Battery explosion

[hipower]

I have a 2003 Newmar Dutch Star and had a deep cycle battery explode last Saturday. I am looking for some thoughts or ideas of what may have been the cause.

I was starting the engine and released the key a fraction of a second before the engine started. My error. I immediately turned the key again to start the engine and the battery connected to the positive cable exploded violently. It sounded like a backfire, but I had never heard a diesel backfire and didn't know what else to think until I got outside to do some other pre trip things and saw fluid leaking from the battery compartment. My first thought was diesel fuel since the fuel filter is just below the battery tray. I was suprised when I opened the compartment and saw the exploded battery.

The batteries are a little over five years old and have been well maintained and performing as expected with no apparent issues.

I'm open to any thoughts anyone may have before I repalce the whole group of four batteries and encounter the same thing again.

[TNGW1500SE]

I had a battery blow up in my boat while parked in the garage. It was not on a charger and nothing near it with a spark or flame. It just shorted out inside I guess and blew plastic all over the garage. Batteries are a bomb. I've seen people who smoke hold their cigarette right next to a battery while working under the hood. Once you see one explode you get a respect for them.

[Geocritter]

A coach battery exploded on my RV last year. I found a loose cable going to the battery which probably sparked, igniting hydrogen gas out-gassing from the battery. BTW the loose cable connection was within the copper connector that is used in attaching the cable to the battery.

I also once had a battery explode when I jumped a car at the car wash. The explosion blew battery acid all over the front of me. Fortunately, I was able to hose off the acid before I got any burns. It did destroy the cotton t-shirt I was wearing. A hard way to learn to never connect the ground cable to the battery but rather to the engine block or car frame.

Steve

[John_S_]

I had this happen last week on my class C. It must have been outgassing and then the spark of starting the generator caused an explosion. It was loud.

[holstein13]

randallb wrote:
Interesting theory as to where this supposed spark came from. I have never in my 40 years in the auto repair business ever seen a negative cable spark.
Randy

There aren't very many negative cables when it is grounded to the frame, but I guess there could be for certain devices and definitely from the batteries. I think it's plausible.

[randallb]

.

[Kayteg1]

I've seen batteries exploding when charged with too high current and also heard about explosions where battery low on acid would have spark between the plates what ignite the hydrogen inside.
Hard to believe things like that happen but how can you confirm it or deny?

[hipower]

rgatijnet1 wrote:

hipower wrote:

rgatijnet1 wrote:
My Deka AGMs, Made in the USA, cost about $200 each for the four in my coach. Lead acid batteries out gas hydrogen which is very explosive in the right concentrations.

Thanks. I happen to deal with a local Deka dealer who is also a fairly good friend. Maybe I can twist his arm a little on price. :B

Since they are made right in Pennsylvania I hope you can get a good deal. East Penn Manufacturing

I checked a lot of places and didn't find any good deals on the AGM's and since the budget is a little cramped right now decided to replace them with the same GC15's that were there for the past five years+. I didn't get a steal on them either, but don't have to drive over 180 miles round trip or pay a crazy freight charge to get them home. The extra $10 per battery to buy from my local guy can be recovered when I make him buy lunch a couple times.

[hipower]

hanko wrote:

jtessnm wrote:
You posted that the battery was a deep cycle battery, I assume that it is a house battery. The real question is, why would a house battery explode when starting the engine? The house battery is not used to start the engine unless the boost switch is used. You may have additional problems. JT

first post that sounds like it might have something to do with what was originally posted

Both valid thoughts. I was not using the boost switch, but a spark from a loose ground on the starting cables could have created a spark.

[hipower]

Thanks for the thought provoking responses. They were all things that I have discussed with my local mechanic who is extremely good. I also just had a pretty extensive conversation with my dealer's shop foreman whom I trust based on past experience for over 15 years.

The conclusions reached at this point indicate there had to be a loose connection, probably a frame ground, that provided a spark at that particular time to cause ignition of the hydrogen gas put off by a battery that had been charging while driving previously. Just a few minutes before starting this time.

I'll pull the batteries and clean the tray and surrounding area with baking soda and a lot of water. Then repaint the whole mess before installing the new batteries. Of course part of that proccess will be cleaning and retightening all cable connections.

Thanks for all of the input. It was confirmation of everything that I had considered before posting my query, and sometimes that is all we need.

[hanko]

jtessnm wrote:
You posted that the battery was a deep cycle battery, I assume that it is a house battery. The real question is, why would a house battery explode when starting the engine? The house battery is not used to start the engine unless the boost switch is used. You may have additional problems. JT

first post that sounds like it might have something to do with what was originally posted

[rgatijnet1]

hipower wrote:

rgatijnet1 wrote:
My Deka AGMs, Made in the USA, cost about $200 each for the four in my coach. Lead acid batteries out gas hydrogen which is very explosive in the right concentrations.

Thanks. I happen to deal with a local Deka dealer who is also a fairly good friend. Maybe I can twist his arm a little on price. :B

Since they are made right in Pennsylvania I hope you can get a good deal. East Penn Manufacturing

[dougrainer]

Mr.Mark wrote:

jtessnm wrote:
You posted that the battery was a deep cycle battery, I assume that it is a house battery. The real question is, why would a house battery explode when starting the engine? The house battery is not used to start the engine unless the boost switch is used. You may have additional problems. JT

Just guessing, but the alternator on the engine will charge the house batteries along with the chassis batteries. I'm thinking that is part of the puzzle.

MM.

When you have any type electrolyte battery(sealed or deep cycle) that either is boiled and the plates exposed or dry and you put a charge current to it. THAT charge current is enough to ignite the excess gas in the battery and blow it up. When it exploded, did you have a gallon of battery acid all over the place? I will bet NOT, since the battery was dry or almost dry and you saw minimal fluid. Also, a loose connection at the battery bank (neg or Pos) will also cause a spark when a load is applied. Doug

[RoyB]

Has to be a spark somewhere to set off the out gassing. Might make sure the battery terminals are tight...

I guess I have been fortunate as the only time I was close to a battery explosion was back in the day when the gas stations would offer a quick one hour charge by sending a battery around 50VDC and having a capacity of a couple hundred amps of current available. This was the way batteries were charged way back then. This one blew the battery top up over the gas station and spewed battery acid everywhere..

When I was in the service you always had to have the batteries in a steel cage when being charged haha... Times changes everything...

Roy Ken

[Mr_Mark1]

jtessnm wrote:
You posted that the battery was a deep cycle battery, I assume that it is a house battery. The real question is, why would a house battery explode when starting the engine? The house battery is not used to start the engine unless the boost switch is used. You may have additional problems. JT

Just guessing, but the alternator on the engine will charge the house batteries along with the chassis batteries. I'm thinking that is part of the puzzle.

MM.