Lithium-ion and lead-acid batteries are not interchangeable commodities and treating them as such is where battery fire risk begins. This guide from lithium-ion battery expert Arnie Fie details lithium-ion battery safety precautions, battery fire prevention tips, what to do and not to do with batteries, and warning signs to look for when investigating these battery fire claims.
A battery is part of a system, not a standalone part
A battery may physically fit a tool without carrying the communication and protection circuitry that the tool’s original manufacturer battery system was designed around. Brand manufacturers pair batteries, chargers, and products as a matched battery system for a reason: the charging profile, thermal limits, use for the type of job it does, and safety cutoffs are calibrated to that specific combination. Another brand battery that “fits” a different tool has usually skipped these considerations or calibrations.
How to identify third-party and counterfeit batteries
Batteries from third party suppliers, or worse knock-off clones, of the brand that made your product have become harder to identify. Pay close attention to labeling on the battery itself; batteries that look like your particular brand but do not have that name brand mentioned on the battery is a first clue. Secondly, if the labeling font or color seems off compared to a known OEM battery, then that battery is likely a clone. Lastly, use your brand’s website to compare what you are buying vs what they really offer.
Warning signs of lithium-ion battery failure
Swelling, unusual heat, odor, leaking, hissing/popping, smoke, or abnormal charging behavior are warning signs of lithium-ion battery failure and reasons to stop using the battery.
Lithium-ion battery temperature and fire risk: batteries like the temperatures people like
Lithium-ion batteries perform best in room temperature, roughly the same range people find comfortable, around 70°F. Two situations can push them out of that range:
Cold-soaked batteries need time to wake up. Very cold batteries have slower chemistry. Allow them to warm naturally toward normal indoor temperature before charging, particularly after winter storage or when using in cold conditions, especially devices for snow removal.
Hot batteries carry real risk. Avoid leaving batteries (pets, children, and candy bars) in hot vehicles, sheds, trailers, or other environments that can reach extreme temperatures.
Charging location matters
Don’t charge lithium-ion batteries on beds, couches, carpeting, or around readily combustible materials. Provide a hard, stable surface and appropriate ventilation and clearance per the manufacturer’s instructions. And lastly consider the worst case, would the location of this charger prevent me from escaping the room or building if the worst occurred?
Tips for preventing lithium-ion battery fires
Use the right battery and charger. “Compatible” does not necessarily mean “approved.” Stick with manufacturer-approved batteries and chargers when possible.
Buy safety, not just specifications. Look for products evaluated or listed by a recognized testing laboratory and be cautious of unusually inexpensive batteries, chargers, and battery-powered products from unknown sources. “You get what you pay for,” has a double meaning with batteries, for the good and the bad.
Your seat belt is buckled, what about the batteries? Based on an informal study, it’s possible you drive like a maniac, especially when on vacation. Therefore, periodic inspection of terminals, cables, and the overall battery “fastened” condition can keep your RV or UTV experience from ending prematurely if the battery and its wiring aren’t properly secured.
Lead-acid batteries can be thirsty. Golf carts and RVs typically have multiple lead-acid type batteries. Use the battery manufacturer’s recommendation to check the battery’s fluid level, which can typically be solved by filling with distilled water. Hot climates can make neglect particularly problematic, especially when charging.
Skip the cola; clean corrosion correctly. Especially with golf carts with lead-acid type batteries, use the battery manufacturer’s recommended cleaning procedure. For flooded lead-acid systems, baking-soda/water solutions are commonly used externally to neutralize acid residue. Use appropriate PPE and avoid getting cleaning solution into cells.
Recycle and dispose of lithium-ion batteries safely. Don’t put lithium-ion batteries in household trash or ordinary recycling. Use an appropriate battery recycling/disposal program. Crushed batteries can and do cause severe fires in waste treatment facilities. Remember that people also work there. So, think of this action as doing something nice for both the environment and others.
Lithium-Ion Battery Safety: What Not to Do
Don’t charge a damaged or swollen lithium-ion battery. A battery that’s damaged, swollen, overheated, wet, or otherwise compromised, shouldn’t go on a charger to “see if it’s still okay.” Connecting it to a charger is a test that could go wrong.
Don’t modify or rebuild a battery pack casually. Rebuilt packs, repurposed cells, altered battery management systems, and improvised repairs can bypass safety features engineered into the original design, and forensic investigations frequently identify these alterations after an incident occurs.
Protect exposed battery terminals. Loose batteries stored with tools, screws, keys, coins, or other conductive objects can join all together to short across exposed terminals. You can think “no-way” all that can happen, but it does all too often.
“It still works” isn’t an inspection. A damaged battery that continues to function hasn’t proven it’s safe, only that it hasn’t failed yet. If the damage is visible and known, the manufacturer’s guidance for repair or recycling is the next step, not continued use.
