Honeywell has issued a customer notice regarding a small number of BW MicroClip gas detectors that have shown signs of battery swelling. While this issue is limited, it’s important for users to understand what’s happening, what causes it, and what actions to take to stay safe.
What’s Happening?
Honeywell identified reports of battery swelling in some BW MicroClip instruments. After third-party testing, Honeywell confirmed that the batteries do not show a manufacturing defect. Instead, the swelling is most likely caused by a combination of:
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High state of charge
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Exposure to high temperatures
As part of Honeywell’s continuous improvement process, a design change has been completed to restrict battery charging to a specific temperature range. This updated design is currently pending certification.
Why Battery Swelling Matters
The BW MicroClip uses a lithium-ion battery. In general, lithium-ion batteries can swell due to internal chemical reactions that increase pressure inside the battery. When swelling occurs, it is a sign that the battery has reached the end of its service life and should be removed and disposed of properly.
A swollen battery can become fragile and may pose a safety risk if not handled correctly.
Common Causes of Battery Swelling
Battery swelling can occur for several reasons, including but not limited to:
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Physical damage or misuse
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Overheating
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Over-charging or over-discharging
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Repeated “top-off” charging
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Age and environmental conditions (especially temperature exposure)
What to Do If You Notice a Swollen Battery
If you or your team identify a BW MicroClip (or any device) with a swollen battery, follow these safety steps:
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Do not ignore swelling. Take action immediately, even if the device still appears to function.
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Do not puncture or attempt to release gases from the battery. This can be extremely dangerous.
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Handle the device with care. Swollen lithium-ion batteries are more fragile.
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If it can be done safely, remove and replace the battery following manufacturer guidance.
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Quarantine the battery in a fireproof container or fire-resistant location before proper disposal.
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Dispose of the battery according to local regulations and safety requirements.
Recommended Next Steps for Employers & Users
Honeywell recommends that users:
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Inspect BW MicroClip batteries as soon as reasonably practical
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Perform regular inspections moving forward
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Monitor charging habits and storage conditions
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Avoid exposing devices to excessive heat
Swollen Battery Reporting Instructions
If you encounter a swollen battery on a Honeywell BW MicroClip, do not return the unit to Honeywell.
Please record the instrument serial number and board serial number, then submit a case through Honeywell Technical Support:
👉 https://sps-support.honeywell.com/s/
When submitting your case, select:
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Case Reason: Quality | Defect | Reliability
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Subject: MicroClip Swollen Battery
If multiple units are affected, include a list of all serial numbers in your submission.
Need Help or Have Questions?
Battery safety is critical, especially for life-saving equipment like gas detectors. If you’re unsure whether your device is affected, need help with inspection, or are looking for replacement equipment or guidance, our team at Colorado Safety Supply is here to help.
Reach out to us for expert advice, service options, or product support to keep your team safe and compliant.
