As Australia’s largest lithium battery manufacturer, we recognise that installers play a critical role in ensuring lithium battery systems are deployed safely. With increasing media attention and public concern around lithium battery fires, it’s more important than ever to understand the facts, the risks, and the mitigation strategies built into professionally engineered energy-storage systems.
Industry and emergency-service data points to a clear rise in lithium-ion battery–related fires. While Fire and Rescue NSW do not publicly classify incidents by battery chemistry or end use, available reporting indicates a strong upward trend. ABC News reported that NSW recorded 324 lithium-ion battery fires in the past year, up from 272 in 2023, and that fire agencies nationally responded to more than 1,000 lithium-ion battery-linked fires over the same period. These incidents are mostly reported at waste and recycling facilities, with a growing proportion linked to consumer products such as e-bikes, e-scooters and small household devices.
The above image compares several lithium-ion battery types across key criteria such as specific energy, specific power, safety, performance, lifespan, and cost. Each battery chemistry has its own strengths and trade-offs. LiFePO₄, for example, may not lead in every category, particularly in specific energy, where it is less energy-dense than some alternatives, but it stands out for its strong balance overall. It offers excellent safety, long lifespan, and high specific power, making it a reliable and durable option. While it is not the cheapest option, it is also not the most expensive, reflecting a middle-ground cost for a battery that prioritises safety, stability and longevity over maximum energy capacity.
While stationary energy-storage systems (ESS) are a separate category with stricter design standards, safety layers, and professional installation requirements, these statistics contribute to public concern. Installers are often on the frontline of addressing these questions, which is why we design every product with fire mitigation, compliance, and safety engineering at its core.
Technical Fire Mitigation Measures
We align our design methodology from initial concept through to testing with these requirements, ensuring our batteries meet current standards while also supporting the next generation of safety expectations as the specification is more widely adopted across the industry.
We integrate safer chemistry, precision engineering, and multiple protective layers to reduce both the likelihood and the consequences of thermal events. The table below outlines the key safety measures every installer should understand:
| Component | Design / Specification | Purpose & Benefit |
|---|---|---|
| Chemistry: Lithium Iron Phosphate (LFP / LiFePO₄) | Use of LFP instead of higher-risk lithium chemistries (NMC, LCO). | High thermal stability, reduced thermal runaway risk, lower flammable gas production. |
| Cell Quality & Tolerance | <1% manufacturing variation; built-in non-maintainable OCP. | Improved consistency, reduced imbalance stress, inherent protection. |
| Battery Management System (BMS) | Monitors voltage, current, temperature, SOC with full protection logic. | Real-time monitoring, fault detection, safe balancing. |
| Mechanical Over-current Protection | External circuit breaker per unit. | Redundant safety layer beyond electronic controls. |
| Enclosure & Containment | Reinforced metal casing with insulation. | Thermal containment and propagation prevention. |
Fire Suppression & Integrated Safety Systems
In addition to these design features, we are incorporating integrated safety systems in response to the ongoing evolution of industry standards, many of which are still emerging and not yet compulsory.
Rather than waiting for formal requirements to be introduced, PowerPlus Energy and the Battery Management System used in the 4851 proactively adopt advanced safety measures aligned with anticipated best-practice standards. As system design and manufacturing practices continue to mature, newer installations reflect higher safety and compliance.
This proactive approach does not suggest that earlier-generation systems are unsafe; instead, it demonstrates a commitment to continuous improvement, using advancing technology to further enhance safety margins as the industry develops.
- Fire Suppression Systems: Interfaces with thermal triggers or detectors to suppress fire without damaging equipment.
- Thermal Monitoring: Detects hotspots, issues alerts, and can initiate an automated shutdown.
- Ventilation & Gas Pathways: Engineered vent paths relieve pressure safely and prevent uncontrolled venting.
- Scheduled Inspections: Maintenance programs ensure long-term system safety and reliability.
- Increased Capacity: Battery capacity increases from 3.3kWh to 3.8kWh and from 4.0kWh to 4.7kWh using improved cell packs.
Compliance With Global, Local and Emerging Standards
We ensure every system is designed, manufactured and tested to comply with stringent safety and performance frameworks, including:
- TS 5398: Technical Specification for Battery Energy Storage Systems (Australia)
- IEC 62133 / IEC 62619: International rechargeable cell and battery safety standards
- UL 9540A / UL 1973: Energy storage fire safety and system evaluation benchmarks
- AS/NZS Standards: Electrical installation and wiring rules for Australia
- Local Building & Fire Codes: Ventilation, enclosure and hazard mitigation requirements
- ISO 13849 / IEC 61508: Functional safety and BMS-related frameworks
Installation & Operational Best Practice
Safe outcomes require both well-engineered products and correct, compliant installation. PowerPlus Energy supports installers across the full installation lifecycle:
- Site Assessment: Evaluate environment, ventilation, access and temperature conditions.
- System Sizing: Ensure safe operating margins.
- Correct Installation: Use certified installers and compliant components.
- Quality Control: Verify electrical and mechanical integrity.
- End-User Training: Provide operational and safety guidance.
- Monitoring & Logging: Track performance and system alerts.
- Emergency Planning: Align procedures with local authorities and site requirements.
Conclusion
Lithium battery fire risks are real, but with the right chemistry, design principles, and installation practices, they are highly preventable. PowerPlus Energy takes a multi-layered approach to safety by combining safer chemistries, strict quality standards, advanced safety electronics, and full alignment with TS5398, global standards, and Australian installation frameworks.
For installers, this means you can deploy PowerPlus Energy systems with confidence, knowing that safety and reliability are built into the design from the outset. While our current products already exceed industry expectations, we continue to evolve with the regulatory landscape. Our next article will introduce the LiFe4851, our latest battery that has undergone UL9540A thermal runaway fire testing — the internationally recognised benchmark for energy storage fire safety.
