Sena 20S warning

[Jetfixer]

My Sena 20S dual system will be two years old in Feb. I've been having issues with the battery life in my headset. Her headset seems to work fine. After attending the Univ of Youtube, I decided to replace the batteries in both headsets with a larger capacity battery. The original unit is a 650mAh battery and I replaced them with 800mAh batteries for longer run time. The process is a little tricky due to the small wire sizes. However, after being successful replacing my headset battery, I started on hers. What I found was shocking. Her battery was about ready to explode! I can only imagine what would have happened if this thing had exploded or just caught fire while riding. Think about this; how do you remove a burning helmet? See the attached photos. Unfortunately, there's no easy way to check for this, you have to disassemble the unit.

 

[Brentc]

Forward to sena

Not for nothing, but for all of our sakes. Can you forward that info to sena support and see if you get any response. For no other reason than to have documented that they have been made aware of the issue. If, god forbid, someone did get hurt down the road and Sena knew there was an issue that’s a whole nother ballgame.

 

[Jetfixer]

Not for nothing, but for all of our sakes. Can you forward that info to sena support and see if you get any response. For no other reason than to have documented that they have been made aware of the issue. If, god forbid, someone did get hurt down the road and Sena knew there was an issue that’s a whole nother ballgame.

I've thought about doing that, but Sena's official stance is that the battery is NOT replaceable. Since opening the unit would void the warranty, there is no reason for a consumer to be opening it up. But unless you open it up, you would not know the battery was failing like this.

 

[Chupaca]

Yikes...!!

You should check with motorcycle Dave (sponsor/vendor on the home page) who deals with the sena comm systems. He should be able to shed some light on this or find out from the source...:thumbup:

 

[Saluda]

Sounds like it's worth following up on. Lot of battery issues lately across the board.

 

[jcthorne]

I had a Sena 20s battery do this. Did not need to disassemble the unit to tell. The wheel would not turn and the unit was physically distorted.

I called Sena and they sent a complete replacement unit.

 

[robhowen]

Replacement battery fit & source

I replaced mine and my old battery was rather swollen as well. Did the 800mAh battery fit well? I've seen some batteries where the measurements seemed too big. Where did you get it? Can you point me to a website link?
Rob

I replaced them with 800mAh batteries for longer run time.

 

[Motorcycledave]

I will send it on to the R&D dept. you may want to email me with more details
[email protected]

My Sena 20S dual system will be two years old in Feb. I've been having issues with the battery life in my headset. Her headset seems to work fine. After attending the Univ of Youtube, I decided to replace the batteries in both headsets with a larger capacity battery. The original unit is a 650mAh battery and I replaced them with 800mAh batteries for longer run time. The process is a little tricky due to the small wire sizes. However, after being successful replacing my headset battery, I started on hers. What I found was shocking. Her battery was about ready to explode! I can only imagine what would have happened if this thing had exploded or just caught fire while riding. Think about this; how do you remove a burning helmet? See the attached photos. Unfortunately, there's no easy way to check for this, you have to disassemble the unit.

View attachment 156057View attachment 156058View attachment 156060

 

[Jetfixer]

I replaced mine and my old battery was rather swollen as well. Did the 800mAh battery fit well? I've seen some batteries where the measurements seemed too big. Where did you get it? Can you point me to a website link?
Rob

https://www.ebay.com/itm/3-7V-800mA...e=STRK:MEBIDX:IT&_trksid=p2055119.m1438.l2649

This battery is almost exactly the same physical size as the original and fit perfectly. You'll need to cut and solder the original connector leads to the replacement battery. I used shrink tubing to insulate the solder points. Keep everything as small as possible and it will work great!

 

[robhowen]

Thanks for the link

Thanks for the link.
Rob

 

[Jetfixer]

I will send it on to the R&D dept. you may want to email me with more details
[email protected]

email sent

 

[scarecrow]

I have been in the RC car hobby/sport for over 30 years. Having been through the nicad phase, the nimh phase and now in the past 7yrs the lipo phase. These cells can and will go up in flame with out warning. These batteries go up like the china syndrome .There is no just throw water or shoot a fire extinguisher at it. Smothering it in sand is the only way to put it out. I have had two friends loose their houses to fires caused by lipo batteries. The fires occured while charging the cell. Yes their 4500 ma and 4.2 volt, but we also use the same batteries as sena to operate the receivers and servos. Now it has bern mandated that all cells be charged in lipo sack. The sack is fire proof. So if it does exploded it cannot get out side out the sack. Another mistake is poking a hole in the battery case air getting in to the case will cause it to ignite. The best thing to do is if you see the battery has swelled up remove it and disguard it safety. Hopefully sena will find a alternative battery. Maybe in lithium ion or Life cells.

 

[finless]

These use LiPo batteries. I have been replacing them in many models of GPS' and headsets for about 2 years now.
FYI I do it for free for people because manufacturers WILL NOT do it as they want you to buy new. So I help folks by replacing them free because I have the equipment and can do it.

Anyway... one of the biggest KILLERS of LiPo batteries is having them in the sun and get hot. ESPECIALLY if they are at 80% or more charged. The worst thing you can do to them. If they are at say 20-30% charge then heat does not cause this as much.
TRUST ME... I have been dealing with LiPo technology since 2004 with electric RC helicopters. So much learned.

So the point. NEVER EVER leave your headset on your helmet cooking in the sun. 100% you will "puff" the pack.
Now with that said, a "puffed pack" does not mean fire. Fires of LiPo's are almost always something that happenes when they are not charged properly or get punctured... So even a puffed pack is not a big risk it just loses capacity and thus how long they work. But with that said, not always true too... sometime they can go off.

I have replaced about 200 LiPo's for people in the last year for free on all kinds of devices. And yes, almost all of them are baloons when I take the old ones out. I have seen this so many times I AM NOT SHOCKED
It's common place.....

Bob

 

[finless]

Want to see some real baloons?
This was a small RC Heli pack (3 cell) I cut the shrink wrap off of. (the 3 cells on the left). On the right is a good pack (not puffed) with the heat shrink still on it. So you see what happens.

LOL....

 

[finless]

LAST COMMENT....

It is unfair to say this is a Sena 20S warning.... It's ANY product that uses LiPo technology batteries. Abuse them and they puff!

So to call this a 20S warning, trust.... It's all headsets as they all use LiPo batteries (Scala, Garmin, Sena, GoPro, etc)... They use LiPo's because unlike LiOn that need more circuits and usually a metal case, is far heavier. Oh and the PRICE... LiOn costs a lot more to use and implement, AND has far less run time compared to charge time.

Bob

 

[finless]

Actually one more comment....

Manucaturers should, when using LiPo, allow users to easily replace the batteries. This is something I think is wrong.
They wan't you to buy NEW when battery life gets low (about 2 years average). These should be designed to allow simple user replacement. Just my take. For now, they wan't you to buy new because 2 years, new models... It's the game

Bob

 

[Bensonoid]

So the point. NEVER EVER leave your headset on your helmet cooking in the sun. 100% you will "puff" the pack.
Now with that said, a "puffed pack" does not mean fire. Fires of LiPo's are almost always something that happenes when they are not charged properly or get punctured... So even a puffed pack is not a big risk it just loses capacity and thus how long they work. But with that said, not always true too... sometime they can go off.



Bob

What are the do's and don'ts on charging properly?

 

[finless]

For Sena headsets you have no choice. The charging is internally regulated. I was speaking to LiPo's in general.

Again what you do not want to do is leave it in the sun to cook especially if it is 80% or more charged.

Bob

 

[Fire34]

I am with you

I've thought about doing that, but Sena's official stance is that the battery is NOT replaceable. Since opening the unit would void the warranty, there is no reason for a consumer to be opening it up. But unless you open it up, you would not know the battery was failing like this.

We have the Nolan B5 systems in our helmets and I thought at a time we were already having battery issues. Took it back to the dealer and he said that same thing, he replaced them with new units, we just charge them after every ride short or long
Dave

 

[Bensonoid]

For Sena headsets you have no choice. The charging is internally regulated. I was speaking to LiPo's in general.

Again what you do not want to do is leave it in the sun to cook especially if it is 80% or more charged.

Bob

OK Thanks.