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AGM battery melt down or gremlins

baddog1016

Regular Contributor
engine is a 2000 225 Evinrude. Engine ran fine when I winterized it in December. I cleaned all of my battery connections today, hooked the batteries up and turned on #1, the AGM. Immediately there were significant sparks from the positive terminal. I turned the battery back off, disconnected the positive cable and made sure there wasn't a short to ground. There wasn't, my meter showed 24M ohms resistance between positive and ground which shouldn't have caused sparks like I saw. I put everything back together and tried again. It turns out the positive terminal stud is a bolt that is soldered into the battery. It came unsoldered! I was perplexed, checked for a short to ground again at the battery cables, at the transom junction and at the motor. Nothing. Being brave or stupid I held the ground wire on my number two battery and turned in on and nothing happened. The battery is charged to 12.84 volts and I had 12.84 volts at the hot side of the starter solenoid and ground. I turned the key and nothing happened, I don't even have engine tilt. I am going to look carefully at the schematic when I'm done writing this but I'm wondering if anyone has ever seen an AGM battery do this. I was in the car business for 35 years and have seen batteries that have exploded but I've never seen a battery do this. Anybody have any clues? It doesn't seem like it could be internal to the battery. The ignition switch was off during the battery meltdown episode. Thanks in advance for any ideas.
 
reversed battery cable connections and blew a main fuse

I hate to admit it but I had the #2 battery in backwards. All the fuses are good, it appears the main power relay is smoked though. After I fixed my mistake the engine would crank for a short period and then nothing unless I waited a minute and then the same thing. The engine did briefly fire a couple of times but I also noticed I was not hearing the fuel pump run. The relay looks burned on the bottom which is why I suspect it. I'm hoping that is the only damage and I didn't blow a diode in the start circuit, or something worse. When I melted the AGM battery I did not have the engine ground hooked up but I did hook it up with the battery in backwards. I figured it out by noticing the "-" sign on my meter. Too bad I didn't notice it right away.
 
.... It turns out the positive terminal stud is a bolt that is soldered into the battery. ...

the studs are usually put into the terminal mold and then its filled with lead to make an integrated unit....the current melted the lead freeing the stud...no soldering used when making the battery as high current will melt it...everything gets crimped...
 
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