Ask the Experts – LITHIUM-ION BATTERY SAFETY

MARK HALVERSON, EXECUTIVE MANAGER STATE FIRE SAFETY SECTION, QUEENSLAND FIRE DEPARTMENT, SHARES SOME KEY LITHIUM-ION BATTERY SAFETY ADVICE TO HELP YOU MITIGATE THE RISK OF A LITHIUM-ION BATTERY FIRE OCCURRING WITHIN YOUR CARAVAN OR MOTORHOME.

• Lithium-ion battery powered devices don’t pose an increased risk if devices are maintained in good working condition and people follow some basic rules. From a fire service perspective, the vast majority of lithium-ion battery fires we’ve seen have been caused by human error.
• Many of these simple rules that should be followed are almost all related to battery charging. Ensure that the charger you use to charge your particular device is the specific charger that’s recommended by the manufacturer. If you buy a quality product from a reputable retailer, you can be confident that the correct charger will be supplied with that product. However, if you buy a discount replacement charger online you need to be very aware where that product is coming from.
• The above also applies to borrowing chargers from friends or family. Just because a charger can physically connect into the charging port of a device or the lithium-ion battery pack, doesn’t mean that it is the correct charger for that device. So always check the manufacturer’s recommendations.
• Damaged batteries also present a fire risk. If there are any signs that a battery has damage to it absolutely do not charge it – have it checked by a battery professional instead.
• Never charge a lithium-ion battery when a device is hot. Always give the battery time to cool after use rather than connecting it to a charger immediately. Similarly, never charge a lithium-ion battery powered tool or device in direct sunlight.
• Another key factor is water ingress. Never charge a battery anywhere that water could potentially penetrate.
• Don’t put a lithium-ion powered tool on charge and leave it unattended within your caravan or motorhome. Certainly, never charge a lithium-ion battery overnight while people are sleeping.
• Never charge personal mobility devices such as e-scooters and e-bikes inside a caravan or motorhome, or in an annexe.
• Always ensure the exit pathway from the beds within caravans or motorhomes are clear of obstructions.
• Under no circumstances attempt to do ‘home modifications’ to increase the power capacity of lithium-ion battery packs. We have seen many examples of this in recent times where people’s attempts at home modifications to their lithium-ion batteries have caused fires.
• The nature of lithium-ion technology and chemistry means fires can escalate very rapidly. What might appear in the first instance to be overheating, a crackling noise, an unusual odour or changes to the shape of the battery, could quickly escalate into a serious fire or in extreme circumstances even an explosion.
• Always maintain oversight while charging lithium-ion batteries so you can spot any of these warning signs within the early stages. If you do see any of these warning signs immediately disconnect the charger from the power if it is safe to do so. If there’s any sign of smoke, evacuate and call 000.
• Smoke alarms give early warning of fire, providing vital time to safely evacuate and should be installed and regularly checked. Noting each state in Australia has slightly different requirements for smoke alarms in caravans and mobile homes registered in the respective states. For example, Queensland introduced new, staged smoke alarm legislation commencing from 1 July 2024.
• Personal safety is absolutely paramount with any type of fire. Put simply: the fire extinguishers you may have within your home or caravan are typically not effective in fighting lithium-ion battery fires. Within larger lithium-ion battery powered devices and tools, there are a large number of battery cells contained within the battery pack, which is also sealed. So, putting water or any other extinguishing medium on the outside of the battery pack itself is unlikely to be effective when the heat is being generated from within.
• It’s also important to be aware of the potential for re-ignition of lithium-ion battery fires. We’ve seen cases where people thought they had effectively extinguished a small fire themselves but were unaware of the heat that remained within. All lithium-ion batteries can be prone to re-ignition minutes or hours later or even the following day. Be aware that re-ignition is a real risk and always call your local fire service so they can take appropriate action.
• Toxic fumes also present a significant safety risk with lithium-ion battery fires, and these fumes are likely to be present even if there’s a minimal amount of smoke or no other smoke present. Toxic fumes are clearly highly dangerous to humans, especially anybody who is in a confined area. So, we strongly recommend people evacuate themselves and anyone else in the vicinity immediately to fresh air and then call 000.
• The number one takeaway tip is don’t attempt to extinguish a lithium-ion battery fire yourself. The number one takeaway tip is, if you see any early sign of a potential fire, whether that is overheating, battery swelling or a crackling noise, disconnect the power immediately if it is safe to do so, clear people from the immediate area, so any fumes that are present can’t be breathed and call the fire service because that is what we are here for.

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Commonwealth Scientific and Industrial Research Organisation (CSIRO) Principal Research Scientist, Dr Adam Best, is a leading lithium-ion battery expert and the co-author of the CSIRO’s report – ‘Lithium-ion Battery Safety’ – which was created for the Australian Competition and Consumer Commission (ACCC). Dr Best shares some key safety considerations around using, and charging, lithium-ion batteries.

Can you describe some of the issues and safety considerations around lithium-ion batteries? To start with, it’s important to state that lithium-ion batteries are statistically a very safe technology. They are a lot safer for example, than internal combustion engines, and many fires are caused each year by leaking fuel tanks. However, while lithium-ion battery fires are statistically a rare event, the problem lies in the scale and intensity of these fires once they are sparked and the difficulty in putting them out. All these factors are creating a lot of recent awareness, concern, and in some cases even hysteria, around lithium-ion battery safety.

Recent fires have been linked to high-energy lithium-ion batteries. Items powered by these batteries can include power tools such as portable drills, household smart devices, power banks, rechargeable vacuums, and toys such as e-bikes and e-scooters. What are your thoughts on this? If you look back through media reports over the last few years, you’ll see reports of fires caused by e-bikes and e-scooters. Small lithium-ion battery-powered devices can also be a concern. Many of these items are built to a cheap price point and when you disassemble these devices and examine them you can see many are shoddily made.

The term ‘thermal runaway’ is often referenced in discussions around the causes of lithium-ion battery fires. Can you explain what the term means and how it applies to lithium-ion battery failure? Basically, the internal heat inside the cell builds up to such a point where you cannot stop it. There’s no intervention that can stop that battery failure from progressing. That’s why it’s a runaway event. The thermal runaway event in the battery can get up to 2,000°C. But when the fire begins, it’s generally with lots of smoke and an intense flame. The smoke is full of asphyxiant gas and toxic chemicals. If you breathe that smoke in, it can have significant impacts on you and you could potentially die from it. That’s true of any battery fire.

Improper charging practices, including the use of non-original chargers that have not been recommended by the original equipment manufacturer (OEM), are often linked to lithium-ion battery fires. Can you share some safe charging advice? If you’re charging a lithium-ion battery, it should be on a surface or substrate that is non-flammable. Don’t charge lithiumion batteries near flammable material, which can spread a potential fire further. Always charge your battery in a cool, dry place. Never charge a battery that’s been sitting out in the sun. In our report the CSIRO prepared for the ACCC [titled ‘Lithium-ion Battery Safety’] we also talk about not leaving lithium-ion batteries on charge while unattended. Because when a battery charger fails, you can be in a lot of strife.

As a safety control, we recommend setting a timer when charging lithium-ion batteries. We also recommend only charging lithium-ion batteries for three hours or the time required to fully charge the battery. Setting a timer and disconnecting the battery from the electrical point means there’s no risk of an overcharging event occurring. After three hours the battery should be well and truly charged, so you can go ahead and use it safely. It’s a simple safety control that can be quite effective. The location of where you charge a battery should also be considered. Never charge a battery anywhere a fire could block your escape route.

Constant charging or ‘trickle charging’ is a term often discussed in terms of lead acid batteries. However, it sounds like there are some unique safety implications when it comes to this practice for high-energy lithium-ion batteries found within tools, toys and devices? In the case of a lead acid battery, a trickle charger will constantly monitor the voltage feedback. So, as soon as the voltage dips back down below its regulated limit, it’ll manually kick in and charge the lead acid battery back up again. However, lithium-ion batteries have a really low self-discharge rate, so aside from safety risks, there’s also really no need to trickle charge lithium-ion batteries. Another key feature of lithium-ion batteries compared to most other battery technologies is the use of what we call a Battery Management System (BMS). With lead-acid batteries when you put them on a constant current regime, it has a system to stop overcharge. However, in a lithium-ion battery, if there is a fault in either the BMS or the charger, you can continue to pump current into the battery to the point you can go into an overcharge regime which is very unsafe. That is probably one of the most common failures that we see and a cause of a lot of lithium-ion battery fires… when batteries are sitting on chargers for extended periods of time, and the charger or the BMS is faulty.

What about charging lithium-ion overnight or when unattended? That’s a massive safety risk and it’s not necessary for lithium-ion batteries. Once the battery is charged, it is charged. With these portable devices and tools people that people are using, just charge it before you use it. Don’t charge it up and then leave it sitting on a charger, because that’s when failures can potentially occur.

Any other safety advice relating to lithium-ion battery charging? Always check your cables to make sure they’re in good condition and not damaged. Check the charger itself regularly as they can get damaged or become faulty over time. As we’ve talked about earlier, if the charger is faulty, it can lead to a failure. Also, always buy and use the charging device recommended by the battery manufacturer. Don’t buy cheap lookalike replacement chargers. Don’t fiddle with battery technology or try to augment the size of the battery. For example, we’ve seen a spate of failures where people have tried to plug in a bigger battery to a device such as a Bluetooth speaker.

Are there visual ‘warning signs’ for potential battery failure that people should look out for? Always check your battery before you use it or charge it. If it feels hot to the touch, don’t charge it. Make sure that the casing looks like it’s intact and that nothing is loose. Check the packaging hasn’t swelled, is not discoloured or leaking fluids. Make sure the contacts are nice and clean. As a rule, if something doesn’t look right or you’re not sure, don’t charge the battery. Instead, take it back to the battery supplier or a reputable specialist battery retailer and have them check it for you. If the battery isn’t in good shape, they help you dispose of the battery and assist you with a new battery. Some of these are common sense, but sometimes common sense is not so common. If the battery is venting gas, hissing, making any unusual noises or leaking fluids those are all major warning signs.

What are your thoughts about storing lithium-ion batteries in fireproof boxes? You can buy them but they’re not going to make a lot of difference and as an engineering control it’s not something that I would recommend. However, if storing them in those boxes keeps the batteries dry and reduces the chances of condensation and water getting to them, they could help.

Lastly, what is your advice in the case of a lithium-ion battery fire? Personal fire extinguishers won’t help. We don’t want people exposing themselves to potentially life-threatening hazards, including toxic gases, based on a false sense of hope that they can effectively fight a battery fire themselves. Just get as far away as you can outside and call for help. When you ring 000, tell them everything you know, so they know what it is that they’re coming to fight.

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Interview with Dr Adam Best originally featured in NM Insurance’s Nautilus Marine Magazine.

Safety best practices

The Australian Competition and Consumer Commission (ACCC) details some important safety advice within their report ‘Lithium-ion Battery Safety’ created by the CSIRO. It is strongly recommended that all owners of caravans and motorhomes adhere to the safety advice put forward by the ACCC and CSIRO, whenever using or charging lithium-ion batteries.

• Monitor charging times of lithium-ion products and disconnect products from chargers once they are fully charged. Consider setting timers as a reminder to unplug products.
• Keep lithium-ion batteries out of household garbage or recycling bins and kerbside hard waste collections.
• Charge lithium-ion batteries and products away from combustible materials such as beds, sofas or carpet.
• Store batteries and lithium-ion products in cool, dry places and out of direct sunlight, including while charging.
• Do not use batteries, products or chargers that are overheating or showing signs of failure such as swelling, leaking, or venting gas.
• Check the charger you are using is suitable for the product being charged.
• Allow time for batteries to cool after use and before charging.
• In the event of a fire, consumers should contact 000 immediately. For more information on what to do in case of fire or explosion contact your state or territory fire department.

Source: ‘Lithium-ion Battery Safety’ report created by the CSIRO for the ACCC.

BILL THIEL IS THE TECHNICAL MANAGER AT GLOBAL HERITAGE WITH OVER 40 YEARS OF ELECTRICAL AND POWER GENERATION EXPERIENCE. BILL HOLDS POSITIONS ON SEVERAL STANDARDS AUSTRALIA COMMITTEES AND HAS BEEN INVOLVED WITH THE CERTIFICATION AND EVALUATION OF LITHIUM-ION BATTERIES AND LITHIUM PRODUCTS. HERE, HE SHARES SOME LITHIUM-ION BATTERY SAFETY ADVICE FOR CARAVAN AND MOTORHOME OWNERS.

Why is lithium-ion battery fire prevention an important safety issue all caravan and motorhome owners should be aware of? The advantages of lithium power outweigh any fear in the minds of the majority of the caravan and motorhome community. Lithium-ion batteries are everywhere. Laptops, phones, torches, drones, toys, drills, hand tools and e-scooters and e-bikes to name a few. Not many of us would wish to go without any of them! There have been fires started by all the products I have listed above.

I am less concerned about quality caravan power systems than I am about portable lithium-ion battery powered appliances, devices or tools stored in the vehicle. If you are trying to save money, don’t do it on the battery system. Quality is not cheap and the likelihood of a professionally built and fitted system failing, is at a much lower risk level. There are some very competent suppliers of both lithium-ion and LiFePO4 systems for the caravan and motorhome community. Look for companies that have good information readily available such as: safety data sheets, IP Rating (Ingress Protection Rating), comprehensive installation instructions to meet AS/NZS3001.2 and a customer help line.

What about industry awareness, such as awareness amongst operators of holiday parks? Increased awareness is essential. While the majority of professionally installed caravan battery systems are safe, I am concerned about what is stored within caravans and motorhomes. Items such as e-bikes and e-scooters which have, until recently, had less ‘suitability controls’ (there is now an Australian standard). We are all aware of fires and deaths caused by these items. Park owners may wish to consider a policy for storage and charging of these items, and also perhaps publishing the list of ACCC’s product recalls.

What are your thoughts regarding the sharing of DIY information relating to lithiumion batteries within online forums and social media accounts? What are some of the key safety considerations here? Any DIY involving lithium-ion batteries is not wise. Just don’t do it. Lithium-ion is not a straight swap for a traditional battery system. It’s a job for a professional. For advice, go to professionals, not forums. This can be a serious issue. The quality of information on forums does not come with guarantees and misinformation can be dangerous in this area.

Please share your five lithium-ion battery safety tips for caravan and motorhome owners.

• Portable lithium-ion battery powered appliances, devices, e-bikes, e-scooters or tools stored in caravans and motorhomes are a safety concern.
• Think twice before embarking on any DIY project involving lithium-ion batteries. DIY with lithium is not safe.
• Always follow charging instructions and use the correct charger for the product. The wrong charger could be very dangerous.
• Never charge lithium-ion batteries while unattended or while you sleep. Never charge or store an e-scooter or e-bike at the exit to your caravan or motorhome, for any reason.
• If your battery is producing gas, call 000. Lithium battery gas is explosive and toxic. Disconnect the battery from power only if safe to do so.

ANDREW HUETT IS THE CEO AND FOUNDER OF OZX CORP, AN AUSTRALIAN TECHNOLOGY COMPANY WHICH DESIGNS AND MANUFACTURES POWER AND CONNECTIVITY SOLUTIONS FOR THE CARAVAN AND RECREATIONAL INDUSTRY. ANDREW DISCUSSES THE ELECTRICAL STANDARDS RELATING TO LITHIUM-ION BATTERIES AND SOME KEY SAFETY ISSUES OWNERS NEED TO KNOW ABOUT CARAVAN AND MOTORHOME ELECTRIFICATION.

Talk us through OzX Corp’s involvement with the electrical Standards, which took effect in November 2023? OzX Corp supported the process with key market trend data, automotive design principles and a forward-looking view on lithium battery adoption and safety. We shared insights about the growing trend for higher power systems and the inevitable move to higher voltages for solar and battery systems.

For caravan and motorhome owners who aren’t familiar with the Standards, can you give us an overview of how they relate to lithium-ion batteries? The new Standards look to build provisions around lithium batteries. So, that in the event of a thermal event or gas release, the risk to the occupant is mitigated and they can take corrective action and exit the caravan. Further, voltages have been contained to mitigate the risks around shock hazards and arc flash.

What do caravan and motorhome owners looking to install a new lithium-ion battery need to be aware of? Lithium batteries installed in caravans and motorhomes are now required to address the minimum certification requirements of IEC62619, which addresses required standards for quality, performance and safety. Installed lithium batteries are required to be mounted within a vented box, which box ensures that the habitable area is truly separated from potential risks that could result from a faulty battery. This includes venting any toxic gas from a faulty battery to the open air and separating a possible thermal event within the box. When purchasing a caravan or motorhome with an installed lithium battery it’s important to look for a sturdy box construction and ensure best practice has been applied. We recommend owners ask for total battery certification and really push for an external mounted battery that truly separates the battery from the occupants in the caravan or motorhome. Overall, the Standards are a ‘good move’ to help address the risks presented by installed battery failure and by applying mitigation methods.

What about caravan and motorhome owners with previously installed lithium-ion batteries? What impact do the Standards have on them? Retrospective lithium installs may have not addressed key fundamental safety concerns and mitigation methods. A professional review of your system is opportune to ease your mind. Carrying out a professional lithium and electrical inspection will also reinforce the resale value of your caravan.

Based on the rapid adoption of powered 12v battery/solar solutions, what do you see happening in terms of powering caravans within the next few years? At OzX Corp we have an eye on the next 10 years. Lithium batteries will grow much larger, be chassis-mounted, have electric regeneration and drive technologies in the wheels and even run nominal 400Volt batteries that are aligned with the automotive sector. In the shorter term of three-to-five years, all-electric caravans and RV’s will grow significantly as the practicality and convenience is accepted. We will also see 12Volt systems be rated nominally at 600 to 800Ah because of the affordability and “sweet-spot” for general convenience while off-gridding and boondocking.

Any other considerations unique to the caravan and motorhome community? Consumers need to ensure that battery certification should be for the total battery solution and not just the cells within. This ensures a total holistic testing process which considers the important safety features of the Battery Management System (BMS). Best practice for any lithium battery or other fuel cell in a caravan includes thermal/ smoke detection that operates 24/7. The electrical eco-system of the caravan or motorhome also needs to be taken into consideration, because the demands on the electrical system are now far greater than the past.

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