Genesis dual battery fire?

[Whaler27]

I installed the Genesis dual battery system a few years ago. Since that time my biggest challenge has been keeping a charge on the batteries. I’ve been working a lot, so the jeep lives in the garage on a battery charger. I’ve been using the Noco 10 amp smart charger, but it doesn't keep the jeep start-ready, whether I connect it per the Genesis videos, or connect it to only the starting batter. It’s appears that the charger will charge the battery up to a point, then turn off, so the battery will be dead again in two or three weeks (or less).

This evening I jump started the jeep to take my wife to dinner. When we got home I let the jeep run for another 30 minutes or so to improve the charge. Ten minutes into that I noticed a terrible stink — like sulfur or rotten eggs. I popped the hood and saw smoke coming from one of the batteries. (See video) I pulled the jeep away from the house and disconnected both grounds.. The rubber caps on the solenoid are melted too. I’m at a loss as to what caused this or how to fix it. Any ideas?

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[Whaler27]

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[Reinen]

Were they new batteries when you installed the Genesis kit? I think one of them might have been bad from the get go and is now failing in a dangerous way.

It's hard to say without looking at it but I'd start with the following.

1. Remove and load test both batteries. See if one of them (likely the smoking one) is bad bad. i.e. has an internal short.
2. Triple check the Genesis wiring to the wiring diagram. Years is a long time to go with incorrect wiring but it could be possible. Never hurts to re-check and confirm.
3. Replace the solenoid. I don't have the Genesis Dual Battery kit, just the Aux relocation kit. I assume the solenoid is between the two batteries and connects/disconnects them. A lot of current went through that solenoid and you should assume it is now compromised and dangerous to use.

But again, I'm guessing here. Can't be certain about anything without examining the wiring physically or with a multi-meter.

 

[THAW]

Given that the boots on the low-current contacts of the solenoid melted, it's possible the internal coil was/is damaged. I'm not sure how that would cause or be caused by a smoking battery - could be unrelated and just the result of running hot over the years. The battery likely smoked because it failed due to age/damage.

Replace the batteries (immediately stop using the battery that smoked) and swap the solenoid for a REDARC BCDC. A smart solenoid is outdated technology anyway; a dedicated DC-to-DC charger is the modern way to run a dual battery system.

 

[Kyanche]

The rotten eggs smell means one of your batteries is toast. The smell is hydrogen sulfide which is not only bad to breathe but also quite flammable - keep it someplace well ventilated.

 

[Whaler27]

Thanks, guys. I disconnected the batteries and left the jeep in the middle of my driveway 50’ from the house last night.

The batteries came new as part of the Genesis kit. I’ll see if I can find replacements today.

At this point I’d be happy with two batteries that worked — without the whiz-bang jump feature on the Genesis system.

 

[jadmt]

how old are the actual batteries? I know you said you installed it a few years ago but time flies is a few years 2 years or 4 or 5 years...sounds like reading on another thread you posted on you probably have had at least one bad battery for a long time. do you have a local battery plus store nearby?

 

[Whaler27]

how old are the actual batteries? I know you said you installed it a few years ago but time flies is a few years 2 years or 4 or 5 years...sounds like reading on another thread you posted on you probably have had at least one bad battery for a long time. do you have a local battery plus store nearby?

You’re right. Time flies, and it flies faster as you get older… I’m not sure how old they are. I’ve had this Jeep six years, so I’m going to guess they’re 4 years Old?

The charge issue is also old. The challenge is, I can go thee or four months between opportunities to fuss with the jeep. I’ll check it, find it near dead, jump it, drive it for a few days without incident, then connect it to a new battery charger. Sometimes I remember to check on it after a week or ten days and let it run, if it will start. Sometimes it’s slow to turn over but fine. Then three or four months later it’s I’ll have to jump it to get it started, drive it a few days, then connect the charger to only the starting battery, etc. If I drive the jeep a lot I probably would not have had this problem.

At this point I’d like to convert it to a simple dual battery set up. I should be able to get new batteries at Autozone this morning. Then I’ll install them, start the jeep, so I can back it into the shop, then disconnect the batteries until I can confirm a safe way to get rid of the @Genesis Offroad solenoid and complexity.

 

[av8or]

One thing to remember if they’re lead acid batteries, is that every time it gets below 50% state of charge the battery gets damaged and the life of the battery will be shortened. If it’s gotten so dead that you’ve had to jump start it more than a few times, it’s most likely bad battery/batteries.

https://poweringautos.com/does-lead-acid-discharge-hurt-the-battery/

 

[Terrymo]

I installed a simple Blue Sea magnetic latching relay when I installed a dual battery setup in a couple of my previous vehicles. I didn’t even install the interior switch since everything can be done mechanically on the relay itself. Simple product and dead nuts reliable
https://www.bluesea.com/products/category/35/91/ML-ACRs

 

[Ratbert]

The obvious people to ask: @Genesis Offroad.

 

[Nokones]

What batteries did you install with your Genesis Gen 2 Dual battery system? Hopefully, you were using AGM betteries.

You need to scrap the Noco charger and get the Odyssey 25 Amp Charger

 

[Slate]

That is the older Genesis system I believe. Not saying anything is related but there it is.

I am not seeing how having old batteries that constantly needed to be charged/jumped is the fault of the Genesis system? The title of the thread sure seems to point at that and not the older batteries.

I have the dual battery set up as well, but mine is the newer (not the newest) version.

 

[Whaler27]

One thing to remember if they’re lead acid batteries, is that every time it gets below 50% state of charge the battery gets damaged and the life of the battery will be shortened. If it’s gotten so dead that you’ve had to jump start it more than a few times, it’s most likely bad battery/batteries.

https://poweringautos.com/does-lead-acid-discharge-hurt-the-battery/

So I took both to Batteries Plus. One was fried… showed 2.3 volts. The second one showed 11 volts.

The only AGM Group 25 option I could find within 80 miles was the Optima red-top. I had to drive about 120 miles, and bend over the desk for a sound beating on price, but I now have two new batteries in the jeep. I fired it up, backed into the garage, and disconnected ground cables until I can figure out what’s wrong and replace the solenoid (at least).

I’ve had lots of Jeeps, trucks, and boats with dual batteries. It’s a great reserve, but I’m not sure the trickier features of the current system are worth the hassle for me.

 

[Slate]

https://www.jlwranglerforums.com/fo...hood-scoop-and-edelbrock-supercharger.102162/

Looking at a photo you posted of your engine bay from back in 2022 those black boots on the solenoid didn't look much better then either although they do look more melty now.

Wonder if this has been an ongoing problem? The frequent jump starts can't be a good thing?

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