Diagnosing Battery Swelling or Overheating

Who this article is for

This article is for users who are confident performing basic checks and configuration reviews, but who should not open equipment or perform electrical repairs.

If you are unsure at any point, stop and contact support.

What does battery swelling or overheating look like?

You may notice one or more of the following symptoms:

• Battery casing appears swollen, bulging, or distorted

• A strong chemical or “hot plastic” smell

• Battery feels hot to the touch during charge or operation

• Device shuts down unexpectedly

• Screen goes blank after battery replacement

• Charging behaviour appears abnormal

⚠️ Important: Any physical swelling is a safety concern.

Why this happens

Based on case data trends, battery swelling or overheating is commonly linked to:

• Incorrect battery type or chemistry configured

• Incorrect battery capacity settings

• Overcharging due to configuration mismatch

• Age-related battery failure

• Internal battery cell damage

• Thermal stress or poor ventilation

In several cases, issues occurred after a battery replacement, especially when settings were not updated to match the new battery.

Immediate safety steps (do this first)

1. Power the unit off immediately

2. Disconnect the charger and loads

3. Do not continue charging

4. Do not attempt to compress or open the battery

5. Move the unit to a well-ventilated area away from flammable materials

If the battery is hot, allow it to cool naturally. Do not actively cool it with water or refrigeration.

Diagnostic checks you can safely perform

1. Confirm battery type and chemistry

Check that the configured battery type matches the installed battery:

• Lithium vs Lead-acid

• AGM / Gel / Flooded (if applicable)

A mismatch can cause incorrect charging behaviour and overheating.

2. Verify battery capacity settings

If the battery was replaced or upgraded:

• Confirm the Ah (amp-hour) capacity is set correctly

• Case data shows incorrect capacity settings can cause:

  • Screen issues

  • Charging instability

  • Thermal stress

If capacity was increased (e.g. upgraded to a higher Ah battery), settings must be updated.

3. Check charging source behaviour

• Ensure the charger is appropriate for the battery type

• Confirm whether the charger output is AC or DC, if applicable

• Incorrect assumptions about charger type have caused damage in reported cases

4. Inspect the environment

Without opening the unit:

• Ensure ventilation openings are not blocked

• Check for heat buildup around the device

• Look for signs of moisture or contamination

Environmental heat can worsen marginal battery conditions.

What NOT to do

• Do not continue using a swollen battery

• Do not replace fuses or reset repeatedly to “see if it settles”

• Do not open the battery casing

• Do not ignore smells or heat — these are early warning signs

When the battery must be replaced

Immediate replacement is required if:

• Physical swelling is visible

• The battery emits smell

• The battery overheats even with correct settings

• The issue persists after configuration checks

A swollen battery is not recoverable and should not be reused.

What to provide when contacting support

Providing the following speeds up resolution:

• Product model

• Battery type and chemistry

• Battery capacity (Ah)

• Whether the battery was recently replaced

• Description of swelling, smell, or heat

• Any configuration changes made

Summary

• Battery swelling or overheating is a serious safety issue

• Most cases are linked to incorrect battery configuration or replacement

• Configuration checks can prevent damage, but physical swelling means stop immediately

• When in doubt: power down and contact support

If it looks wrong, smells wrong, or feels hot — it probably is.