored for extended periods, particularly when stored at high states of charge and elevated temperatures. Once this capacity is lost, it cannot be recovered during the remaining life of the battery.
For batteries that will not be used for an extended period:
- Avoid storing batteries at 100% state of charge.
- Store batteries at a state of charge below 50% when appropriate for the battery manufacturer's specifications.
- Keep batteries in a cool, controlled environment.
- Minimize the amount of time batteries remain in storage.
Proper storage can help preserve available capacity and extend the useful life of the battery.
2. Do Use Your Battery—Don’t Leave It Permanently on a Charger
Rechargeable batteries are designed to be charged and discharged during normal operation. Leaving a battery continuously connected to a charger for extended periods can effectively place the battery in a prolonged storage condition at a high state of charge.
For battery fleets, periodically removing batteries from charging and using them can help maintain operational readiness.
When appropriate:
- Remove batteries from charging periodically.
- Exercise batteries through normal use.
- A partial discharge is generally sufficient; the battery does not need to be completely discharged.
- Discharging approximately 20–50% of the available energy before recharging may be appropriate, depending on the battery and application.
Always follow the battery manufacturer's recommendations for charging and usage.
3. Don’t Expose Batteries to Excessive Heat
Temperature is one of the most important factors affecting lithium-ion battery performance, life, and safety.
Never leave batteries in hot vehicles, direct sunlight, near heating equipment, or other extreme-temperature environments.
At extremely high temperatures, chemical reactions inside lithium-ion cells can become unstable and increase the risk of thermal events, including fire.
As a general safety practice:
Keep batteries away from excessive heat and follow the manufacturer's specified operating and storage temperature ranges.
Temperature exposure can also accelerate battery degradation, reducing the amount of usable capacity available over time.
4. Do Replace Aging Batteries
Lithium-ion battery capacity naturally decreases over time. Battery degradation can be influenced by:
- Number of charge and discharge cycles
- Operating and storage temperature
- Depth of discharge
- Charging conditions
- Usage patterns
- Physical abuse or damage
- Age and time in service
This becomes particularly important when managing a fleet of battery-powered devices.
For example, a shipping or distribution facility may have hundreds of handheld scanners operating throughout the facility. Even if the devices are identical, their batteries may age at different rates depending on usage and operating conditions.
A structured battery replacement program can help ensure that aging batteries do not negatively impact overall fleet performance.
5. Do Remove Old or Damaged Batteries from Service
Aging, damaged, or degraded batteries should not remain inactive service indefinitely.
As lithium-ion batteries age, their internal components can deteriorate. Physical damage, abnormal swelling, leakage, overheating, or other signs of battery failure require immediate attention.
A Battery Management Program can establish clear criteria for identifying and removing batteries from service before they become an operational or safety concern.
Depending on the application, replacement criteria may include:
- Battery age
- Measured capacity
- Number of cycles
- Physical condition
- Runtime performance
- Manufacturer recommendations
6. Do Recycle Used Batteries
Battery recycling is an important part of responsible battery management.
Spent lithium-ion batteries contain materials that can potentially be recovered and reused. Proper recycling helps divert batteries from conventional waste streams while supporting the recovery of valuable materials.
Organizations managing large battery fleets should establish a process for collecting, storing, and properly recycling batteries that have reached the end of their useful life.
When a battery reaches the end of its service life, recycle it through an appropriate battery recycling program.
7. Don’t Open, Crush, Drop, or Abuse a Battery
Lithium-ion batteries contain cells, electrical components, and stored energy that require proper handling.
Never intentionally:
- Open a battery pack
- Crush or puncture a battery
- Drop or physically abuse a battery
- Attempt to repair a damaged battery without proper authorization
- Use a battery with a damaged enclosure
If a battery casing is damaged or opened, discontinue use and follow appropriate procedures for removal and recycling.
Exposed electrical components can create a short-circuit hazard, while damaged cells may release flammable electrolyte. Physical damage can therefore increase the risk of overheating, fire, or other hazardous events.
8. Never Short-Circuit Battery Terminals
Never connect the external terminals of a battery with wire, metal objects, clips, or other conductive materials.
A short circuit can cause a battery to release a large amount of energy very quickly. This can generate significant heat and potentially result in fire or other hazardous conditions.
Keep battery terminals protected and prevent contact with conductive materials.
This is particularly important when transporting, storing, or handling loose batteries.
9. Never Use an Unqualified Battery or Non-Approved Device
A battery is not simply a source of voltage and capacity. A properly engineered battery pack can incorporate safety features, protection circuitry, cell matching, thermal management, and battery management electronics designed specifically for the intended application.
Using a non-qualified replacement battery or pairing a battery with a device or charger for which it was not designed can introduce unnecessary risks.
Lower-cost third-party batteries may not provide the same safety features, protection mechanisms, performance characteristics, or compatibility as a properly qualified battery.
For critical applications, always verify battery and device compatibility before use.
10. Do Use the Correct Battery Charger
The battery and charger should be treated as a system.
A properly matched charger is designed to deliver the appropriate voltage and current required by the battery. Using an incorrect orunapproved charger can result in improper charging, reduced battery life, premature battery failure, overheating, or other safety hazards.
Always:
- Use the charger specified or approved for the battery.
- Follow the battery manufacturer's charging instructions.
- Avoid makeshift or incompatible charging equipment.
- Verify charger and battery compatibility before use.
Proper charging is one of the most important factors in maintaining lithium-ion battery performance and safety.
11. Do Follow the Battery Manufacturer’s Instructions
Every battery is engineered for a particular application and operating environment. Manufacturer documentation provides important information regarding:
- Charging requirements
- Operating temperature
- Storage temperature
- State-of-charge recommendations
- Expected service life
- Handling procedures
- Transportation
- Maintenance
- End-of-life requirements
Always consult the battery manufacturer's technical documentation and follow the recommended procedures for your specific battery.
12. Do Establish a Battery Management Program
For organizations operating multiple battery-powered devices, one of the most effective ways to improve battery reliability is to establish a Battery Management Program.
A structured program can track battery age, deployment, capacity, usage, and replacement requirements.
Consider recording:
Manufacturing Date:
Use the date code provided on the battery label to identify when the battery was manufactured.
Date Placed in Service:
Add an internal date label or tracking record showing when the battery was placed into operation.
Capacity:
Where practical, monitor battery capacity and establish a replacement threshold.
Age:
Depending on the application and manufacturer's recommendations, establish a defined maximum service period. A 24–36-month replacement interval maybe an appropriate planning benchmark for some battery fleets, but actual replacement timing should be based on the battery design, application, usage, and manufacturer guidance.
Condition:
Remove batteries showing physical damage, swelling, leakage, abnormal heating, or other signs of failure.
A proactive approach allows organizations to replace batteries based on planned criteria rather than waiting for unexpected battery failure.
Better Battery Management Starts with Better Battery Practices
Proper battery management isn't simply about extending battery life. It is about maintaining safe, reliable, and predictable power throughout the operating life of the equipment.
For organizations managing portable equipment or battery-powered fleets, simple practices—such as proper storage, controlled charging, temperature management, routine inspection, planned replacement, and responsible recycling—can make a significant difference.
And when battery performance is critical to your application, selecting the right battery from the beginning is just as important as managing it properly.
Need Help Managing Your Battery Requirements?
AMP Engineering helps businesses evaluate battery requirements and develop battery solutions designed around the specific needs of their applications.
From battery selection and battery management systems to custom battery pack design and engineering support, AMP can help you identify the right power solution for your equipment.
The right battery is more than a power source. It is… The Power Behind Your Brand.
Contact us to learn more about battery design, battery management, and custom battery solutions built for your application.
