These instructions apply to all products, devices, batteries, battery storage units, chargers, and accessories supplied by VOGT-CTE, provided they are operated with rechargeable batteries. They serve as general safety and behavioral guidelines for storage, transport, charging, operation, malfunctions, fire incidents, maintenance, and disposal. The product-specific operating instructions, the nameplate, the technical data sheet, the manufacturer’s approvals, and the applicable legal and operational regulations always take precedence. For lithium-ion batteries, various organizations specifically highlight risks associated with mechanical damage, thermal stress, short circuits, improper storage, and incorrect charging.

Principle
Batteries store electrical energy in a small space. If handled improperly, they can overheat, release gas, leak, catch fire, explode, or release toxic fumes. Lithium-based batteries in particular, such as Li-Ion, LiPo, and LiFePO4, require careful handling, as damaged or improperly charged cells can cause an internal short circuit and subsequently trigger a fire. All batteries must be handled in such a way as to avoid the following risks:

• Short circuit
• Overcharging
• Deep discharge
• Overheating
• Mechanical damage
• Water ingress or moisture damage
• Incorrect charger
• Improper storage
• Improper repair
• Disposal in household waste

Check before each use
Before each use, charging, or transport, the battery must be inspected visually and functionally. In particular, check:

• Condition of the casing
• Deformations, dents, or swelling
• Cracks, breaks, holes, or leaks
• Visible moisture or corrosion
• Cables, plugs, and contacts
• Charging port
• Unusual odors
• Unusual heating
• Signs of fire, melting, or discoloration
• Loose or damaged components

A battery must not be used if there is any doubt about its safety.

Immediately take damaged batteries out of service
Batteries must not be reused, charged, or transported if they:

• are swollen or deformed
• have cracks, holes, or leaks
• have leaked
• have become very hot
• have been dropped or crushed
• have been submerged in water
• emit smoke, odors, hissing, or sparks
• lose capacity unusually quickly
• react noticeably while charging

Damaged lithium batteries or batteries in an unclear condition should be stored separately in accordance with fire safety regulations and disposed of properly or evaluated by qualified personnel.

Do not attempt repairs yourself
Batteries, battery storage units, cell packs, chargers, BMS electronics, cables, seals, and housings must not be opened, modified, or repaired on your own. Improper opening or repair can lead to the following damage:

• Short circuit
• Water ingress
• Leaks
• Fire
• Electric shock
• Battery damage
• Damage to the connected device
• Loss of warranty or guarantee claims

Repairs may only be performed by authorized service centers, the manufacturer, or approved service partners.

Storage
Batteries must always be stored in a cool, dry, clean, shaded, and well-ventilated area. Recommended storage conditions:

• ideally approx. 5 to 20 °C
• dry and frost-free
• no direct sunlight
• no high humidity
• Do not store near heaters
• Do not store near flammable materials
• Do not store in damp rooms
• Do not store in vehicles or containers that have become very hot

Closed vehicles, trunks, construction containers, or equipment boxes can become extremely hot when exposed to sunlight. Batteries must not be stored there for extended periods.

Keep away from flammable materials
Batteries should not be stored directly next to the following materials:

• Paper
• Cardboard
• Textiles
• Wood shavings
• Fuels & gases
• Solvents & paints
• Cleaning chemicals
• Other highly flammable substances

For lithium batteries, fire safety guidelines recommend keeping them physically separated from flammable materials and storing damaged or abnormal batteries separately.

State of charge during long-term storage
The correct state of charge depends on the battery type.

• Li-Ion / LiPo / LiFePO4: for long-term storage, usually a moderate state of charge, often approx. 40 to 60%, unless the manufacturer specifies otherwise
• Lead-gel / AGM / Lead-acid: Do not store in a discharged state; keep charged as much as possible and recharge regularly
• NiMH / NiCd: Do not store in a discharged state for extended periods; check regularly and recharge according to the manufacturer’s instructions

Lithium-based batteries should not be stored permanently fully charged or deeply discharged. For lead-acid batteries, prolonged storage in a discharged state often leads to sulfation and loss of capacity.

Transport only when in safe condition
Batteries may only be transported if they are undamaged, dry, clean, and protected against short circuits. Do not transport under normal conditions if:

• Cracks
• Leaks
• Deformation
• Water damage
• Burn marks
• Excessive heat
• Swollen casing
• Damaged contacts
• Unknown or critical condition

Secure the contacts
Before any transport, battery terminals and electrical contacts must be protected against short circuits. Appropriate measures:

• Use the original packaging
• Use pole caps
• Cover the contacts
• Pack the battery individually
• Do not store loose metal parts in the same bag
• Do not transport together with tools, screws, keys, or jewelry

Avoid mechanical stress
Batteries must not be:

• be thrown
• be dropped
• be crushed
• be pierced
• be bent
• be crushed under heavy objects
• be exposed to strong vibrations without protection
• bounce around loosely in packaging

Mechanical damage can cause internal cell damage that is not immediately visible from the outside. In the event of mechanical damage, for example due to puncture, crushing, impact, or piercing, internal cell layers in the battery may be damaged. This can lead to an internal short circuit. The battery may overheat, swell, release gas, emit smoke, catch fire, or, in extreme cases, explode.

This is particularly critical with lithium-ion and LiPo batteries, as their high energy density and chemical components can react very quickly if damaged. Even if little damage is initially visible on the outside, the battery may be internally damaged and could later become dangerous during charging, transport, or operation.

A mechanically damaged battery must therefore not be reused, charged, opened, or repaired. It must be safely isolated, kept away from flammable materials, and inspected by a qualified professional, the manufacturer, distributor, or trained specialist retailer, or disposed of properly.

Observe hazardous materials regulations
Depending on energy content, cell type, quantity, packaging, and mode of transport, lithium batteries may be classified as hazardous materials. For commercial transport, shipping, air transport, or international transport, applicable hazardous materials regulations, manufacturer specifications, and packaging requirements must be followed. VdS and DGUV explicitly refer to special requirements for transport, storage, testing, and fire protection when handling lithium batteries.

Use only approved chargers
Only chargers that are expressly approved for the respective battery may be used. Please note:

• Battery type
• Nominal voltage
• Cut-off voltage
• Charging current
• Number of cells
• Polarity
• Plug
• Charging program
• Temperature range
• Balancer function for multi-cell lithium packs

Using the wrong charger can cause overheating, overcharging, gassing, cell damage, fire, or explosion.

Charging location
Batteries must be charged on a non-flammable, flat, and stable surface. Suitable surfaces or environments:

• Ceramic tile
• Metal tray
• Fireproof charging mat
• Suitable charging cabinet
• Fire-safe charging area

The following are not suitable:

• Beds
• Sofas
• Carpets
• Paper or cardboard surfaces
• Unprotected wooden surfaces
• Closed bags
• Damp rooms
• Areas with highly flammable materials

Supervise the charging process
Batteries should not be left to charge overnight unattended. The charge level and temperature must be checked regularly. If any abnormalities are detected, stop charging immediately. Stop immediately if:

• Excessive heating
• Odor
• Smoke
• Hissing
• sparks
• Deformation
• Leaking fluid
• Unusual charging behavior
• Charger shuts down with an error message

Do not charge in wet or dirty conditions
Batteries and chargers must only be charged in a dry and clean environment. Do not charge if:

• a wet battery
• wet contacts
• Salt or dirt residue
• visible corrosion
• damaged cables
• a damaged charging port
• Suspected water ingress
• Cracked or leaking housing

Do not force fast charging
Fast charging is only permitted if the battery, charger, cell chemistry, BMS, and manufacturer specifications explicitly allow it. Forced fast charging can:

• overheat the battery
• shorten the service life
• cause cell damage
• overload safety features
• increase the risk of fire

Observe permissible operating conditions
Batteries and devices must only be used within the specified operating conditions. The following must be observed:

• Ambient temperature
• Humidity
• Dust exposure
• Mechanical stress
• Permissible current consumption
• Maximum output power
• IP protection rating of the product
• Cooling and ventilation
• Intended use according to manufacturer’s specifications

Avoid overloading
Only connect devices whose voltage, power, and current consumption are suitable for the battery or the device. Overloading can lead to:

• Overheating
• Shutdown
• Cell damage
• Cable fire
• Melting damage
• Fire
• Can lead to destruction of the electronics

Ensure proper ventilation
Ventilation openings, heat sinks, chargers, and battery packs must not be covered. Heat buildup must be avoided. Not permitted:

• Operation under blankets or cloths
• Charging in closed bags
• Operation in unventilated boxes
• Covering the charger
• Operation in direct sunlight without necessity
• Operation near heat sources

Avoid deep discharge
Batteries must not be discharged below the minimum voltage specified by the manufacturer. Deep discharge can cause:

• permanent loss of capacity
• Cell damage
• Refusal to charge due to the protection circuit
• Increased internal resistance
• Safety risks during recharging
• Total failure
  
  

Deep discharge means that a battery has been discharged below its permissible minimum voltage. It is then not simply empty, but may already be damaged internally. This can happen if a battery is stored for too long, not recharged after use, or left in the device even though the device continues to consume power.

Deep discharge is dangerous because it can cause permanent damage to the cells. The battery loses capacity, no longer charges properly, or fails completely. It is particularly critical to attempt to reactivate a deeply discharged battery by short-circuiting, bridging contacts, applying external voltage, or using other methods. This can result in internal short circuits, excessive heat, smoke, fire, or explosion.

A deeply discharged battery must therefore not be tampered with, opened, or charged using unsuitable methods. It should only be tested and charged using the charger intended for that purpose. If it is not recognized by the charger, it must be taken out of service and inspected by a qualified professional, the manufacturer, distributor, or a trained specialist retailer