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February 1, 2023 NHTSA CAMPAIGN NUMBER: 23E005000
Battery Corrosion May Cause Fire
A short circuit increases the risk of a fire.
NHTSA Campaign Number: 23E005
Manufacturer Navico Group
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 4,746
Summary
Navico Group is recalling certain RELiON InSight 48 V lithium-ion batteries, Part Number 48V030-GC2. Improperly formed capacitors may cause an internal battery leak and corrosion, resulting in a short circuit.
Remedy
Dealers will repair or replace the batteries as necessary, free of charge. The manufacturer has not yet provided a schedule for recall notification. Owners may contact Navico Group customer service at 1-803-324-6644 or by email at AMER-recall@oneasg.com.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Navico Group Equipment Report โ RELiON 48v Lithium-ion Batteries
Transaction ID: 23-0033215-28941-10
Chronology of events leading up to the defect decision or test data for the noncompliance decision:
October 14, 2022: Navico Group engineering was made aware of two incidents. Initial reports from the manufacturer indicated that the application included unapproved wiring of the batteries. Regardless, company engineers made the decision to temporarily stop shipping the batteries to allow time to investigate the incidents and began to gather information. The engineering team preliminarily concluded there was no product defect but, consistent with company process, notified Navico
Group’s
Product Performance Committee (“PPC”), which is responsible for reviewing and assessing product risks.
November 16, 2022: PPC decided to continue the stop shipping order while it conducted its investigation. Over the course of its investigation, the PPC reviewed information from the engineering team and the manufacturer. Due to the complex nature of the events, including conflicting preliminary reports of the potential cause, such as the unapproved wiring present, the company retained Exponent for forensic analysis. Battery cell propagation testing showed the battery cells did not propagate or exhibit battery cell thermal runaway. Given those findings (although the investigation continued), the engineering team concluded that the batteries did not present a risk of fire, but rather that any thermal events were safely contained within the battery case and would not present a risk of injury or fire.
December 16, 2022: Exponent presented information to the PPC showing that its thermal expert had concluded that there was possible, probable, and actual flame escape from certain battery cases in question, which led to the conclusion that the batteries may present a risk of fire.
December 19, 2022: Navico Group submitted an initial report to CPSC, and continued its investigation into whether the subject batteries were potentially also used in motor vehicle applications.
December 2022 โ January 2023: Navico Group investigated possible motor vehicle applications for the subject battery, and determined that the RELiON battery website noted a potential application for the batteries in โlow speed vehicles.โ Navico
Group also determined that it had distributed batteries to Garia and WAEV, which manufacture of golf carts and low speed vehicles. After discussions with Garia and WAEV, Navico
Group determined that some subject batteries were installed in new Garia and WAEV low speed (FMVSS 500) vehicles.
January 31, 2023: Navico Group determined that some of the batteries were distributed as โmotor vehicle equipment,โ and began preparing a Part 573 report for submission to NHTSA.
This data is internal to Brunswick.
1 Affected Product
Equipment
BRAND | PART NO. | PRODUCTION DATES |
RELION | INSIGHT 48V LITHIUM BATTE |
4 Associated Documents
Defect Notice 573 Report
RCLRPT-23E005-4596.PDF 215.418KB
Recall Acknowledgement
RCAK-23E005-9035.pdf 708.794KB
Miscellaneous Document – Chronology
RMISC-23E005-3744.pdf 119.491KB
Recall 573 Report – 2/14/2023
RCLRPT-23E005-4316.PDF 215.432KB
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23E-005 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Navico Group Submission Date : FEB 01, 2023 NHTSA Recall No. : 23E-005 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Navico
Group Address : N85 W12545 Westbrook Crossing Menomonee Falls WI 53051 Company phone : 5807749054 Population : Number of potentially involved : 4,746 Estimated percentage with defect : 1 % Equipment Information : Brand / Trade 1 : RELiON Model : InSight 48V lithium-ion battery Part No. : 48V030-GC2 Size : NR Function : NR Descriptive Information : For replacement equipment, the recall population was determined based on reviewing affected serial number data provided by the manufacturer. The potential defect is isolated to products built or reworked after May 19, 2021, when modifications were made in production to the sense board and a sense ribbon cable was added to the battery (replacing a traditional wire harness). For batteries installed as original equipment in motor vehicles, Navico
Group determined the population based on information from the two vehicle manufacturers. In total, Navico
Group has identified 357 products installed as original equipment in motor vehicles. Production Dates : MAY 19, 2021 – NOV 18, 2022 Description of Defect : Description of the Defect : The concern with the product has been identified as a capacitor manufacturing issue. In some cases, improperly formed capacitors can leak electrolyte onto the Printed Circuit Board for the Battery Management System, resulting in corrosion across the terminal for the voltage sense ribbon. The corrosion can result in a short circuit across the voltage sense ribbon terminal which can lead to thermal damage of the resistors. Navico
Groupโs testing establishes that the battery cells themselves pass propagation testing and do not lead to a battery cell thermal runaway event. FMVSS 1 : NR Part 573 Safety Recall Report 23E-005 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 FMVSS 2 : NR Description of the Safety Risk : The potential defect could give rise to thermal damage that could result in fire which could potentially escape the battery enclosure, posing a potential ignition risk to surrounding materials, and the potential risk of associated burn injuries. Navico
has received no reports of thermal events, fires or burn injuries in any battery installed in a motor vehicle within NHTSA’s jurisdiction. Description of the Cause : Improperly formed capacitors. Identification of Any Warning that can Occur : A thermal event may generate odor and/or smoke. However, Navico
has received no reports of thermal events, fires or burn injuries in any battery installed in a motor vehicle within NHTSA’s jurisdiction. Involved Components : Component Name : RELiON InSight 48 V lithium-ion battery Component Description : Battery used to power off-road and on-road vehicles, as well as used for standalone units to increase system capacity. Component Part Number : 48V030-GC2 Supplier Identification : Component Manufacturer Name : BMTPow (Shenzhen) Ltd. Address : A404, Block 1, Phase 1, Intelligent Park Long Gang District Shenzhen Foreign States 518112 Country : China Chronology : Chronology provided as a separate attachment. Part 573 Safety Recall Report 23E-005 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Description of Remedy : Description of Remedy Program : Navico
Group will repair and replace in-field batteries and repair existing inventory. Once notified, customers will be provided an approved shipping container for return of the affected product(s), in compliance with applicable transportation laws and regulations. Navico
Group will engage Cirba Solutions (โCirbaโ), a third party recycling partner that specializes in battery recycling, logistics, and transportation. Navico
Group will pay all shipping and repair/replacement costs. How Remedy Component Differs from Recalled Component : Navico
has identified a repair for the manufacturing issue detailed herein. The repair plan will address the root cause of the capacitors, which were added to the pack to prevent customer โnuisanceโ faults in the event of a current spike, and do not impact normal operation. Removing these capacitors eliminates the corrosion potential resulting from leaking electrolyte. Additionally, a thermal switch or fuse will be installed to disable the pack in the event of elevated pack temperatures. Identify How/When Recall Condition was Corrected in Production : Navico
stopped producing the affected batteries on November 18, 2022. Production has not yet resumed. Preliminarily, Navico
anticipates production to resume in May of 2023. Newly manufactured units built after production resumes will have a different serial number. The recall condition will be corrected in production by removing the capacitors and installing a thermal fuse to disable the battery in the event of elevated pack temperatures. Recall Schedule : Description of Recall Schedule : NR Planned Dealer Notification Date : NR – NR Planned Owner Notification Date : NR – NR Purchaser Information : The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: Name : Garia Inc. Address : 14820 North Freeway, Suite 200 Houston TX 77090 Country : US Company Phone : NR Part 573 Safety Recall Report 23E-005 Page 4 The information contained in this report was submitted pursuant to 49 CFR ยง573 Name : Waev Inc. Address : 2114 W Ball Road Anaheim CA 92804 Country : US Company Phone : NR * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23E-005 The information contained in this report was submitted pursuant to 49 CFR ยง573 Manufacturer Name : Navico Group Submission Date : FEB 14, 2023 NHTSA Recall No. : 23E-005 Manufacturer Recall No. : NR Manufacturer Information : Manufacturer Name : Navico
Group Address : N85 W12545 Westbrook Crossing Menomonee Falls WI 53051 Company phone : 5807749054 Population : Number of potentially involved : 4,746 Estimated percentage with defect : 1 % Equipment Information : Brand / Trade 1 : RELiON Model : InSight 48V lithium-ion battery Part No. : 48V030-GC2 Size : NR Function : NR Descriptive Information : For replacement equipment, the recall population was determined based on reviewing affected serial number data provided by the manufacturer. The potential defect is isolated to products built or reworked after May 19, 2021, when modifications were made in production to the sense board and a sense ribbon cable was added to the battery (replacing a traditional wire harness). For batteries installed as original equipment in motor vehicles, Navico
Group determined the population based on information from the two vehicle manufacturers. In total, Navico
Group has identified 357 products installed as original equipment in motor vehicles. Production Dates : MAY 19, 2021 – NOV 18, 2022 Description of Defect : Description of the Defect : The concern with the product has been identified as a capacitor manufacturing issue. In some cases, improperly formed capacitors can leak electrolyte onto the Printed Circuit Board for the Battery Management System, resulting in corrosion across the terminal for the voltage sense ribbon. The corrosion can result in a short circuit across the voltage sense ribbon terminal which can lead to thermal damage of the resistors. Navico
Groupโs testing establishes that the battery cells themselves pass propagation testing and do not lead to a battery cell thermal runaway event. FMVSS 1 : NR Part 573 Safety Recall Report 23E-005 Page 2 The information contained in this report was submitted pursuant to 49 CFR ยง573 FMVSS 2 : NR Description of the Safety Risk : The potential defect could give rise to thermal damage that could result in fire which could potentially escape the battery enclosure, posing a potential ignition risk to surrounding materials, and the potential risk of associated burn injuries. Navico
has received no reports of thermal events, fires or burn injuries in any battery installed in a motor vehicle within NHTSA’s jurisdiction. Description of the Cause : Improperly formed capacitors. Identification of Any Warning that can Occur : A thermal event may generate odor and/or smoke. However, Navico
has received no reports of thermal events, fires or burn injuries in any battery installed in a motor vehicle within NHTSA’s jurisdiction. Involved Components : Component Name : RELiON InSight 48 V lithium-ion battery Component Description : Battery used to power off-road and on-road vehicles, as well as used for standalone units to increase system capacity. Component Part Number : 48V030-GC2 Supplier Identification : Component Manufacturer Name : BMTPow (Shenzhen) Ltd. Address : A404, Block 1, Phase 1, Intelligent Park Long Gang District Shenzhen Foreign States 518112 Country : China Chronology : Chronology provided as a separate attachment. Part 573 Safety Recall Report 23E-005 Page 3 The information contained in this report was submitted pursuant to 49 CFR ยง573 Description of Remedy : Description of Remedy Program : Navico
Group will repair and replace in-field batteries and repair existing inventory. Once notified, customers will be provided an approved shipping container for return of the affected product(s), in compliance with applicable transportation laws and regulations. Navico
Group will engage Cirba Solutions (โCirbaโ), a third party recycling partner that specializes in battery recycling, logistics, and transportation. Navico
Group will pay all shipping and repair/replacement costs. How Remedy Component Differs from Recalled Component : Navico
has identified a repair for the manufacturing issue detailed herein. The repair plan will address the root cause of the capacitors, which were added to the pack to prevent customer โnuisanceโ faults in the event of a current spike, and do not impact normal operation. Removing these capacitors eliminates the corrosion potential resulting from leaking electrolyte. Additionally, a thermal switch or fuse will be installed to disable the pack in the event of elevated pack temperatures. Identify How/When Recall Condition was Corrected in Production : Navico
stopped producing the affected batteries on November 18, 2022. Production has not yet resumed. Preliminarily, Navico
anticipates production to resume in May of 2023. Newly manufactured units built after production resumes will have a different serial number. The recall condition will be corrected in production by removing the capacitors and installing a thermal fuse to disable the battery in the event of elevated pack temperatures. Recall Schedule : Description of Recall Schedule : NR Planned Dealer Notification Date : FEB 23, 2023 – FEB 27, 2023 Planned Owner Notification Date : FEB 23, 2023 – FEB 27, 2023 Purchaser Information : The following manufacturers purchased this defective/noncompliant equipment for possible use or installation in new motor vehicles or new items of motor vehicle equipment: Name : Garia Inc. Address : 14820 North Freeway, Suite 200 Houston TX 77090 Country : US Company Phone : NR Part 573 Safety Recall Report 23E-005 Page 4 The information contained in this report was submitted pursuant to 49 CFR ยง573 Name : Waev Inc. Address : 2114 W Ball Road Anaheim CA 92804 Country : US Company Phone : NR * NR – Not Reported
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