User Error
Common Battery Failures from Misuse
While lithium batteries are built for performance, improper use can quickly lead to failure. Below are some of the most common user-related issues to watch out for:
Over-Discharge
Running a battery below its minimum voltage rating (usually around 3.0V per cell) can cause permanent damage. Most modern devices have safety cutoffs around 3.4V per cell to help avoid this, but ignoring those warnings—or disabling them—can lead to loss of capacity, poor performance, and long-term degradation. If a battery drops too low, it's best to stop using it and consult a qualified technician or battery expert.
Over-Charge
With today’s smart chargers, overcharging is rare—so long as your settings are correct. However, intentionally bypassing limits to squeeze out more runtime or power (charging above 4.2V per cell) is dangerous. Not only does it pose a safety risk, but it also significantly reduces cycle life. We do not recommend charging beyond standard voltage limits for any reason.
Short Circuits
Shorting a battery—either through accidental contact between positive and negative terminals or crash damage that compromises the cell structure—can be catastrophic. Internal or external shorts are one of the main causes of thermal runaway (fire), especially when the battery is at a high state of charge. Damage to wires, connectors, or the battery casing itself can all create a direct short and should be taken seriously.
Over-Amperage
Pulling more current than a battery is rated for generates excess heat. Once a pack crosses 140°F (60°C) during use, you risk cell damage. Even a single over-amped discharge can permanently impact the battery. Warning signs include swelling, heat during or after use, venting, or melted shrink wrap. Always monitor your load and make sure your setup stays within safe limits.
Component Mismatch
Just because a battery can deliver high current doesn’t mean your connectors or wiring can handle it. For example, pushing 200A through an XT60 connector (which isn’t rated for that) can cause heat buildup and failure at the connector—potentially leading to cell damage as well. Always ensure your wiring and connectors are rated for the job.
Salt Water Exposure
While lithium batteries are generally sealed and resistant to water, salt water is extremely corrosive. It can degrade internal components and often leads to early failure. If you’re operating in a marine environment or near salt spray, use a fully sealed battery enclosure and waterproof connectors to minimize exposure.