# G.H. Johnson & Associates, Inc. — Hazardous Materials Safety Interpretation **Citation:** 98-0602 **Type / status:** guidance / guidance **Agency:** Pipeline and Hazardous Materials Safety Administration **Effective:** Not stated **Published:** 1998-04-17 98-0602 response to G.H. Johnson & Associates, Inc. concerning 173.159. ## Document text <<>> • U.S. Department of Transportation Washington, D.C. 400 Seventh Street, S.W. 20590 Special Programs Research and Administration APR 1 7 1998 Mr. James A. Noone G.H. Johnson & Associates, Inc. 1211 Connecticut Avenue, N.W., Suite 302 Washington, D.C. 20036-2603 Dear Mr. Noone: This is in response to your letter of March 25, 1997, requesting clarification on the shipping requirements for batteries manüfactured by your company under the provisions of the Hazardous Materials Regulations (HMR; 49 CFR Parts 171-180). Specifically, you ask if your batteries are subject to the HMR. The information you provided demonstrates that your batteries are constructed in such a manner that the sulfuric acid electrolyte is completely sealed and cannot leak even if the battery is cracked open or punctured. In addition, the sulfuric acid electrolyte is absorbed in a fibrous glass separator. Thus, your batteries appear to meet the criteria for non-spillable batteries in § 173.159(d). When securely of the Hazardous Materials Regulations. packaged and protected against short circuits, non-spillable batteries are not subject to the provisions In addition, under the International Civil Aviation Organization's (ICAO) Technical Instructions for the Safe Transport of Dangerous Goods by Air, special provision A67, a non-spillable battery is considered to be non-regulated if, at a temperature of 55°C, the electrolyte will not flow from a cracked or ruptured case. I hope that this information is helpful. If you need further assistance, please contact us. Sincerely, i Chich Re Baliness Chief, Regulations Development Office of Hazardous Materials Standards <<>> G. H. Johnson & Associates, Inc. Government and Military Marketing Representatives for: OPTIMA S BATTERIES 113. THE ULTIMATE POWER SOURCE 127. March 25, 1998 J. Suzanne Hedgepeth Director Office of Hazardous Materials Exemptions and Approvals Office of the Associate Administrator For Hazardous Materials Safety Research and Special Programs Administration Department of Transportation 400 Seventh Street, SW Washington, DC 20590 Re: Request for Determination Dear Ms. Hedgepeth: I am writing to seek an updated determination from the U.S. Department of Transportation ("DOT") that batteries manufactured by OPTIMA Batteries, Inc. ("Optima"), of Aurora, Colorado, are not subject to the Hazardous Materials Regulations and, therefore, can be shipped commercially by air and surface means without restriction. Optima utilizes a spiral design for battery cells that was originally developed by The Gates Rubber Company ("Gates") of Denver, Colorado. The technology was invented by Gates in the 1970s, and commercial production began in 1987 under the Optima name. In 1990, Optima was incorporated as a division of Gates. In 1992, Optima was purchased from Gates by The Gylling Group of Scandinavia, the current parent company. This history of Optima is outlined in "The Optima Manual," Attachment A. In 1981, in response to a request by Gates, the Research and Special Programs Administration ("RSPA") of DOT informed Gates that because of the sealed design of the batteries eventually to be sold under the Optima name, such batteries were not subject to the Hazardous Materials Regulations. See Attachment B, letter of February 18, 1981, from Joseph T. Horning, Chief, Regulations Development Branch, Office of Hazardous Materials Regulations, Materials Transportation Bureau, RSPA. Colorado Office 270 Tahosa Road South, POB 457 Washington Office Alienspark, CO 80510-0457 1211 Connecticut Avenue, N.W., Suite 302 Tel: (303) 747-2065 Fax: (303) 747-2915 Washington, D.C. 20036-2603 E-mail: ghjassoc@mci2000.com Tel: (202) 466-7336 Fax: (202) 955-5879 E-mail: kn1211conn@aol.com <<>> Optima would like to obtain a current determination by the appropriate DOT office that its battery is not subject to the Hazardous Materials Regulations and is authorized for shipping by commercial means. So that a proper evaluation may be done pursuant to this request, I am enclosing the following additional materials: One-page promotional sheet showing technical specifications (Attachment C) A current Material Safety Data Sheet (MSDS), most recently revised on December 5, 1997 (Attachment D) Letter of June 2, 1995, from the International Air Transport Association ("IATA") confirming that Optima batteries are not regulated by the IATA Dangerous Goods Regulations (Attachment E) As explained in substantial detail in these attachments and in Attachment A, the Optima battery is completely sealed. In addition, the sulturic acid electrolyte is absorbed in a fibrous glass separator material. Because of the design and construction, acid cannot leak even if the battery were to be punctured.: For your information, we have been in communication with the U.S. Postal Service ("USPS) in recent weeks with respect to a determination that the Optima battery can be shipped by the USPS as a non-hazardous product. We have been advised that USPS is in the process of revising its regulations to reflect such a determination. We will forward documentation reflecting this change as we receive it from USPS. We would very much appreciate your expeditious consideration of this request. Please use the undersigned as the point of contact in the Washington Office of Johnson Associates/Optima: (202) 466-7330 (P); (202) 955-5879 (F). As indicated on this letterhead, the mailing address is: G.H. Johnson & Associates, Inc./OPTIMA Batteries, Washington Office, 1211 Connecticut Avenue, NW, Suite 302, Washington, DC 20036. information. Please do not hesitate to contact me should you require additional technical or other Sincerely, Tues Too Macer Washington Representative JAN: dkt 2 <<>> S - ОРІШМА SPIRALCELL" TECHNOLOGY BATTERIES THE ULTIMATE STARTER 7 дат: 800S ONLY OPTIMA's 800U 850/6 SPIRALCELL TECHNOLOGY™ OFFERS ALL THESE BENEFITS: available. Our patented SPIRALCELL Technology OPTIMA is the most advanced engine-starting battery provides many features and benefits not found in LONGER SHELF LIFE. conventional automotive batteries: With its low rate of self discharge, the OPTIMA can go is ideal for boats, farm equipment, collector cars, and unused for up to a year without recharging. The OPTIMA FASTER, CRISPER STARTS. power for faster, crisper starts. The 800U and 800S 12- The OPTIMA's SPIRALCELL Technology provides more other seasonal equipment. volt models deliver 800 Cold Cranking Amps at 0°F. FASTER RECHARGE. allow the OPTIMA to be recharged in less time than Greater plate surface area and lower internal resistance In performance tests, the OPTIMA lasted three to five LONGER BATTERY LIFE, GREATER SAVINGS. conventional automotive batteries. times longer than conventional, flat-plate batteries. FAST ENERGY RESPONSE. Electrolyte in the OPTIMA is completely absorbed. It COMPLETELY SEALED. faster when demanded by accessories such as stereos, The OPTIMA's low internal resistance provides power can't leak even if the battery is cracked open. This means winches, etc. the OPTIMA is safer for people, equipment, and the environment. BETTER RECOVERY FROM DISCHARGE. UNEQUALED VIBRATION RESISTANCE. Vibration is a primary killer of conventional batteries. vibration, and eliminates plate shedding. OPTIMA's tightly wound SPIRALCELL resists jarring and UNIVERSAL SIZE & FIT. The OPTIMA fits a wide variety of cars, trucks, and other equipment. The OPTIMA can be mounted in any position Tests prove the OPTIMA performs better in extreme cold MORE POWER IN ANY CLIMATE. - even upside-down. and hot temperatures than conventional lead-acid batteries of similar size. OUTSTANDING WARRANTY. Thanks to recombinant technology, absorbed electrolyte, ZERO MAINTENANCE / NO CORROSION Because the OPTIMA is built for some of the roughest warranties. See an OPTIMA dealer for complete warranty conditions, it's backed by one of the best automotive and sealed construction, the OPTIMA won't corrode details. battery terminals, cables, or the vehicle. And the OPTIMA never needs to have water added. OPTIMA Batteries, Inc. / 17500 E. 22nd Avenue / Aurora, CO 80011 / Phone (303) 340-7440 / Fax (303) 340-7474 Gylling Group of Scandinavia -- Established 1912 PN 06-1001 3/96 <<>> OPTUMA BATTERIES TECHNICAL THE ULTIMATE STARTER 800U 800S 850/6 INFORMATION Voltage PERFORMANCE RESEALABLE PRESSURE ERO-MAINTENANCE RELIEF VALVES TERMINALS Reserve Capacity Cold Cranking Amps 800 12 800 12 6 Capacity (C/20 rate) 120 min. 56 Amp Hours 120 min. 120 min 850 DIMENSIONS 56 Amp Hours 56 Amp Hours Length Height Width 915/16 Dual SAE & GM 39.5 Ibs. 7 13/16" 6 7/8" 915/16 7 13/16" 6 3/4" 9 29/32" 3 3/8" Type Post/Terminal Weight SAE Post 39.0 Ibs. 7 13/16 20.0 Ibs. BCI Group 34 34 SAE Post N/A Cranking Amperes vs. Temperature HEAVY-DUTY 1200 Amperage CAST-ON STRAPS 1000 CONSTRUCTION & RUGGED SPIRALCELL 800 CLOSE PLATE SPACING .. RESISTANCE & HIGHER SUPERIOR VIBRATION 600 POWER 400 200 GLASS SEPARATOR MICROPOROUS LEAD GRIDS HIGH-PURITY - 150F 0°F 20°F 32°F 40°F 60°F 80°F Temperature (OF) Charging Data Self Discharge Vehicle Charge: Voltage regulation - 13.8 to 14.4 Volts Voltage @ 74º Degrees F Normal Charging: : Voltage - 13.8 to 14.8 Volts Maximum Time - 6-8 hours Maximum Current - 10 Amps 13.0 12.8 Float Applications: Voltage - 13.2 to 13.8 Volts Maximum Time - Indefinite Maximum Current - 1 Amp 12.6 12.4 (at lower charge voltages) Boost Recharge: Voltage - 15.6 Volts (Regulated) 12.2 Maximum Current - 60 Amps Maximum Time - 1 hour 12.0 50 Duration (days) 100 150 200 NOTE: Charging systems should be voltage regulated. Warranty Information YOUR DEALER / DISTRIBUTOR (72 month) Consumer car/truck maining 48 months pro-rati No year replaceme (36 month) Commercial emaining 24 months pro-rate ne year replacemen 4 mont ar stereo/racir mainina 12 months pro-rat le year replaceme Abusive service Determined on individual basis OPTIMA Batteries, Inc. / 17500 E. 22nd Avenue / Aurora, CO 80011 / Fax (303) 340-7474 Phone (303) 340-7440 Gylling Group of Scandinavia -- Established 1912 <<>> Material Safety Data Sheet BATTERIES Number: OBI-0001 B Issue Date: 02/20/90 THE ULTIMATE POWER SOURCE™ Revision Date: 12/05/97 Section 1 - Material Identification Product Name: Sealed Lead Acid Battery Common Synonym: Automotive Battery UN Number: UN2800 (See Section 16 for additional information) Engine Starting Batteries Battery Model No. National Stock Number (NSN) 800U 6140-01-374-2243 800S 6140-01-378-8232 1000M 6140-01-441-4280 850/6 Not Available Deep Cycle Batteries Battery Model No. D750U National Stock Number (NSN) 6140-01-441-4272 D750S Not Available D900M Not Available Company Information Emergency Phone Number Optima Batteries, Incorporated Chemtrec 17500 E 22^d Avenue United States: 800-424-9300 Aurora, Colorado 80011 (303) 340-7400 International: 703-527-3887 Cage Code OUJ55 (collect) The OPTIMA sealed lead acid battery is considered an article as defined by 29 CFR 1910.1200( c) OSHA Hazard Communication. The information on this sheet is supplied at the customer's request for information only. Emergency Overview: Exposure not expected for product under normal conditions of use. In its manufactured and supplied state, the product is considered non-hazardous. Keep away from flames during and immediately after charge. No significant health effects are associated with the product. Section 2 - Composition Hazardous Components Material % by weight or volume CAS Number Lead Compounds 63 - 81 7439-92-1 Sulfuric Acid Electrolyte 17 - 25 7664-93-9 Case Matl Polypropylene 2-6 9003-07-0 Separator/Paster Paper Fibrous Glass 1-4 65997-17-3 Section 3 - Hazards Rating The Hazards rating for the Sealed Lead Acid Battery are: Hazards Rating (HMIS System) Health Flammability 0 Reactivity <<>> Section 4 - Hazards Identification Potential Health Effects None expected for finished product under normal conditions of use. Fire and Explosion The sealed lead acid battery is not considered flammable, but it will burn if involved in a fire. Short circuit can also result in fire. Evacuate area. Self-contained breathing apparatus must be worn to prevent possible inhalation of acid mists, smoke and decomposition products in a fire. Remove all ignition sources. Cool battery(s) to prevent rupture. Section 5 - First-Aid Inhalation - Not expected for product under normal conditions of use. However, if acid vapor is released due to overcharging or abuse of the battery, remove exposed person to fresh air. If breathing is difficult, oxygen may be administered. If breathing has stopped, artificial respiration should be started immediately. Seek medical attention. Eyes - Exposure not expected for product under normal conditions of use. However, if acid from broken battery case enters eyes, flush with water for at least 15 minutes. If irritation develops, seek prompt medical attention. Skin - Exposure not expected for product under normal conditions of use. However, if acid contacts skin, flush with water and mild soap. If irritation develops, seek medical attention. Ingestion - Not expected due to physical form of finished product. However, if any materials are ingested, seek prompt medical attention. Section 6 - Fire-fighting Measures Extinguishing media - Multipurpose dry chemical or multipurpose CO2. Fire fighting procedures - Evacuate area. Self-contained breathing apparatus must be worn to prevent possible inhalation of acid mists, smoke and decomposition products in a fire. Remove all ignition sources. Cool battery(s) to prevent rupture. Unusual fire and explosion hazards - Hydrogen gas may be produced and may explode if ignited. Remove all ignition sources. Ventilate area. Section 7 - Accidental Release Measures Spill or leak cleanup procedures: Avoid contact with acid materials. Use soda ash, baking soda or lime to neutralize acid if released Waste disposal: Dispose of in accordance with all local, state, and federal regulations. Handling - Do not carry battery by terminals. Do not drop battery, puncture or attempt to open battery case. Keep away from flames during and immediately after charge. Avoid prolonged Storage - Store at ambient room temperature. Do not subject product to open flame or fire. Avoid conditions which could cause arcing between battery terminals. Hygiene - Wash hands thoroughly before eating or smoking after handling batteries. Section 9 - Exposure Control Material Lead compounds Exposure Limits Sulfuric Acid Electrolyte 0.05 mg/m.3 1.00 mg/m3 OSHA 2 • <<>> - Section 10 -Personal Protection: Eye: Not necessary under normal conditions of use for finished product. Skin: Not necessary under normal conditions of use for finished product. Respiratory: Not necessary under normal conditions of use for finished product. Ventilation: Not necessary under normal conditions of use for finished product. Work Practices: Not necessary under normal conditions of use for finished product. Section 11 - Physical and Chemical Properties Boiling Point: N/A Appearance/Odor: Vapor Pressure: N/A N/A Specific Gravity (H2O=1): Vapor Density (air=1) N/A Melting Point: N/A Solubility in water: N/A Evaporation Rate: N/A N/A (Butyl Acetate = 1) Section 12 - Stability and Reactivity Stability: Stable Conditions to avoid: Avoid shorting, use only approved charging methods. Do not Hazardous reactions: puncture battery case N/A Decomposition Products: N/A Hazardous Polymerization: Will not occur Section 13 - Toxicological Information Threshold limit value: Not applicable for finished product. Route of entry: Not applicable for finished product under normal conditions of use. Signs of symptoms of acute exposure: None expected for finished product under normal conditions of use. Chromic Exposure: None expected for finished product under normal conditions of use. Medical Conditions aggravated by exposure: None expected for finished product under normal conditions of use. Effects of overexposure, conditions to avoid: No exposure expected for finished product. However, do not puncture or open battery case. Acid electrolyte may be released. Use only standard charging methods. If overcharged, battery may release gases (Hydrogen and oxygen). Carcinogen listing: NTS: no IARC: no OSHA regulated: NA for finished product under normal conditions of use. Section 14 - Disposal Considerations Send to a lead recycling facility which follows applicable Federal, State and Local regulations for routine disposition of spent or damaged batteries. The distributor / user is responsible to know that "spent" and/or "damaged" batteries (scrap batteries) are disposed of in an environmentally sound way in accordance with all applicable Federal, State, and Local Environmental Regulations. OPTIMA batteries are 100% recyclable by any licensed reclamation operation. Section 15 - Regulatory Information According to the OSHA Hazard Communication Standard, Sealed Lead Acid Battery in its manufactured and supplied state is considered non-hazardous. Transportation: Sealed Lead Acid Battery is not a DOT Hazardous Material. 3 <<>> Section 16 - Supplemental Information Under the Dangerous Goods Regulations, 34" Edition, Effective 1 January 1993, produced by International Air Transport Association (IATA): OPTIMA batteries are classified as non- regulated by special provisions A-48 and A-67 for UN Number of UN2800: Batteries, wet, non- spillable, electric storage: A-48: Packaging tests are not considered necessary. A-67: Non-spillable batteries are considered to be non-dangerous if, at a temperature of 55°C (130°F), the electrolyte will not flow from a ruptured or cracked case and there is no free liquid to flow and if, when packaged for transport, the terminals are protected from short circuit. The manufacturer of this finished article cannot foresee every possible use or misuse of the product. However, the following information is supplied: In its manufactured and supplied state, the product is considered non-hazardous. Excessive overcharging or abuse to the terminals can result in the release of gases (hydrogen and oxygen). As a general practice, batteries should not be used in enclosed, non-ventilated spaces. Avoid immersion in water as it may lead to hydrogen generation. If the battery is crushed in a collision or similar accident, the absorbent separator may be squeezed causing the release of a small amount of acid electrolyte. Neutralize the acid electrolyte with baking soda and flush with plenty of water. Under the Code of Federal Regulations #49, October 1, 1994 Edition, OPTIMA batteries are classified as an exception from all other requirements or conditions as stated in the following areas: Batteries, wet, 173.159 (d)(3)(i) and (d)(3)(i)(i). (d)(3)(i): vibration test (d) (3)(1)(i): pressure differential test These conditions have been tested and certified by the following: Energy Research Laboratory Information is on file at main company location. (ERL A/S), Batteritest Laboratory, Munkebjergvaenget 13, DK-5230, Odense M. Denmark. The information and recommendations contained herein have been compiled from sources believed to be reliable and to represent current knowledge on the subject. No warranty, guarantee, or representation contained herein and OPTIMA Batteries, Inc., its subsidiaries or affiliates assume no responsibility in connection therewith, nor can it be assumed that all acceptable safety measures are contained herein, or that other or additional measures may not be required under particular or exceptional conditions or circumstances. 4 <<>> _LULODUL the OPTIMA MANUAL <<>> the OPTIMA MANUAL OPTIMA BATTERIES THE ULTIMATE STARTER <<>> TABLE OF CONTENTS SECTION TOPIC PAGE Table of Contents........ ..i Introduction.. ... 1 2 The OPTIMA Manual....... 3 ...2 History of the OPTIMA Battery.. ....3 4 OPTIMA Concept and Design.. 5 4 Summary of Features and Benefits. 5 6 Understanding the OPTIMA Technology... .. 6 7 OPTIMA Versus Conventional Batteries.. 8 ....9 The OPTIMA: Features, Functions, Benefits 9 .. 13 The OPTIMA Battery: Applications and Advantages. ..23 Quick Reference Customer Benefit Chart ..28 10 Inappropriate Uses of OPTIMA S.L.I. Batteries. .... 11 ..29 Quality Control in Action - The Bitrode/Finishing Line ..30 12 Rating of S.L.I. Batteries (Starting, Lighting, Ignition)...... 13 .31 Basic Battery Technology and Terminology.. ..32 A. What is a Battery?.... ..32 B. Various Types of Batteries.. ..33 C. What Happens Inside a Lead-Acid Battery?... ..34 D. Types of Lead-Acid Batteries.. 36 14 Charging Procedures........ 37 A. Charging with an Alternator/Generator. 38 B. Charging with an External Charger.. ...38 C. Recommended Charging Limits for OPTIMA Batteries ......39 D. Problems Caused by Incorrect Charging Procedures. ...39 Appendix A: Glossary........... 41 <<>> THIS PAGE INTENTIONALLY LEFT BLANK August 14, 1996 <<>> 1. INTRODUCTION The OPTIMA battery represents a new standard for the automotive S.L.I (Starting, Lighting, Ignition) market. Its superior starting ability, high reserve capacity, long life, safety, and versatility make it outstanding for a wealth of uses. One customer recently praised it as "the most dependable, lowest maintenance battery on the market today." What makes the OPTIMA unique? Its SPIRALCELL, sealed design provides more power for faster, crisper starts at any temperature. It outperforms flat plate batteries by three to one. The OPTIMA delivers an amazing 800 cold cranking amps for the 12 volt 800S and 800U models. Completely sealed, the OPTIMA is maintenance-free; it is much safer than conventional batteries since it cannot spill or leak. Its tightly-wound spiral elements resist jarring and vibration, making the OPTIMA an ideal choice for almost any application or equipment. Introduced in 1984, the OPTIMA is the result of nearly 20 years of research and development. Originally developed by the Gates Rubber Company of Denver, Colorado, OPTIMA Batteries, Inc. is now owned by Gylling OPTIMA Batteries, A.B. of Stockholm, Sweden. All OPTIMA batteries are manufactured at the company's Colorado facility in Aurora. OPTIMA batteries are sold wholesale to distributors throughout the U.S. and abroad. in a wide range of applications including: While originally designed for the automotive S.L.I market, OPTIMA batteries are finding acceptance Commercial fleets - passenger cars, light trucks, vans, utility vehicles • Private automobiles, light trucks and vans • Diesel-powered vehicles - light and medium sized trucks • Agricultural, forestry and construction equipment - tractors, harvesters, dump trucks, water trucks, generators, fork lifts, skid loaders Marine starting applications - fishing boats, house boats, sail boats, ski boats • Collector and specialty vehicles - antique cars, show cars, custom cars, street rods, lowriders Motor sports and racing cars Car audio systems • Military Aerospace Ground Support Equipment (AGE), generators, and military vehicles This manual is a complete reference source regarding the OPTIMA's design, technical specifications, features, benefits, applications, warranty and more. Please contact us at 303-340-7440 (phone) or 303-340-7474 (fax) with any questions you many have about the OPTIMA battery. 1 August 14, 1996 <<>> 2. THE OPTIMA MANUAL in representing OPTIMA batteries. This manual is your source for reference, background information, and tools to enhance your success REFERENCE: Use this manual as a reference tool. You'll find the answers to most questions in "The OPTIMA Manual. " We've included summaries of features, functions, and benefits; specifications; applications; basic battery technology; warranty procedures; a glossary; and more. BACKGROUND INFORMATION: Learn about the OPTIMA battery, its advantages, and how it compares to conventional battery for so many applications. We've included a time line describing the battery's development. This technology. We start by explaining the new OPTIMA technology, describing why it is superior manual also covers basic battery technology, terminology, and testing procedures. TOOLS: Understand the OPTIMA technology and how to apply it to applications. Testimonial letters that describe how the OPTIMA battery is saving customers time and money are available. 2 J August 14, 1996 <<>> 3. HISTORY OF THE OPTIMA BATTERY 1973 Gates Rubber Company, one of the world's largest producers of rubber products for the automotive industry, develops the initial battery technology incorporating a SPIRALCELL with recombinant technology. The company produces millions of battery cells for tools, appliances, and emergency lighting. i 1983 Gates recognizes the need for an advanced automotive battery. The company begins research and development to further explore the battery technology. 1984 The S.L.I. (Starting, Lighting, Ignition) battery project team is established at Denver, Colorado. 1987 Limited S.L.I. production begins; the first automotive batteries go to market. 1990 Gates incorporates the division as OPTIMA Batteries, Inc. Gylling Teledata A/S of Norway begins limited importation and distribution of OPTIMA batteries. Soon after, Gylling obtains distribution rights for all of Scandinavia. 1991 Gates divests itself of OPTIMA Batteries, Inc. 1992 The Gylling Group of Scandinavia purchases OPTIMA Batteries, Inc. from Gates. 1993 Public demand for the OPTIMA battery begins to rapidly increase. 1994 OPTIMA Batteries, Inc. breaks ground for a new, larger, modern manufacturing facility in Aurora, Colorado. 1995 OPTIMA Batteries Inc. moves into its new headquarters in Aurora, Colorado. Sub-contract with General Motors is signed to develop a monoblock battery for their hybrid vehicles. 1996 Full production begins at new facility and sales efforts expand throughout the North and South America as well as world-wide. August 14, 1996 <<>> OPTIMA CONCEPT AND DESIGN Lighting, & Ignition) battery. Several parameters were of critical importance during the design of the OPTIMA S.L.I. (Starting, What requirements were crucial for the design of the OPTIMA battery? Capability High power for quick, sure engine starts. (Performance) • Ample electrical reserve capacity. V Safe to operate. v Compact in size and weight compared to traditional Construction S.L.I. batteries with similar output. r Compatible with most vehicles. v Operates in any position or orientation, even upside down. No spillage even if the case is cracked. r Recyclable. v Truly zero maintenance. Maintenance V Low self discharge rate for a long shelf life. r Long operational life. v Rapid charge (recharge) rate. Resilience Dependable even in extreme hot and cold temperatures. • Resistant to vibration, impact, and jarring. The OPTIMA battery, with significantly fewer parts, appears to be simple in design when compared to traditional battery construction. Still, it is a very complicated battery to mass produce. Not only is the design unique, but most of the manufacturing equipment had to be specially designed and built to produce the OPTIMA. 4 August 14, 1996 <<>> 5. SUMMARY OF FEATURES AND BENEFITS • SUPERIOR STARTING CAPACITY. The OPTIMA delivers 800 Cold Cranking Amps (C.C.A.) for the 800S and 800U models and 850 C.C.A. for the 6 volt battery (CCA is measured @ 0ºF or -18°C). The 1000M marine starting battery is rated at 1000 Cranking Amps (CA is measured @ 32°F OI 0°C). CANNOT CRACK DUE TO FREEZING. OPTIMA's unique separator material allows for expansion in the event of freezing. ZERO MAINTENANCE. Completely sealed. There is no venting to corrode the terminals, connectors, battery tray, or surrounding equipment. Customers never need to add water. EASY TO TRANSPORT. Because the OPTIMA battery is considered non-hazardous/now-dangerous, it can be shipped by air. FASTER RECHARGE. Recharge in less time due to low internal resistance and tight plate spacing. FITS MOST VEHICLES AND EQUIPMENT. HANDLES ABUSIVE TEMPERATURES. Operates effectively in extreme hot or cold temperatures. HIGH RESERVE CAPACITY. OPTIMA has a reserve capacity of 120 minutes. LONGER SHELF LIFE. After one year it will start most engines. Total shelf life is 2 years or more. MUCH SAFER. location and is less likely to explode. Absorbed electrolyte, no free acid to spill or leak. The OPTIMA can be installed in any OUTLASTS CONVENTIONAL BATTERIES. OPTIMA. The high purity lead grids minimize plate corrosion and plate deformation in the RESISTANT TO VIBRATION. Tightly-wound SPIRALCELL ™ resists jarring, vibration, and shedding of the active paste material. •. VERSATILITY OF INSTALLATION. OPTIMA can be installed in any orientation, even upside down. 5 August 14, 1996 <<>> 6. UNDERSTANDING THE OPTIMA TECHNOLOGY, conventional battery. To better understand the OPTIMA battery, let's compare it to the design and construction of a i in approximately 100 years. Traditional batteries are constructed with about 120 different parts and have undergone little change TERMINAL TAPERED POSTS VENT PLUGS THROUGH THE CONNECTORS PARTITION COVER -POST STRAP -PLATE LUGS POSITIVE PLATE ENVELOPE SEPARATORS : CONTAINER ELEMENT RESTS SEDIMENT SPACE Figure 1 CONVENTIONAL FLAT PLATE BATTERY 6 J August 14, 1996 <<>> The OPTIMA battery requires only 30 components; this means there is less opportunity for failure. Four letion origin. The scle pete are separated b injection-molded case. The cells are electrically connected with thick cast lead intercell straps. The design greatly reduces the potential for mechanical failure. electrolyte is injected and totally absorbed within the separator material between the plates. This unique pressure valve Resealable Corrosion-free/Zero maintenance terminals Minimal free space Heavy cast-on straps Individual cell chambers Sealed plastic case Starved electrolyte design Microporous glass separator Thin, high-purity grids Figure 2 OPTIMA SPIRALCELL BATTERY DESIGN 7 August 14, 1996 <<>> THIS PAGE INTENTIONALLY LEFT BLANK : August 14, 1996 : <<>> OPTIMA VERSUS CONVENTIONAL BATTERIES 21Z PLATE/ GRID CONSTRUCTION S OPTIMA Conventional battery design High purity lead plates are used to make the grid for cells of the OPTIMA battery. Two long In conventional batteries, each cell contains a series continuous bands of grid are wound into a tight of short flat grids. Materials such as antimony and spiral configuration then pressure inserted into calcium are added to the grids to improve strength individual cylinders within the case. This design and stiffness needed for manufacturing. These alloys provides the cell's mechanical strength, eliminating can increase plate corrosion, self discharge, internal the need for alloys in the lead. resistance, and promote shedding of the active material (lead paste applied to grid). Using unalloyed lead extends the life of the OPTIMA grid will resist corrosion and last longer OPTIMA battery by reducing grid corrosion. The As a result, the battery loses capacity and power. With age, the grids shed their active paste material. in high temperature environments. engines are harder to start and in cold temperatures. This power loss becomes especially noticeable when While conventional batteries are adversely affected by heat, the effects of heat on a high purity lead Using alloys in the grid sacrifices performance for OPTIMA battery are minimal. and paste adherence but lowers electrical strength. For example, antimony improves castability internal resistance. This low resistance allows the The use of high purity lead contributes to the low conductivity and increases the rate of self discharge and gassing. to meet the demands of vehicle electrical systems OPTIMA to deliver high amounts of power quickly When a conventional battery is stored for long and on-board electronic components. periods without recharging, the alloys in the grid corrode. This shortens the battery's life considerably. Another advantage of using the high purity lead is a low self-discharge rate. The alloys in conventional material and the grid, causing a loss of electrical batteries accelerate the reaction between the active charge. (See Figure 2) (See Figure 1) August 14, 1996 <<>> CELL DESIGN OPTIMA Conventional battery design Individual cells of the OPTIMA contain only two purity lead plates are wound into a tight spiral, and plates, one positive and one negative. These thin high The cell of a conventional battery contains several plates connected together and suspended in a pool of separator is very thin, allowing for closer plate are separated by an absorbent glass material. The electrolyte. Alloys are added to the lead grid to increase its strength and stiffness. Stiffness and the flow of current and lowers the internal resistance. spacing. The close proximity of the plates enhances strength are required for the plates to retain the active material during operation and to make the plates The porous separator material retains the electrolyte easier to work with during manufacturing. like a sponge, preventing the active material on the plates from drying out. intribute to corrosion, higher internal resistance at hile the alloys add strength to the grid, they al The tightly wound spiral allows the use of a very thin shedding of active grid material. more winds in the spiral. This increases the amount of Using thinner plates allows surface area in the cell, thus boosting the amount of Sufficient space between the plates in the cell is power generated from the battery. The plate surface electrical shorts. This material falls from the plates required for shedding of the active material to prevent similar size conventional battery and utilizes almost area of an OPTIMA cell is much larger than that of a and accumulates at the bottom of the case. the full height of the container. The extra space results in a larger battery with higher After the cell is wound, it is pressure-inserted into an internal resistance and lower energy density (energy individual cylinder chamber with a tight interference per pound) than the OPTIMA. fit. This design increases the strength of the cell and prevents the active paste from falling off or shedding. material throughout the life of the battery. When a The flat, suspended grids cannot retain the active lead The tightly wound cell resists vibration. There is no conventional battery is used in harsh conditions such free space between the plates. This prevents as high temperatures or high vibration, shedding of movement of the plates which causes plate to plate the active material increases. This causes a loss in shorting and shedding of the active material. battery power and capacity which leads to battery failure. Typically, the battery fails due to loss of active material or plate to plate shorting. 10 August 14, 1996 i <<>> ELECTROLYTE: OPTIMA • Conventional battery design The OPTIMA battery is an absorbed electrolyte, gas recombinant battery. All the electrolyte is A conventional battery is a flooded system. Flooded material between the plates in the SPIRALCELL. absorbed (like a sponge) within the separator the level of the plates. This excess electrolyte is required means that there is excess electrolyte in the battery above to prevent the plates from drying out, which causes The electrolyte consumes approximately 95% of sulfation of the active material. This leads to a failure of the voids in the separator material. The remaining the sulfated part of the plate, which reduces the capacity 5% is left as open space for gas passages. of the battery. positive plate combines with the hydrogen at the During the charging procedure, oxygen from the Gases in a conventional battery collect in the free space above the plates; which are then vented from the battery. negative plate to form water which recombines When a battery is overcharged, gassing increases. The can be totally sealed. Since the electrolyte is with the electrolyte. Thus, the OPTIMA battery gases being vented (hydrogen and oxygen) are very combustible. If ignited, they could cause a battery if the case is ruptured or broken. contained within the separator, it cannot leak, even explosion A portion of the vented gas corrodes the battery cables Since the electrolyte cannot escape via leakage, and connectors. This corrosion is often noticeable by the evaporation or venting, the plates will not dry out appearance of a white powder or blue/green fuzz on the and cause loss of capacity. terminals. Because the OPTIMA never needs water and does The conventional battery case must contain vents for vehicle. not vent, it can be mounted anywhere in the gases to escape. If the battery is tipped over or tilted, acid will leak from the vents. If the case is cracked or ruptured, the acid will spill. Loss of the acid will cause should not be installed in an air-tight space. Some Good engineering practices dictate that any battery the conventional battery to fail. The escaped acid can also cause harm to people, equipment, and the charging system fails, causing an abusive ventilation is necessary in case the vehicle's environment. overcharge. Overcharge could cause the OPTIMA's internal safety valves to release some of the pressure within the battery case. If this happens, some of the internal gases would escape. The sealed, no-venting design eliminates corrosion of battery cables, connectors, and vehicle components. August 14, 1996 <<>> i Figure 3 THE OPTIMA SPIRALCELL 12 August 14, 1996 <<>> 8. THE OPTIMA: FEATURES, FUNCTIONS, AND BENEFITS OPTIMA BATTERIES FEATURE FUNCTION BENEFIT 132* Greater plate surface area • Increases starting power. * 800 C.C.A. (cold cranking amps). • Recharges more quickly. SPIRAL Strigger mechanical V Withstands vibration thereby increasing life. • Eliminates shedding of active material. : + Reduces internal shorting. CELL High purity lead grid • Reduces corrosion for longer life. / Lower self discharge. • Lower internal resistance increases DESIGN conductivity for more starting power and. quicker recharging. Thinner plates / grid V Higher C.C.A. means more starting power. V Faster recharging. Closer, consistent plate spacing r More effective chemical reaction increases starting power. / Faster recharging. Reduced battery size V Higher power-to-weight ratio • Produces power equivalent to conventional batteries several times its size. V Fits more vehicles. August 14, 1996 <<>> Charger: Alternátor Power Current Supply HO Absorbed Separator PbO Electrolyte • Pb H2O 02 H2o Figure 4 ABSORBED ELECTROLYTE Figure 4 shows the absorbent separator material wound between the positive and negative plates of the OPTIMA SPIRALCELL. 14 August 14, 1996 - <<>> • • OPTIMA BATTERIES FEATURE FUNCTION BENEFIT Precise quantity of • Fills approximately 95% of the voids in : electrolyte in each cell (computer controlled filling process) sealed battery v Proper distribution of acid for efficient operation and longer life. ABSORBED Absorbent separator ELECTROLYTE material V Allows hydrogen and oxygen gases to recombine into water, making the battery completely maintenance free. & Tightly wound separator material prevents internal shorting between the battery failure. plates, eliminating a common cause of • Voids in the separator material provide expansion capacity in case the battery from cracking. freezes. This helps to prevent the case • No spilling/leaking. Absorbent separator ruptured. retains electrolyte even if case is V Allows use of taller plates to better utilize case height. This results in more plate surface areas and higher power. August 14, 1996 <<>> Figure 5 : The completely sealed OPTIMA recombinant battery prevents electrolyte from escaping. It can be mounted in any orientation, even upside down. 16 August 14, 1996 <<>> OPTIMA BATTERIES FEATURE FUNCTION BENEFIT • Allows battery to be mounted in any flexible installation options. position, even upside down, for more • Safer for people, equipment and the environment. It will not leak even if the case is broken. • Eliminates corrosion of battery terminals, Totally contained system cables and surrounding equipment. Completely eliminates battery maintenance. r Sealed, contained system can be transported COMPLETELY conveniently by air, U.P.S. or other SEALED methods as the OPTIMA is non-regulated. • The OPTIMA requires no special storage and handling procedures. • Since the OPTIMA never needs water, it is completely maintenance free. Recombinant technology • Does not lose water which would cause cells to dry out, leading to failure. August 14, 1996 <<>> Thick Cast On Straps Figure 6 The OPTIMA's thick cast on straps. 18 August 14, 1996 <<>> OPTIMA BATTERIES FEATURE FUNCTION BENEFIT / Lower internal resistance. Delivers energy more efficiently, improving THICK power for engine starting and CAST ON Stronger intercell accessories. STRAPS connections " No "through the partition" connections, another potential point of corrosion or failure from vibration. • Larger connection area between cell flow. and straps for more efficient current 19 August 14, 1996 <<>> Resealable pressure valve maintenance terminals Corrosion-free/Zero Minimal free space Heavy cast-on straps Individual cell chambers Sealed plastic case Starved electrolyte design i glass separator Microporous Thin, high-purity grids Figure 7 OPTIMA's unique case construction. 20 August 14, 1996 <<>> OPTIMA BATTERIES FEATURE FUNCTION. BENEFIT • Minimal free space for gas build-up Minimal free space eliminates the chance of explosion. within the cells • Efficient use of case volume for plate surface area. UNIQUE CASE • The spiral cells in individual DESIGN Individual cylinders wear and abuse. This eliminates compartments are stronger, resisting shedding of active material and increases battery life. • Greater outside surface area provides better dissipation of heat, increasing battery life. 21 August 14, 1996 <<>> THIS PAGE INTENTIONALLY LEFT BLANK 22 August 14, 1996 <<>> 9. THE OPTIMA BATTERY: APPLICATIONS AND ADVANTAGES The OPTIMA 12V group 34 and 6 volt batteries were designed as automotive S.L.I. batteries. Understanding the OPTIMA battery's strengths and limitations is important in order to properly determine the right application for each individual customer. life will vary depending on the application. OPTIMA has an estimated life three to four times longer than that of conventional batteries but the actual APPLICATION VEHICLE TYPE THE OPTIMA ADVANTAGE • In the S.A.E. (Society of Automotive Engineers) J240 life cycle tests, the OPTIMA battery outperformed average flat plate conventional batteries more than 3 to 1 (12,000 start cycles for the OPTIMA compared to 4,000 for the average conventional battery). This makes the OPTIMA ideal for commercial vehicles and fleets (taxis, ambulances, police cars, military, etc.). • Numerous engine starts and punishing operating conditions result in more frequent replacement of conventional batteries. Although an Passenger cars, OPTIMA costs more initially, it is the most economical battery based on actual cost of ownership. An OPTIMA has been known to Light trucks, continue to operate even after being shot. Commercial Vans, The OPTIMA will recharge more quickly from the heavy loads fleets created by additional accessories such as sirens, communication Utility vehicles radios, emergency lights, etc. (Vehicles 2 tons * The OPTIMA starts engines better in cold temperatures and has a longer life in hot climates. and less) • Because the OPTIMA does not leak or vent, it eliminates routine battery cables, connectors and trays. This adds cost savings. battery-related maintenance such as replacing and/or cleaning • Since OPTIMA does not shed paste it doesn't lose power and capacity as it ages. In conventional batteries this puts more wear on alternators and starters. • OPTIMA provides a consistent "flat" voltage to the starter when discharging, resulting in better starts and less wear. <<>> APPLICATION VEHICLE THE OPTIMA ADVANTAGE TYPE • OPTIMA lasts 3 to 4 times longer than a high quality conventional battery. Private Passenger cars, automobiles • The OPTIMA does not corrode and is completely maintenance Light trucks, free. A true "install it and forget it" battery. Vans • The OPTIMA is ideal for extreme climates. It provides quick, sure starts in very cold weather. Also important is OPTIMA's long life in very hot climates. * The OPTIMA has more starting power than any battery its size. Hard cranking diesel engines will start more readily, especially in cold weather climates. Diesel engine Light trucks, * The OPTIMA does not corrode terminals and trays and is vehicles (commercial and Medium trucks, completely maintenance free. private) Passenger cars Note: Although one OPTIMA battery will usually start most large diesel starting system and electrical accessories such as winches, emergency lights, engines, the correct number of OPTIMAs must be configured to match the etc. Operating conditions, such as extremely cold weather, are also an Tractors, • The OPTIMA delivers enough starting power to crank rugged equipment, even in extremely hot and cold temperatures. Harvesters, • In machinery that must perform over rough, uneven terrain, the Dump trucks, OPTIMA's resistance to vibration provides a longer lifetime. The Agricultural, SPIRALCELL prevents shedding of the active material and forestry and Water trucks, weakening of the plate structure. construction equipment Generators, • The leak-free design reduces corrosion and equipment maintenance. Fork lifts • The OPTIMA can remain safely in machines left dormant from season to season. Due to the low rate of self discharge, operators of (gas/diesel), seasonal equipment find they can usually restart engines after many months of inactivity. Skid loaders, • Because of OPTIMA's many features and benefits, the 850/6 (six etc. volt) is widely accepted in the agriculture market. Its unique size and shape allow it be installed in a large variety of equipment. * Reduces down time and service calls. 24 <<>> - APPLICATION VEHICLE TYPE: THE OPTIMA ADVANTAGE • The OPTIMA is ideal for boats since their engines are often difficult to start. * The OPTIMA recharges much faster than conventional batteries. • The OPTIMA's resistance to vibration eliminates plate shorts Ski boats, which can kill a battery in inconvenient places. • The low rate of self-discharge is a plus because boats sit idle during Marine Craft Fishing boats, the winter. The OPTIMA has the power to start a boat engine that has been sitting for an extended period. House boats, • The OPTIMA can be mounted in a confined space in any position. Sail boats Since it is completely maintenance free, there is no need for periodic access. (All batteries should have adequate ventilation.) These vehicles often sport expensive specialty equipment such as Antique cars, gold plated battery connectors and chrome plated installation. hardware. Since the OPTIMA is completely sealed, it eliminates the corrosion damage associated with conventional batteries. Show cars, Collector and * The low self-discharge rate provides the starting power when Specialty Vehicles Street rods, vehicles have been garaged for months at a time. Custom cars, * The OPTIMA delivers 800 C.C.A. and a high "flat" voltage to turn Lowriders over large, high performance engines. • Many specialty cars require that the battery, or multiple batteries, be installed on their sides or in out of the way places, such as the trunk. Since the OPTIMA is completely sealed, it can be installed anywhere, in any position. • Best 6 volt available for antique cars, there is no need to do an 8 volt upgrade. 25 <<>> APPLICATION VEHICLE TYPE THE OPTIMA ADVANTAGE • The OPTIMA provides the cranking power for large, high compression engines. • The OPTIMA's resistance to vibration reduces battery failure. This is especially important for off-road vehicles that operate in isolated areas. Racing cars, Motor sports * The OPTIMA recharges quickly, a plus for vehicles with hard and racing Off road trucks, starting engines and accessories such as winches and fog lights. • The low self discharge provides starting power for vehicles that are Dune buggies only used periodically. • The OPTIMA will not explode or leak, even in a collision. This makes it safer for both the driver and the pit crew. • SPIRALCELL design prevents "plate collapse" during rapi cceleration such as with drag racing * The OPTIMA's high C.C.A. (Cold Cranking Amps) and low internal resistance quickly delivers the power required by large amplifiers. This helps generate clearer bass and purer sound. • Due to its sealed, leak-proof design, the OPTIMA can be installed Car audio Cars and trucks in any location and in any position, even upside down. systems with high power car audio * The OPTIMA's corrosion-free, sealed container prevents costly systems damage to gold plated battery terminals and other specialty hardware. Note: We do not recommend the OPTIMA S.L.I. battery if the customer the car engine off). However, most high end car stereo owners use their typically operates in a deep-cycle manner (long periods of stereo operation with source. equipment only when the engine is running or they have an external power 26 <<>> APPLICATION AVEHICLE(. TYPE THE OPTIMA ADVANTAGE * Thanks to its high cranking ability, the OPTIMA can power many fewer varieties of batteries. types of special purpose equipment. Therefore, agencies can stock The sealed, maintenance-free design makes the OPTIMA easier to transport and store. The International Air Transportation Association designates the OPTIMA as a non-regulated battery. This means agencies can use standard procedures for transporting and storing OPTIMA batteries. * The OPTIMA outperforms conventional batteries in extremely hot and cold climates. * The OPTIMA's quick recharging capability is ideal for demanding applications such as emergency vehicles, tactical vehicles, ground support equipment, etc. A.G.E (Aerospace Ground support • A low self-discharge rate makes the OPTIMA ideal for powering Military and Equipinent), generators that sit unused for long periods. Commercial Equipment Electrical • The OPTIMA's corrosion-free design reduces maintenance costs. generators, It eliminates replacement or cleaning of battery terminals, cables, and battery trays. General purpose • OPTIMA's longer life reduces battery consumption. Therefore, cars and light fewer batteries need to be purchased and ultimately discarded or trucks recycled. * The OPTIMA has proven successful in the following military applications: → Aircraft Ground Support Equipment (AGE) → Command and Control Equipment → Communications vehicles → Generators and compressors → Tactical and Non-tactical Vehicles (pickup trucks, hummers, weapons carriers, passenger cars In 1993 after competitive tests, the U.S. Air Force selected the OPTIMA as the battery of choice for aerospace ground support equipment! 27 <<>> OPTIMA Application Benefit Reference Sheet *= Customer "hot buttons" * = Other features to discuss Application Vardee 800 C.G.A. Vibration resistance Low internal resistance 120 minute reserve capacity 3 - 5 times longer life Fast recharge Corrosion & maintenance free Safe, no spills or leaks. shellite Page # for info. Fleet Trucks/ vans Less than 2 tons * * 25 vehicles Sedans * Automobiles Personal x X 26 Pickup trucks and 4 X4's * * X 26 Forestry Mining R Dump trucks * * * * X 26 Building Farming Large hauling trucks * * * 26 Tractors * * 26 * Boats and Motor boats * X 21 Marine Sail boats House boats x X 21 Customa Antique cars and Show Cars x X * 27 Specialty Cars Street Rods, Custom Cars, Lowrider * * * X 27 Car audio Large car stereo systems x * X 28 * Racing vehicles Reading on or * * * 28 * Off road rucks, Jeeps, car: &4 X4 port utility vehicle * * X X 28 AGE Aerospace ground Military support equipment * x 29 * * * general purpose vehicles Trucks, vans & * X X 29 28 <<>> - 10. INAPPROPRIATE USES OF OPTIMA S.L.I. BATTERIES The OPTIMA S.L.I. battery is not recommended for the following applications: CYCLE SERVICE APPLICATIONS (DEEP CYCLE) OPTIMA S.L.I batteries are not suitable for electric power applications that must withstand repeated deep discharges such as in wheelchairs, golf carts or forklifts. (You must use OPTIMA's deep cycle battery for this type of application.) Cycle service (traction) batteries require thick plates because they must deliver lower amperage for a long period of time. S.L.I. batteries have thin plates that cover a greater surface area, making them able to deliver high amperage for short periods. For example: S.L.I. An S.L.I. battery must deliver 250 to 350 amps for a few seconds to start a vehicle. It is typically used to power vehicle accessories such as lights and windshield wipers for a few minutes while driving slowly or during short trips. This load is usually about 10 to 25 amperes. The average depth of discharge for an S.L.I. battery is approximately 2% to 3% of its capacity. Deep cycle In a deep cycle application such as a trolling motor, the battery may need to deliver 15 amps for a couple of hours. The average depth of discharge is typically 60% to 70% or more of the battery capacity. When an S.L.I. battery is used in deep cycle applications, its life will be greatly reduced. Deep cycling an S.L.I. battery will hasten decomposition of the active material on its plates While the OPTIMA is not designed for these deep discharges, it will outperform conventional S.L.I. batteries under deep discharge conditions. For RV applications, battery requirements depend on individual conditions. The OPTIMA S.L.I. performs well during moderate use requiring frequent, shallow discharges. This is sometimes referred to as "wet-camping"; an R.V. owner parks at a facility where the vehicle can be plugged into an electrical power source. Most of the accessories are then powered by the external source. Applications requiring repeated deep discharges are best handled by batteries designed for this use, such as the OPTIMA Deep Cycle battery. Regardless of the application, the total capacity of the replacement batterys) should meet or exceed the average load requirements. 29 August 14, 1996 <<>> 11. QUALITY CONTROL IN ACTION - THE FINISHING LINE OPTIMIA Batteries, Inc. prides itself on the quality of its batteries. Every unit leaving the production facility has undergone many strenuous tests to ensure that it is the highest quality battery that can be produced. Every battery manufactured at OPTIMA is subjected to a computer monitored, fully automated, five-stage quality test. This assures that our customers receive the highest quality, battery on the market. No other S.L.I. battery manufactured in the United States has such high quality standards. As each battery moves through the line, it is tracked by a computerized bar code system that records and stores the date, lot number, work shift and battery number. This information is then combined with the test results as described below. the Test Lab for analysis. Any battery that fails to meet specifications in the following system is "kicked out" and sent to OPTIMA QUALITY TESTING PROCEDURES: 1. O.C.V. (Open Current Voltage). This test measures the existing voltage in the battery and detects those which do not receive a proper formation (formation is the initial charge applied to a battery during the manufacturing process). 2. LOAD TEST. A 1200-1400 ampere load test is applied to each battery to check strap (intercell connector) integrity. This detects weaknesses in the strap such as cracks, shorts and/or poor strap to cell bonding. 3. VOLTAGE UNDER LOAD. During the load test, the voltage is measured and recorded. Voltage • expectancy. analysis testing and statistical modeling has enabled OPTIMA to accurately predict battery life 4. INTERNAL RESISTANCE. Low resistance translates to greater cranking power for engine starting and quicker charging. Resistance readings also detect various manufacturing defects. 5. WEIGHT. During the last stage, each battery is automatically weighed to verify the correct acid to lead relationship. Quality control is evident throughout the entire OPTIMA manufacturing process. In addition to the five step quality process described above, every stage of production is monitored for quality of material and accuracy. Also, due to the sealed design of the OPTIMA, every battery made is checked for case integrity. After the top cover is sealed, each battery is pressurized with air and submerged in water. If the battery were to have any leaks they become immediately evident. 30 August 14, 1996 <<>> 12. RATING OF S.L.I. BATTERIES batteries. Reserve Capacity and Cold Cranking Amps are the industry standard measurements for S.L.I. Reserve Capacity (R.C.) - Time in Minutes: This test measures, in minutes, how long a battery can maintain a minimum of 10.5 volts (at 80°F) while being discharged at 25 amps. The R.C. rating is especially important for emergency situations such as in the case of alternator failure. Cold Cranking Amperes (C.C.A.) - Power: The primary function of an S.L.I. battery is to start the engine. Since starting is increasingly difficult as the temperature drops, the best measurement is the amount of power a battery can deliver in cold temperatures. This unit of measurement is called C.C.A. (Cold Cranking Amps). C.C.A. is measured in accordance with the S.A.E. (Society of Automotive Engineers) standards. It (1.2 volts per cell). measures how much current can be delivered for 30 seconds at 0°F (-18°C) while staying above 7.2 volts Cranking Amperes (C.A.): C.A., sometimes referred to as Marine Cranking Amps (MCA), measures how much current can be delivered for 30 seconds at 32°F (0°C) while staying above 7.2 volts. Formerly, the measure of a battery's electrical storage was Ampere-hour (amp-hr). It was determined by multiplying the current in amps by the time of discharge. Example: A battery that delivers been replaced by C.C.A. and Reserve Capacity (R.C.). 5 amperes for 20 hours (5 amperes times 20 hours), has a 100 amp-hr capacity. The amp-hr rating has The following table compares the OPTIMA's Reserve Capacity and Cold Cranking Amperes to traditional B.C.I. (Battery Council International) Group 34 batteries. However, the unique characteristics of the OPTIMA allow it to be used in applications beyond those requiring a B.C.I. Group 34. BATTERY TYPE E C.C.A7 (Cold Cranking Amperes): RESERVE CAPACITY OPTIMA 800 C.C.A. 120 minutes (1000 MCA) B.C.I. manual) Standard Group 34 (from 375 - 650 C.C.A. 100 - 110 minutes : OPTIMA versus the conventional Group 34 battery August 14, 1996 <<>> 13. BASIC BATTERY TECHNOLOGY AND TERMINOLOGY battery are quite complicated. On the surface, battery technology appears simple. However, the electrochemical reactions within a A. WHAT IS A BATTERY? A battery is an energy storage device that converts chemical energy into electrical energy. The electrochemical reactions involve the transfer of electrons from one material to another through an external electrical circuit and the motion of ions in an internal medium (the electrolyte). While the term "battery" is often used, the basic electrochemical unit is the "cell." A battery contains one or more cells, connected in a series, parallel, or both, depending on the desired output voltage and/or capacity. A cell consists of three major components: • Electrodes: more commonly called plates. Each cell requires at least one positive and one negative electrode. Cells may contain multiple electrodes. • Electrolyte: typically a liquid that provides the medium for the transfer of charge, as ions, between electrodes inside the cell. • Separator: a divider between the positive and negative plates which allows the current to flow through it. The separator prevents the positive and negative plates from contacting each other and causing an electrical short. Separators are typically made of glass material, plastic, or a void (space between plates). When the battery is discharged, the negative plate reacts, transferring electrons to the external circuit (head lights, starter motor, etc.). To complete the circuit, the positive plate reacts, accepting electrons from the external circuit. When the battery is being recharged, a similar process occurs in reverse order. battery has the genera Case hydro be vended to en eve inates prescel This ne ors during the replaced regularly. If the gasses are not vented, they must be recombined as water inside the cell (as with sealed batteries such as the OPTIMA). 32 August 14, 1996 <<>> B. VARIOUS TYPES OF BATTERIES Different materials can store energy and the names of batteries often identify their active materials such as Nickel-Cadmium, Nickel-Iron, and Lithium-Ion. Other batteries are named for the type of material found in the plates and the type of electrolyte system used; the most common is the lead-acid battery. Batteries are classified in two ways. They are either rechargeable (also called secondary) which can be recharged repeatedly, or non-rechargeable (also called primary) which consist of single cells usually configured as flat buttons or cylinders for one time use. Various types of electrolytes are used in batteries. The lead-acid based battery uses sulfuric acid electrolyte (HI,SO,), while alkaline-based batteries, such as nickel-cadmium, use potassium hydroxide (KOH). the plates. Most large lead-acid batteries are "flooded cell" batteries with large reservoirs of electrolyte covering Some lead-acid batteries are named for their electrolyte systems such as "gel cells" and "absorbed electrolyte". Gel cells use electrolyte in a gel form instead of a free flowing liquid electrolyte. Absorbed electrolyte batteries (such as the OPTIMA) have the electrolyte retained by the absorbent separator material between the plates, preventing the electrolyte from flowing freely. The trade-offs in performance, weight, volume, cycle life and cost dictate the need for many battery types. No one battery system can meet all the needs of all users. Lead-acid Batteries Lead-acid batteries were first manufactured in the mid 1800s when scientists found that lead immersed in a sulfuric acid solution produced an electric voltage and could be recharged. Lead-acid batteries are unique because they typically use inexpensive lead for both the negative and positive plates. Despite extensive research into alternative technologies, lead-acid batteries are still the most prevalent today. Their popularity and widespread use are largely due to the following benefits: Wide temperature range for cycling and non-cycling operations Low cost materials Ready recycling of lead and other components Reliability • Proven manufacturing process High power density 33 August 14, 1996 <<>> In a lead-acid battery, the active material reacts with the electrolyte to produce the chemical reaction that creates electrical energy. The active material in the positive plate is lead dioxide (PbO,) and the negative is pure spongy lead (Pb). The electrolyte is sulfuric acid (H_SO,). When we talk about the active material in lead-acid batteries, we mean the lead dioxide and spongy lead. Lead dioxide and spongy lead are made into paste and applied to lead grids. This grid is not active material but acts as the electrical conductor or path to cell terminals. In most designs, the grid provides mechanical strength to support the active material in the cell. C. WHAT HAPPENS INSIDE A LEAD-ACID BATTERY? In most cell designs, the plates are immersed in a free liquid acid. In sealed cells, the acid is absorbed additive (gel-cell technology). completely in the plates and separator structure (absorbed acid technology) or converted to a gel by an All lead-acid batteries have the same general overall chemical reaction for charge and discharge. → → → Discharge cycle Charge cycle On discharge, the lead dioxide (PbOz) of the positive electrode and the spongy lead (Pb) of the negative electrode are both converted to lead sulfate (PbSO.). On charge, the lead sulfate in the positive electrode is converted to lead dioxide (POz), which then converts to oxygen on overcharge. The lead sulfate sponge lead in the negative electrode is converted to spongy lead, which then converts to hydrogen on overcharge. The electrolyte, sulfuric acid (H,SOA), is an active component in the reactions at both plates. If a flooded type battery is overcharged, oxygen gas is generated at the positive electrode. Gas bubbles rise to the surface and escape from the cell. At the same time, hydrogen gas is generated at the negative electrode and also escapes from the cell. The overall result is water loss which must be replaced periodically. In the OPTIMA battery, during charge, oxygen combines with the freshly formed lead at the negative electrode in the presence of H,SO4, to form lead sulfate and water. This oxygen recombination prevents hydrogeri from forming at the negative electrode. Therefore, there is no water loss during charging. 34 August 14, 1996 <<>> Electrolyte: The electrolyte in the lead-acid cell is a solution of sulfuric acid (H,SO,) and water. It plays an active role in the chemical reactions that convert energy within the cell. Changing the density (specific gravity) of the acid solution affects performance factors such as capacity, maintenance, and battery life. Table 1 (below) shows the relationship between acid specific gravity and battery capability. Battery: Acid specific gravity capacity Maintenance of Battery life battery (longevity) Higher Increase Increase Decrease Lower Decrease Decrease Increase Table 1 The effect of specific gravity on battery performance A fully charged conventional battery at 80°F (26.7°C) has electrolyte with a specific gravity of 1.265. Because the OPTIMA is completely sealed, it does not lose water during the charging cycle as does a conventional battery. Within the OPTIMA, a measured amount of electrolyte is absorbed in the separator material between the plates. It is the precise amount to generate chemical reactions that optimize battery capacity and life. Plate Materials calcium. In a conventional battery, the lead grid must be strengthened with alloys such as antimony or While alloys add mechanical structure, they increase the rate of corrosion within a battery. More alloys are added to counteract this corrosion. This decreases the battery's performance. Antimony improves castability, mechanical properties, and paste adherence, but reduces the grid's electrical conductivity and increases self-discharge. Antimony can be completely eliminated from the battery by hardening the lead with a small amount of calcium. Some non-antimony alloys are an improvement, offering a longer shelf life and good cold crankins haracteristics. Still, while tin-calcium grids reduce the tendency of lead calcium positive plates to resist recharge when deeply discharged, they do not completely eliminate corrosion. OPTIMA batteries use high purity lead for a long life, high cranking capability, low self discharge and maintenance free operation. The physical design of the plates and the SPIRALCELL configuration strengthen the OPTIMA without alloys. 35 August 14, 1996 <<>> D. IYPES OF LEAD-ACID BATTERIES Lead-acid technology can be varied to meet different requirements. Batteries are classified according to their applications and their designs differ in three major ways: plate structure and design, composition of the active material, and the specific gravity of the electrolyte. Applications for lead-acid batteries fall into three broad categories: • Standby (Float) Service • Cycle Service • Starting/Lighting/Ignition (S.L.I.) • Standby (Float) Service Standby battery systems provide an uninterrupted supply of power to an electrical load component. They discharge immediately when primary (AC) power is interrupted. The electrolyte and electrode grid material are designed for long term service life. Typical standby applications include emergency lighting. and computer backup. • Cycle Service Batteries in cycle service are used as primary energy sources for applications such as: Backup power for devices in photovoltaic systems. • Electric vehicles such as fork lifts and golf carts. Recreation vehicles. • Trolling motors. • Wheelchairs. In each of these applications, the battery is the primary energy source. It must deliver sufficient power to the vehicle or device before requiring recharge. The number and depth of cycles limits the life of these batteries; hence, their life is expressed in cycles rather than years. These batteries are subject to a constant, relatively low rate of discharge over a long period. Cycle service batteries typically have very thick plates with heavy duty grids to provide as many cycles as possible. • Starting/Lighting/Ignition (S.L.I.) : S.L.I. batteries are primarily used for starting internal combustion engines. Their duty cycle is characterized by a short discharge at a very high current, immediately followed by recharging. During a normal start, the battery loses very little capacity. S.L.I. batteries also operate lights, radios, and other equipment for short periods without running the engine or when the engine is operating at low speeds (idling). S.L.I, batteries can keep the engine running for a short time if the alternator fails. 36 August 14, 1996 <<>> - To start engines, the battery must produce high power for short durations. This capacity is designed into the S.L.I. battery via increased plate surface area and heavy-duty intercell connectors. 14. GENERAL CHARGING PROCEDURES When a lead-acid battery is charged by connection to an external power source, the electrons flow in the opposite direction of that used in discharge. For this to happen, the outside power source must generate a higher voltage than the battery. An example of recharging the battery with a vehicle alternator is shown graphically in Figure 8. In this example, the voltage limit is set at 14.4 volts and the alternator supplies 25 amps. The battery initially accepts the full 25 amps. Voltage increases proportionally to 13.9 volts as the battery becomes recharged. When the battery is fully charged, the current is reduced to less than one amp. The excess batteries, the gas escapes, allowing the battery to dry out. In a recombinant battery such as the nergy from the charge is converted into gas in ALL lead-acid batteries. In conventional floodec OPTIMA, the gas recombines with the electrolyte to form water. Typical Vehicle System Charge Amperes @ 74° Degrees F Voltage 28.0 17.0 24.0 16.0 20.0 15.0 16.0 14.0 12.0 13.0 8.0 12.0 4.0 -.- Amps Volts 11.0 0.0 0 1 2 3 4 =-- $10.0 5 6 7 Charge Time (Hours) FIGURE 8 37 August 14, 1996 <<>> The charge curves in Figure 8 illustrate the relationship between voltage and current for the OPTIMA battery. In a properly functioning charging system, the battery will begin to limit charge current as it becomes fully charged. Voltage increases proportionally to the percent of the battery charge. General guidelines for charging lead-acid batteries depend on the type of charging system being used. A. Charging with a Vehicle Alternator: An S.L.I. battery is usually charged by the vehicle's alterna- tor. An alternator setting of approximately 13.2 to 14.4 volts for automobiles in the United States will usually assure proper battery performance. Exceeding this voltage for long periods can overcharge the battery. When this happens the battery will gas excessively, lose electrolyte, and dry out the plates, deteriorating the active material and shortening life. Vehicles are generally equipped with voltage- regulated charging systems which allows the battery to reduce the amount of current it accepts as it becomes fully charged. Most vehicles also have temperature compensating regulators which automatically decrease the voltage setting as temperature increases. Thus, overcharging an S.L.I. battery in a vehicle with a properly working charging system is rare. The way a vehicle is operated can also impact the effectiveness of the charging system. The following paragraphs describe typical charging conditions for passenger vehicles and commercial vehicles such as taxis. Passenger Vehicles High electrical power consumption and frequent short trips require a higher alternator voltage to recharge the battery more quickly. Long trips require a lower voltage. Owners generally use their cars for both long and short trips, requiring an alternator setting of about 14.4 volts. Commercial Vehicles Taxis and similar vehicles driven short distances are usually equipped with a high output alternator which produces a charging voltage between 14.4 and 14.8 volts. A higher output alternator is required to fully charge the battery during short trips. B. Charging with an External Charger Batteries used in non-automotive applications or a battery that has been inadvertently discharged and can no longer start the car must be recharged. A charger with voltage regulation is necessary to charge an OPTIMA battery. The regulated charging system will detect the degree of charge needed and adjust its charge rates accordingly (see Figure 8). The OPTIMA battery can be charged with a bench charger. We suggest a voltage setting range of 13.8 to 14.8 volts and a suggested current output of 10 amperes. At 10 amps, a completely discharged battery will be fully recharged in 5.5 to 6 hours. 38 August 14, 1996 <<>> C. Recommended charging limits for OPTIMA batteries: • Normal recharge: Voltage - 13.8 volts to 14.8 volts Maximum available current - 10 amps • Float applications: Voltage - 13.2 volts to 13.8 volts Maximum available current - 1.0 amp Maximum recharge time - Indefinite at lower charge voltages. ! (The OPTIMA battery is not designed or recommended for float applications although many customers have successful used it for this purpose.) • Boost recharge: Voltage - 15.6 volts maximum Maximum available current - 60 amps Maximum recharge time - 1 hour or when the battery starts to get hot. D. Problems Caused by Incorrect Charging Procedures Overcharging is a common problem caused by continuing to charge the battery after it has been filly charged. The following conditions will occur when a battery has been overcharged: Oxy-hydrogen Gas: In a conventional battery, overcharging causes hydrogen and oxygen to build up and escape faster than normal. Since these gasses can form explosive oxygen and hydrogen, conventional batteries must always be charged in a well-ventilated area. With proper charging recombination batteries are not as susceptible to loss of water. Their ability to recombine gases into water reduces gas build up. If overcharging occurs (usually from an unregulated charger or failed vehicle charging system), more gas may be generated than can be recombined. The pressure from this excess gas will eventually cause the safety valves te release, allowing gas to escape; the valves will then reseal. A hissing or whistling noise signals that pressure is being released. If this happens, immediately disconnect the battery from the charging system. If enough electrolyte is lost, battery performance will be reduced, similar to conventional S.L.I. batteries. Generally this happens to the OPTIMA battery only when it has been abusively overcharged. However, unlike conventional batteries, it is not possible to replace the water in the OPTIMA battery and the abusive overcharge can damage it permanently. Any battery that feels very warm or if the case is visibly damaged or distored should be removed from charging immediately. Appendix A). When an OPTIMA battery overcharge is suspected, weigh the battery (see the warranty procedures, Electrode Damage: When gassing occurs within a battery, water is evaporated from the electrolyte, reducing its volume and increasing its density (specific gravity). If enough water is lost, the active material on the plates is exposed to air. This will accelerate sulfation of the active material, leading to battery failure. Distilled water is usually added to a conventional battery to make up for loss during overcharge. The OPTIMA battery does not lose water unless it has been abusively overcharged. 39 August 14, 1996 <<>> THIS PAGE INTENTIONALLY LEFT BLANK ! 40 August 14, 1996 <<>> ..... .... ....-. ••... ... Appendix A GLOSSARY -A-! Active material - Lead dioxide in the positive plates and metallic sponge lead in the negative plates 2H,SO4 = 2PЬSO4 + 2H,O which reacts with sulfuric acid during charging and discharging a lead-acid battery. PO, + P + Ampere (amp) - The measure of electron flow or current through a circuit. current in amperes by the discharge time in hours. Ampere-hour - The measure of a battery's electrical storage capacity. It is obtained by multiplying the cycle life but increases water consumption and corrosion. Antimony - A element alloyed with lead to achieve greater mechanical strength. Antimony improves B.C.I. - Battery Council International Boost-charging - A short-duration charge applied to a battery that is nearly fully charged. ... C.A. - Cranking Amps. Sometimes referred to as Marine Cranking Amps at 32°F. The discharge load in amperes that a new, fully charged battery at 32°F (0°C) can continuously deliver for 30 seconds while maintaining a terminal voltage equal to or higher than 1.2 volts per cell of a total of 7.2 volts (for a 12 volt battery). Capacity - A fully charged battery's ability to deliver a specified quantity of electricity at a given rate over a definite period of time. A battery's capacity depends on many factors: the amount of active material on the grid, density of the active material, adhesion of active material to the grid, quantity of plates, the amount of surface area of the plates/grids, distance between the positive and negative plates, design of separators, specific gravity and quantity of available electrolyte, grid/plate purity, temperature, internal and external resistance. voltage of at least 7.2 volts for a 12 volt battery. C.C.A. - Cold Cranking Amps. Starting current available for 30 seconds at 0°F (-18°C) with a final Corrosion - The gradual oxidization of lead to lead oxide. water flows. Current - The rate of electrical flow. Measured in amperes, it is comparable to the way a stream of 41 August 14, 1996 <<>> Cycle - The discharge and subsequent charge of a secondary cell that restores it to its original condition. performance criteria. Cycle life - The number of cycles available from a secondary cell before it fails to meet specified Deep cycle - Withdrawal of at least 80% of the rated capacity of the battery. (Also known as "deep discharge"). DIN - German standard. (Deutsche Industrienorm.) Discharge - The conversion of a cell's chemical energy into electrical energy. Electrode - The site, area or location where electrochemical processes take place. (Also called "plate".) Electrolyte - The medium providing the ion (electron) transport mechanism between the positive and negative plates of a cell. (Sulfuric acid diluted with water in a lead-acid battery.) Electron - A negatively-charged particle within an atom. • • Flooded cell - A cell containing excess liquid electrolyte. Formation - Electrochemical conversion of electrode materials to the active state. G: Gassing - The evolution of gas from the plates in a cell. When it is charged, a battery generates aydrogen at the negative plate and oxygen at the positive plate. These gases result from the lecomposition of water when a battery is charged at a higher rate than it can accept Gel cell - A cell in which the electrolyte has been immobilized by converting it into a gel-like mixture. Grid - A framework for a plate or electrode which supports and/or retains the active materials and acts as a current transporter. August 14, 1996 <<>> Internal resistance - The opposition or resistance to the flow of direct current within a cell. Its value may vary with the current, state-of-charge, battery age, and air temperature. Ion - An electrically-charged atom or group of atoms that transports electricity through the electrolyte. formation. It is also formed electrochemically when a battery is discharged. Lead sulfate - A lead salt formed by the action of sulfuric acid on lead oxide during paste mixing and Maintenance-free - A term applied to batteries that never need maintenance. • OHM - A unit for measuring electrical resistance. Over-charge - The forcing of current through a cell after all the active material has been converted to the charged state. In other words, continued charging after a battery has been totally charged. Oxy-hydrogen gas - Oxy-hydrogen gas is a mixture of hydrogen and oxygen at a 1:2 ratio. Hydrogen and oxygen are formed by the negative and positive electrodes respectively. -P-L Parallel connection - Two or more batteries connected together while the voltage remains the same. Batteries in parallel are connected by hooking like posts together, for example: positive to positive and negative to negative. ARA. Rated Capacity - The number of ampere-hours a cell can deliver under specified conditions (rate of discharge, end voltage, temperature.) Recombination - State where the gases formed within the battery cell recombine during normal operation to form water. 43 August 14, 1996 <<>> -S - S.A.E. - Society of Automotive Engineers. American standard corresponding to the German DIN standard. Safety valve - Re-closable valve activated if the gas pressure in the battery exceeds a safe level. Self discharge - When a battery delivers current while in an open circuit (nothing connected). Typically caused by contaminants on the electrodes (plates) discharging the battery's active materials. Series connection - A circuit in which the positive pole of one battery is connected to the negative pole of an adjacent battery to increase voltage while maintaining the same capacity. Specific gravity - The density of a liquid compared with the density of water. The specific gravity of the electrolyte is the weight of the electrolyte compared to the weight of an equal volume of pure water. ! Sulfation - The formation of lead sulfate on a plate whose physical properties make it extremely difficult, if not impossible, to reconvert it to active material. Trickle charge - A continuous, low rate charge sufficient to compensate for self discharge loss. 22320 Vent - A mechanism that allows gases to escape from a battery. Volt - The measure of electrical potential. CHEMICAL GLOSSARY РЬ = Lead PbO, = . Lead Dioxide = Oxygen H,SO, = Sulfuric Acid HO = Water = Hydrogen (-) = Electrons Pb-Ca = Lead-calcium PbSO, = Lead Sulfate Pb-Sb = Lead-Antimony 44 August 14, 1996 <<>> OPTOMA BATTERIES THE ULTIMATE STARTER 17500 E. 22nd Avenue Aurora, Colorado U.S.A. 80011. Fax: (303) 340-7474 Telephone: (303) 340-7440 ## Provenance - Official: Yes - Source: - Source ID: `phmsa` - SHA-256: `a991c7984eee6c505fd98fc175b7e8ea203d97b6a4b46de039945fb15c8b61bd` - Retrieved: 2026-08-20T00:59:31.977Z - Exported: 2026-08-23T08:04:59.800Z - Document slug: `phmsa-interpretation-98-0602` ### Source metadata ```json { "materialSubtype": "interpretation", "interpretationArea": "hazardous_materials", "representation": "full_text_from_official_pdf", "companies": [ "G.H. Johnson & Associates, Inc." ], "individuals": [ "Mr. James A. 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