{"operation":"document","citation":"98-0602","title":"G.H. Johnson & Associates, Inc. — Hazardous Materials Safety Interpretation","source_type":"guidance","agency":"Pipeline and Hazardous Materials Safety Administration","status":"guidance","official":true,"published_on":"1998-04-17","effective_on":null,"summary":"98-0602 response to G.H. Johnson & Associates, Inc. concerning 173.159.","machine_formats":{"json":"https://regulus.evalyn.ai/document/phmsa-interpretation-98-0602.json","markdown":"https://regulus.evalyn.ai/document/phmsa-interpretation-98-0602.md"},"app_url":"https://regulus.evalyn.ai/document/phmsa-interpretation-98-0602","source_url":"https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/legacy/interpretations/Interpretation%20Files/1998/980602.pdf","body":"<<<PAGE 1>>>\n\n•\nU.S. Department\nof Transportation\nWashington, D.C.\n400 Seventh Street, S.W.\n20590\nSpecial Programs\nResearch and\nAdministration\nAPR 1 7 1998\nMr. James A. Noone\nG.H. Johnson & Associates, Inc.\n1211 Connecticut Avenue, N.W., Suite 302\nWashington, D.C. 20036-2603\nDear Mr. Noone:\nThis is in response to your letter of March 25, 1997, requesting clarification on the shipping\nrequirements for batteries manüfactured by your company under the provisions of the Hazardous\nMaterials Regulations (HMR; 49 CFR Parts 171-180). Specifically, you ask if your batteries are\nsubject to the HMR.\nThe information you provided demonstrates that your batteries are constructed in such a manner that\nthe sulfuric acid electrolyte is completely sealed and cannot leak even if the battery is cracked open\nor punctured. In addition, the sulfuric acid electrolyte is absorbed in a fibrous glass separator. Thus,\nyour batteries appear to meet the criteria for non-spillable batteries in § 173.159(d). When securely\nof the Hazardous Materials Regulations.\npackaged and protected against short circuits, non-spillable batteries are not subject to the provisions\nIn addition, under the International Civil Aviation Organization's (ICAO) Technical Instructions for\nthe Safe Transport of Dangerous Goods by Air, special provision A67, a non-spillable battery is\nconsidered to be non-regulated if, at a temperature of 55°C, the electrolyte will not flow from a\ncracked or ruptured case.\nI hope that this information is helpful. If you need further assistance, please contact us.\nSincerely,\ni Chich Re Baliness\nChief, Regulations Development\nOffice of Hazardous Materials Standards\n\n<<<PAGE 2>>>\n\nG. H. Johnson & Associates, Inc.\nGovernment and Military Marketing Representatives for:\nOPTIMA\nS\nBATTERIES\n113.\nTHE ULTIMATE POWER SOURCE\n127.\nMarch 25, 1998\nJ. Suzanne Hedgepeth\nDirector\nOffice of Hazardous Materials\nExemptions and Approvals\nOffice of the Associate Administrator\nFor Hazardous Materials Safety\nResearch and Special Programs Administration\nDepartment of Transportation\n400 Seventh Street, SW\nWashington, DC 20590\nRe:\nRequest for Determination\nDear Ms. Hedgepeth:\nI am writing to seek an updated determination from the U.S. Department of\nTransportation (\"DOT\") that batteries manufactured by OPTIMA Batteries, Inc. (\"Optima\"),\nof Aurora, Colorado, are not subject to the Hazardous Materials Regulations and, therefore,\ncan be shipped commercially by air and surface means without restriction.\nOptima utilizes a spiral design for battery cells that was originally developed by The\nGates Rubber Company (\"Gates\") of Denver, Colorado. The technology was invented by\nGates in the 1970s, and commercial production began in 1987 under the Optima name. In\n1990, Optima was incorporated as a division of Gates. In 1992, Optima was purchased from\nGates by The Gylling Group of Scandinavia, the current parent company. This history of\nOptima is outlined in \"The Optima Manual,\" Attachment A.\nIn 1981, in response to a request by Gates, the Research and Special Programs\nAdministration (\"RSPA\") of DOT informed Gates that because of the sealed design of the\nbatteries eventually to be sold under the Optima name, such batteries were not subject to the\nHazardous Materials Regulations. See Attachment B, letter of February 18, 1981, from\nJoseph T. Horning, Chief, Regulations Development Branch, Office of Hazardous Materials\nRegulations, Materials Transportation Bureau, RSPA.\nColorado Office\n270 Tahosa Road South, POB 457\nWashington Office\nAlienspark, CO 80510-0457\n1211 Connecticut Avenue, N.W., Suite 302\nTel: (303) 747-2065 Fax: (303) 747-2915\nWashington, D.C. 20036-2603\nE-mail: ghjassoc@mci2000.com\nTel: (202) 466-7336 Fax: (202) 955-5879\nE-mail: kn1211conn@aol.com\n\n<<<PAGE 3>>>\n\nOptima would like to obtain a current determination by the appropriate DOT office that\nits battery is not subject to the Hazardous Materials Regulations and is authorized for shipping\nby commercial means. So that a proper evaluation may be done pursuant to this request, I am\nenclosing the following additional materials:\nOne-page promotional sheet showing technical specifications (Attachment C)\nA current Material Safety Data Sheet (MSDS), most recently revised on\nDecember 5, 1997 (Attachment D)\nLetter of June 2, 1995, from the International Air Transport Association\n(\"IATA\") confirming that Optima batteries are not regulated by the IATA\nDangerous Goods Regulations (Attachment E)\nAs explained in substantial detail in these attachments and in Attachment A, the Optima\nbattery is completely sealed. In addition, the sulturic acid electrolyte is absorbed in a fibrous\nglass separator material. Because of the design and construction, acid cannot leak even if the\nbattery were to be punctured.:\nFor your information, we have been in communication with the U.S. Postal Service\n(\"USPS) in recent weeks with respect to a determination that the Optima battery can be\nshipped by the USPS as a non-hazardous product. We have been advised that USPS is in the\nprocess of revising its regulations to reflect such a determination. We will forward\ndocumentation reflecting this change as we receive it from USPS.\nWe would very much appreciate your expeditious consideration of this request. Please\nuse the undersigned as the point of contact in the Washington Office of Johnson\nAssociates/Optima: (202) 466-7330 (P); (202) 955-5879 (F). As indicated on this letterhead,\nthe mailing address is: G.H. Johnson & Associates, Inc./OPTIMA Batteries, Washington\nOffice, 1211 Connecticut Avenue, NW, Suite 302, Washington, DC 20036.\ninformation.\nPlease do not hesitate to contact me should you require additional technical or other\nSincerely,\nTues Too Macer\nWashington Representative\nJAN: dkt\n2\n\n<<<PAGE 4>>>\n\nS\n-\nОРІШМА\nSPIRALCELL\"\nTECHNOLOGY\nBATTERIES\nTHE ULTIMATE STARTER\n7 дат:\n800S\nONLY OPTIMA's\n800U\n850/6\nSPIRALCELL TECHNOLOGY™\nOFFERS ALL THESE BENEFITS:\navailable. Our patented SPIRALCELL Technology\nOPTIMA is the most advanced engine-starting battery\nprovides many features and benefits not found in\nLONGER SHELF LIFE.\nconventional automotive batteries:\nWith its low rate of self discharge, the OPTIMA can go\nis ideal for boats, farm equipment, collector cars, and\nunused for up to a year without recharging. The OPTIMA\nFASTER, CRISPER STARTS.\npower for faster, crisper starts. The 800U and 800S 12-\nThe OPTIMA's SPIRALCELL Technology provides more\nother seasonal equipment.\nvolt models deliver 800 Cold Cranking Amps at 0°F.\nFASTER RECHARGE.\nallow the OPTIMA to be recharged in less time than\nGreater plate surface area and lower internal resistance\nIn performance tests, the OPTIMA lasted three to five\nLONGER BATTERY LIFE, GREATER SAVINGS.\nconventional automotive batteries.\ntimes longer than conventional, flat-plate batteries.\nFAST ENERGY RESPONSE.\nElectrolyte in the OPTIMA is completely absorbed. It\nCOMPLETELY SEALED.\nfaster when demanded by accessories such as stereos,\nThe OPTIMA's low internal resistance provides power\ncan't leak even if the battery is cracked open. This means\nwinches, etc.\nthe OPTIMA is safer for people, equipment, and the\nenvironment.\nBETTER RECOVERY FROM DISCHARGE.\nUNEQUALED VIBRATION RESISTANCE.\nVibration is a primary killer of conventional batteries.\nvibration, and eliminates plate shedding.\nOPTIMA's tightly wound SPIRALCELL resists jarring and\nUNIVERSAL SIZE & FIT.\nThe OPTIMA fits a wide variety of cars, trucks, and other\nequipment. The OPTIMA can be mounted in any position\nTests prove the OPTIMA performs better in extreme cold\nMORE POWER IN ANY CLIMATE.\n- even upside-down.\nand hot temperatures than conventional lead-acid\nbatteries of similar size.\nOUTSTANDING WARRANTY.\nThanks to recombinant technology, absorbed electrolyte,\nZERO MAINTENANCE / NO CORROSION\nBecause the OPTIMA is built for some of the roughest\nwarranties. See an OPTIMA dealer for complete warranty\nconditions, it's backed by one of the best automotive\nand sealed construction, the OPTIMA won't corrode\ndetails.\nbattery terminals, cables, or the vehicle. And the OPTIMA\nnever needs to have water added.\nOPTIMA Batteries, Inc. / 17500 E. 22nd Avenue / Aurora, CO 80011 / Phone (303) 340-7440 / Fax (303) 340-7474\nGylling Group of Scandinavia -- Established 1912\nPN 06-1001 3/96\n\n<<<PAGE 5>>>\n\nOPTUMA\nBATTERIES\nTECHNICAL\nTHE ULTIMATE STARTER\n800U\n800S\n850/6\nINFORMATION\nVoltage\nPERFORMANCE\nRESEALABLE PRESSURE\nERO-MAINTENANCE\nRELIEF VALVES\nTERMINALS\nReserve Capacity\nCold Cranking Amps\n800\n12\n800\n12\n6\nCapacity (C/20 rate)\n120 min.\n56 Amp Hours\n120 min.\n120 min\n850\nDIMENSIONS\n56 Amp Hours\n56 Amp Hours\nLength\nHeight\nWidth\n915/16\nDual SAE & GM\n39.5 Ibs.\n7 13/16\"\n6 7/8\"\n915/16\n7 13/16\"\n6 3/4\"\n9 29/32\"\n3 3/8\"\nType Post/Terminal\nWeight\nSAE Post\n39.0 Ibs.\n7 13/16\n20.0 Ibs.\nBCI Group\n34\n34\nSAE Post\nN/A\nCranking Amperes vs. Temperature\nHEAVY-DUTY\n1200\nAmperage\nCAST-ON\nSTRAPS\n1000\nCONSTRUCTION &\nRUGGED SPIRALCELL\n800\nCLOSE PLATE SPACING ..\nRESISTANCE & HIGHER\nSUPERIOR VIBRATION\n600\nPOWER\n400\n200\nGLASS SEPARATOR\nMICROPOROUS\nLEAD GRIDS\nHIGH-PURITY\n- 150F 0°F\n20°F 32°F 40°F\n60°F\n80°F\nTemperature (OF)\nCharging Data\nSelf Discharge\nVehicle Charge:\nVoltage regulation - 13.8 to 14.4 Volts\nVoltage\n@ 74º Degrees F\nNormal Charging:\n: Voltage - 13.8 to 14.8 Volts\nMaximum Time - 6-8 hours\nMaximum Current - 10 Amps\n13.0\n12.8\nFloat Applications: Voltage - 13.2 to 13.8 Volts\nMaximum Time - Indefinite\nMaximum Current - 1 Amp\n12.6\n12.4\n(at lower charge voltages)\nBoost Recharge:\nVoltage - 15.6 Volts (Regulated)\n12.2\nMaximum Current - 60 Amps\nMaximum Time - 1 hour\n12.0\n50\nDuration (days)\n100\n150\n200\nNOTE: Charging systems should be voltage regulated.\nWarranty Information\nYOUR DEALER / DISTRIBUTOR\n(72 month)\nConsumer car/truck\nmaining 48 months pro-rati\nNo year replaceme\n(36 month)\nCommercial\nemaining 24 months pro-rate\nne year replacemen\n4 mont\nar stereo/racir\nmainina 12 months pro-rat\nle year replaceme\nAbusive service\nDetermined on individual basis\nOPTIMA Batteries, Inc. / 17500 E. 22nd Avenue / Aurora, CO 80011 / Fax (303) 340-7474 Phone (303) 340-7440\nGylling Group of Scandinavia -- Established 1912\n\n<<<PAGE 6>>>\n\nMaterial Safety Data Sheet\nBATTERIES\nNumber: OBI-0001 B\nIssue Date: 02/20/90\nTHE ULTIMATE POWER SOURCE™\nRevision Date: 12/05/97\nSection 1 - Material Identification\nProduct Name:\nSealed Lead Acid Battery\nCommon Synonym: Automotive Battery\nUN Number:\nUN2800 (See Section 16 for additional information)\nEngine Starting Batteries\nBattery Model No.\nNational Stock Number (NSN)\n800U\n6140-01-374-2243\n800S\n6140-01-378-8232\n1000M\n6140-01-441-4280\n850/6\nNot Available\nDeep Cycle Batteries\nBattery Model No.\nD750U\nNational Stock Number (NSN)\n6140-01-441-4272\nD750S\nNot Available\nD900M\nNot Available\nCompany Information\nEmergency Phone Number\nOptima Batteries, Incorporated\nChemtrec\n17500 E 22^d Avenue\nUnited States: 800-424-9300\nAurora, Colorado 80011\n(303) 340-7400\nInternational: 703-527-3887\nCage Code OUJ55\n(collect)\nThe OPTIMA sealed lead acid battery is considered an article as defined by 29 CFR 1910.1200( c)\nOSHA Hazard Communication. The information on this sheet is supplied at the customer's\nrequest for information only.\nEmergency Overview:\nExposure not expected for product under normal conditions of use. In its manufactured and\nsupplied state, the product is considered non-hazardous. Keep away from flames during and\nimmediately after charge. No significant health effects are associated with the product.\nSection 2 - Composition Hazardous Components\nMaterial\n% by weight or volume\nCAS Number\nLead Compounds\n63 - 81\n7439-92-1\nSulfuric Acid Electrolyte\n17 - 25\n7664-93-9\nCase Matl Polypropylene\n2-6\n9003-07-0\nSeparator/Paster Paper Fibrous Glass\n1-4\n65997-17-3\nSection 3 - Hazards Rating\nThe Hazards rating for the Sealed Lead Acid Battery are:\nHazards Rating (HMIS System)\nHealth\nFlammability\n0\nReactivity\n\n<<<PAGE 7>>>\n\nSection 4 - Hazards Identification\nPotential Health Effects\nNone expected for finished product under normal conditions of use.\nFire and Explosion\nThe sealed lead acid battery is not considered flammable, but it will burn if involved in a fire.\nShort circuit can also result in fire. Evacuate area. Self-contained breathing apparatus must be\nworn to prevent possible inhalation of acid mists, smoke and decomposition products in a fire.\nRemove all ignition sources. Cool battery(s) to prevent rupture.\nSection 5 - First-Aid\nInhalation - Not expected for product under normal conditions of use. However, if acid vapor is\nreleased due to overcharging or abuse of the battery, remove exposed person to fresh air. If\nbreathing is difficult, oxygen may be administered. If breathing has stopped, artificial respiration\nshould be started immediately. Seek medical attention.\nEyes - Exposure not expected for product under normal conditions of use. However, if acid from\nbroken battery case enters eyes, flush with water for at least 15 minutes. If irritation develops,\nseek prompt medical attention.\nSkin - Exposure not expected for product under normal conditions of use. However, if acid\ncontacts skin, flush with water and mild soap. If irritation develops, seek medical attention.\nIngestion - Not expected due to physical form of finished product. However, if any materials are\ningested, seek prompt medical attention.\nSection 6 - Fire-fighting Measures\nExtinguishing media - Multipurpose dry chemical or multipurpose CO2.\nFire fighting procedures - Evacuate area. Self-contained breathing apparatus must be worn to\nprevent possible inhalation of acid mists, smoke and decomposition products in a fire. Remove all\nignition sources. Cool battery(s) to prevent rupture.\nUnusual fire and explosion hazards - Hydrogen gas may be produced and may explode if ignited.\nRemove all ignition sources. Ventilate area.\nSection 7 - Accidental Release Measures\nSpill or leak cleanup procedures: Avoid contact with acid materials. Use soda ash, baking soda or\nlime to neutralize acid if released\nWaste disposal: Dispose of in accordance with all local, state, and federal regulations.\nHandling - Do not carry battery by terminals. Do not drop battery, puncture or attempt to open\nbattery case. Keep away from flames during and immediately after charge. Avoid prolonged\nStorage - Store at ambient room temperature. Do not subject product to open flame or fire. Avoid\nconditions which could cause arcing between battery terminals.\nHygiene - Wash hands thoroughly before eating or smoking after handling batteries.\nSection 9 - Exposure Control\nMaterial\nLead compounds\nExposure Limits\nSulfuric Acid Electrolyte\n0.05 mg/m.3\n1.00 mg/m3 OSHA\n2\n•\n\n<<<PAGE 8>>>\n\n-\nSection 10 -Personal Protection:\nEye: Not necessary under normal conditions of use for finished product.\nSkin: Not necessary under normal conditions of use for finished product.\nRespiratory: Not necessary under normal conditions of use for finished product.\nVentilation: Not necessary under normal conditions of use for finished product.\nWork Practices: Not necessary under normal conditions of use for finished product.\nSection 11 - Physical and Chemical Properties\nBoiling Point:\nN/A\nAppearance/Odor:\nVapor Pressure:\nN/A\nN/A\nSpecific Gravity (H2O=1):\nVapor Density (air=1) N/A\nMelting Point:\nN/A\nSolubility in water:\nN/A\nEvaporation Rate:\nN/A\nN/A\n(Butyl Acetate = 1)\nSection 12 - Stability and Reactivity\nStability:\nStable\nConditions to avoid:\nAvoid shorting, use only approved charging methods. Do not\nHazardous reactions:\npuncture battery case\nN/A\nDecomposition Products:\nN/A\nHazardous Polymerization:\nWill not occur\nSection 13 - Toxicological Information\nThreshold limit value: Not applicable for finished product.\nRoute of entry: Not applicable for finished product under normal conditions of use.\nSigns of symptoms of acute exposure: None expected for finished product under normal\nconditions of use.\nChromic Exposure: None expected for finished product under normal conditions of use.\nMedical Conditions aggravated by exposure: None expected for finished product under normal\nconditions of use.\nEffects of overexposure, conditions to avoid: No exposure expected for finished product.\nHowever, do not puncture or open battery case. Acid electrolyte may be released. Use only\nstandard charging methods. If overcharged, battery may release gases (Hydrogen and oxygen).\nCarcinogen listing: NTS: no IARC: no OSHA regulated: NA for finished product under normal\nconditions of use.\nSection 14 - Disposal Considerations\nSend to a lead recycling facility which follows applicable Federal, State and Local regulations for\nroutine disposition of spent or damaged batteries. The distributor / user is responsible to know\nthat \"spent\" and/or \"damaged\" batteries (scrap batteries) are disposed of in an environmentally\nsound way in accordance with all applicable Federal, State, and Local Environmental Regulations.\nOPTIMA batteries are 100% recyclable by any licensed reclamation operation.\nSection 15 - Regulatory Information\nAccording to the OSHA Hazard Communication Standard, Sealed Lead Acid Battery in its\nmanufactured and supplied state is considered non-hazardous.\nTransportation:\nSealed Lead Acid Battery is not a DOT Hazardous Material.\n3\n\n<<<PAGE 9>>>\n\nSection 16 - Supplemental Information\nUnder the Dangerous Goods Regulations, 34\" Edition, Effective 1 January 1993, produced by\nInternational Air Transport Association (IATA): OPTIMA batteries are classified as non-\nregulated by special provisions A-48 and A-67 for UN Number of UN2800: Batteries, wet, non-\nspillable, electric storage:\nA-48: Packaging tests are not considered necessary.\nA-67: Non-spillable batteries are considered to be non-dangerous if, at a temperature of 55°C\n(130°F), the electrolyte will not flow from a ruptured or cracked case and there is no free liquid to\nflow and if, when packaged for transport, the terminals are protected from short circuit.\nThe manufacturer of this finished article cannot foresee every possible use or misuse of the\nproduct. However, the following information is supplied:\nIn its manufactured and supplied state, the product is considered non-hazardous. Excessive\novercharging or abuse to the terminals can result in the release of gases (hydrogen and oxygen).\nAs a general practice, batteries should not be used in enclosed, non-ventilated spaces. Avoid\nimmersion in water as it may lead to hydrogen generation. If the battery is crushed in a collision\nor similar accident, the absorbent separator may be squeezed causing the release of a small amount\nof acid electrolyte. Neutralize the acid electrolyte with baking soda and flush with plenty of water.\nUnder the Code of Federal Regulations #49, October 1, 1994 Edition, OPTIMA batteries are\nclassified as an exception from all other requirements or conditions as stated in the following\nareas: Batteries, wet, 173.159 (d)(3)(i) and (d)(3)(i)(i).\n(d)(3)(i):\nvibration test\n(d) (3)(1)(i):\npressure differential test\nThese conditions have been tested and certified by the following: Energy Research Laboratory\nInformation is on file at main company location.\n(ERL A/S), Batteritest Laboratory, Munkebjergvaenget 13, DK-5230, Odense M. Denmark.\nThe information and recommendations contained herein have been compiled from sources\nbelieved to be reliable and to represent current knowledge on the subject. No warranty, guarantee,\nor representation contained herein and OPTIMA Batteries, Inc., its subsidiaries or affiliates\nassume no responsibility in connection therewith, nor can it be assumed that all acceptable safety\nmeasures are contained herein, or that other or additional measures may not be required under\nparticular or exceptional conditions or circumstances.\n4\n\n<<<PAGE 10>>>\n\n_LULODUL\nthe\nOPTIMA\nMANUAL\n\n<<<PAGE 11>>>\n\nthe\nOPTIMA\nMANUAL\nOPTIMA\nBATTERIES\nTHE ULTIMATE STARTER\n\n<<<PAGE 12>>>\n\nTABLE OF CONTENTS\nSECTION\nTOPIC\nPAGE\nTable of Contents........\n..i\nIntroduction..\n... 1\n2\nThe OPTIMA Manual.......\n3\n...2\nHistory of the OPTIMA Battery..\n....3\n4\nOPTIMA Concept and Design..\n5\n4\nSummary of Features and Benefits.\n5\n6\nUnderstanding the OPTIMA Technology...\n.. 6\n7\nOPTIMA Versus Conventional Batteries..\n8\n....9\nThe OPTIMA: Features, Functions, Benefits\n9\n.. 13\nThe OPTIMA Battery: Applications and Advantages.\n..23\nQuick Reference Customer Benefit Chart\n..28\n10\nInappropriate Uses of OPTIMA S.L.I. Batteries. ....\n11\n..29\nQuality Control in Action - The Bitrode/Finishing Line\n..30\n12\nRating of S.L.I. Batteries\n(Starting, Lighting, Ignition)......\n13\n.31\nBasic Battery Technology and Terminology..\n..32\nA. What is a Battery?....\n..32\nB. Various Types of Batteries..\n..33\nC. What Happens Inside a Lead-Acid Battery?...\n..34\nD. Types of Lead-Acid Batteries..\n36\n14\nCharging Procedures........\n37\nA. Charging with an Alternator/Generator.\n38\nB. Charging with an External Charger..\n...38\nC. Recommended Charging Limits for OPTIMA Batteries\n......39\nD. Problems Caused by Incorrect Charging Procedures.\n...39\nAppendix A: Glossary...........\n41\n\n<<<PAGE 13>>>\n\nTHIS PAGE INTENTIONALLY LEFT BLANK\nAugust 14, 1996\n\n<<<PAGE 14>>>\n\n1. INTRODUCTION\nThe OPTIMA battery represents a new standard for the automotive S.L.I (Starting, Lighting,\nIgnition) market. Its superior starting ability, high reserve capacity, long life, safety, and versatility make\nit outstanding for a wealth of uses. One customer recently praised it as \"the most dependable, lowest\nmaintenance battery on the market today.\"\nWhat makes the OPTIMA unique? Its SPIRALCELL, sealed design provides more power for faster,\ncrisper starts at any temperature. It outperforms flat plate batteries by three to one. The OPTIMA\ndelivers an amazing 800 cold cranking amps for the 12 volt 800S and 800U models. Completely sealed,\nthe OPTIMA is maintenance-free; it is much safer than conventional batteries since it cannot spill or\nleak. Its tightly-wound spiral elements resist jarring and vibration, making the OPTIMA an ideal choice\nfor almost any application or equipment.\nIntroduced in 1984, the OPTIMA is the result of nearly 20 years of research and development.\nOriginally developed by the Gates Rubber Company of Denver, Colorado, OPTIMA Batteries, Inc. is\nnow owned by Gylling OPTIMA Batteries, A.B. of Stockholm, Sweden. All OPTIMA batteries are\nmanufactured at the company's Colorado facility in Aurora. OPTIMA batteries are sold wholesale to\ndistributors throughout the U.S. and abroad.\nin a wide range of applications including:\nWhile originally designed for the automotive S.L.I market, OPTIMA batteries are finding acceptance\nCommercial fleets - passenger cars, light trucks, vans, utility vehicles\n• Private automobiles, light trucks and vans\n• Diesel-powered vehicles - light and medium sized trucks\n• Agricultural, forestry and construction equipment - tractors, harvesters, dump trucks, water\ntrucks, generators, fork lifts, skid loaders\nMarine starting applications - fishing boats, house boats, sail boats, ski boats\n•\nCollector and specialty vehicles - antique cars, show cars, custom cars, street rods, lowriders\nMotor sports and racing cars\nCar audio systems\n• Military Aerospace Ground Support Equipment (AGE), generators, and military vehicles\nThis manual is a complete reference source regarding the OPTIMA's design, technical\nspecifications, features, benefits, applications, warranty and more. Please contact us at 303-340-7440\n(phone) or 303-340-7474 (fax) with any questions you many have about the OPTIMA battery.\n1\nAugust 14, 1996\n\n<<<PAGE 15>>>\n\n2. THE OPTIMA MANUAL\nin representing OPTIMA batteries.\nThis manual is your source for reference, background information, and tools to enhance your success\nREFERENCE:\nUse this manual as a reference tool. You'll find the answers to most questions in \"The OPTIMA\nManual. \" We've included summaries of features, functions, and benefits; specifications;\napplications; basic battery technology; warranty procedures; a glossary; and more.\nBACKGROUND INFORMATION:\nLearn about the OPTIMA battery, its advantages, and how it compares to conventional battery\nfor so many applications. We've included a time line describing the battery's development. This\ntechnology. We start by explaining the new OPTIMA technology, describing why it is superior\nmanual also covers basic battery technology, terminology, and testing procedures.\nTOOLS:\nUnderstand the OPTIMA technology and how to apply it to applications. Testimonial letters that\ndescribe how the OPTIMA battery is saving customers time and money are available.\n2\nJ\nAugust 14, 1996\n\n<<<PAGE 16>>>\n\n3.\nHISTORY OF THE OPTIMA BATTERY\n1973\nGates Rubber Company, one of the world's largest producers of rubber products for the automotive industry,\ndevelops the initial battery technology incorporating a SPIRALCELL with recombinant technology. The\ncompany produces millions of battery cells for tools, appliances, and emergency lighting.\ni\n1983\nGates recognizes the need for an advanced automotive battery. The company begins research and\ndevelopment to further explore the battery technology.\n1984\nThe S.L.I. (Starting, Lighting, Ignition) battery project team is established at Denver, Colorado.\n1987\nLimited S.L.I. production begins; the first automotive batteries go to market.\n1990\nGates incorporates the division as OPTIMA Batteries, Inc.\nGylling Teledata A/S of Norway begins limited importation and distribution of OPTIMA batteries.\nSoon after, Gylling obtains distribution rights for all of Scandinavia.\n1991\nGates divests itself of OPTIMA Batteries, Inc.\n1992\nThe Gylling Group of Scandinavia purchases OPTIMA Batteries, Inc. from Gates.\n1993\nPublic demand for the OPTIMA battery begins to rapidly increase.\n1994\nOPTIMA Batteries, Inc. breaks ground for a new, larger, modern\nmanufacturing facility in Aurora, Colorado.\n1995\nOPTIMA Batteries Inc. moves into its new headquarters in Aurora, Colorado. Sub-contract with General\nMotors is signed to develop a monoblock battery for their hybrid vehicles.\n1996\nFull production begins at new facility and sales efforts expand throughout the\nNorth and South America as well as world-wide.\nAugust 14, 1996\n\n<<<PAGE 17>>>\n\nOPTIMA CONCEPT AND DESIGN\nLighting, & Ignition) battery.\nSeveral parameters were of critical importance during the design of the OPTIMA S.L.I. (Starting,\nWhat requirements were crucial for\nthe design of the OPTIMA battery?\nCapability\nHigh power for quick, sure engine starts.\n(Performance)\n• Ample electrical reserve capacity.\nV Safe to operate.\nv Compact in size and weight compared to traditional\nConstruction\nS.L.I. batteries with similar output.\nr Compatible with most vehicles.\nv Operates in any position or orientation, even upside\ndown.\nNo spillage even if the case is cracked.\nr Recyclable.\nv Truly zero maintenance.\nMaintenance\nV Low self discharge rate for a long shelf life.\nr Long operational life.\nv Rapid charge (recharge) rate.\nResilience\nDependable even in extreme hot and cold\ntemperatures.\n• Resistant to vibration, impact, and jarring.\nThe OPTIMA battery, with significantly fewer parts, appears to be simple in design when compared\nto traditional battery construction. Still, it is a very complicated battery to mass produce. Not only is\nthe design unique, but most of the manufacturing equipment had to be specially designed and built to\nproduce the OPTIMA.\n4\nAugust 14, 1996\n\n<<<PAGE 18>>>\n\n5. SUMMARY OF FEATURES AND BENEFITS\n• SUPERIOR STARTING CAPACITY.\nThe OPTIMA delivers 800 Cold Cranking Amps (C.C.A.) for the 800S and 800U\nmodels and 850 C.C.A. for the 6 volt battery (CCA is measured @ 0ºF or -18°C). The\n1000M marine starting battery is rated at 1000 Cranking Amps (CA is measured @ 32°F\nOI 0°C).\nCANNOT CRACK DUE TO FREEZING.\nOPTIMA's unique separator material allows for expansion in the event of freezing.\nZERO MAINTENANCE.\nCompletely sealed. There is no venting to corrode the terminals, connectors, battery tray,\nor surrounding equipment. Customers never need to add water.\nEASY TO TRANSPORT.\nBecause the OPTIMA battery is considered non-hazardous/now-dangerous, it can be\nshipped by air.\nFASTER RECHARGE.\nRecharge in less time due to low internal resistance and tight plate spacing.\nFITS MOST VEHICLES AND EQUIPMENT.\nHANDLES ABUSIVE TEMPERATURES.\nOperates effectively in extreme hot or cold temperatures.\nHIGH RESERVE CAPACITY.\nOPTIMA has a reserve capacity of 120 minutes.\nLONGER SHELF LIFE.\nAfter one year it will start most engines. Total shelf life is 2 years or more.\nMUCH SAFER.\nlocation and is less likely to explode.\nAbsorbed electrolyte, no free acid to spill or leak. The OPTIMA can be installed in any\nOUTLASTS CONVENTIONAL BATTERIES.\nOPTIMA.\nThe high purity lead grids minimize plate corrosion and plate deformation in the\nRESISTANT TO VIBRATION.\nTightly-wound SPIRALCELL ™ resists jarring, vibration, and shedding of the active\npaste material.\n•. VERSATILITY OF INSTALLATION.\nOPTIMA can be installed in any orientation, even upside down.\n5\nAugust 14, 1996\n\n<<<PAGE 19>>>\n\n6. UNDERSTANDING THE OPTIMA TECHNOLOGY,\nconventional battery.\nTo better understand the OPTIMA battery, let's compare it to the design and construction of a\ni\nin approximately 100 years.\nTraditional batteries are constructed with about 120 different parts and have undergone little change\nTERMINAL\nTAPERED\nPOSTS\nVENT PLUGS\nTHROUGH THE\nCONNECTORS\nPARTITION\nCOVER\n-POST STRAP\n-PLATE LUGS\nPOSITIVE\nPLATE\nENVELOPE\nSEPARATORS\n:\nCONTAINER\nELEMENT RESTS\nSEDIMENT SPACE\nFigure 1\nCONVENTIONAL FLAT PLATE BATTERY\n6\nJ\nAugust 14, 1996\n\n<<<PAGE 20>>>\n\nThe OPTIMA battery requires only 30 components; this means there is less opportunity for failure.\nFour letion origin. The scle pete are separated b\ninjection-molded case. The cells are electrically connected with thick cast lead intercell straps. The\ndesign greatly reduces the potential for mechanical failure.\nelectrolyte is injected and totally absorbed within the separator material between the plates. This unique\npressure valve\nResealable\nCorrosion-free/Zero\nmaintenance terminals\nMinimal free space\nHeavy cast-on straps\nIndividual cell chambers\nSealed plastic case\nStarved electrolyte design\nMicroporous\nglass separator\nThin, high-purity grids\nFigure 2\nOPTIMA SPIRALCELL BATTERY DESIGN\n7\nAugust 14, 1996\n\n<<<PAGE 21>>>\n\nTHIS PAGE INTENTIONALLY LEFT BLANK\n:\nAugust 14, 1996\n:\n\n<<<PAGE 22>>>\n\nOPTIMA VERSUS CONVENTIONAL BATTERIES\n21Z PLATE/ GRID CONSTRUCTION S\nOPTIMA\nConventional battery design\nHigh purity lead plates are used to make the grid for\ncells of the OPTIMA battery. Two long\nIn conventional batteries, each cell contains a series\ncontinuous bands of grid are wound into a tight\nof short flat grids. Materials such as antimony and\nspiral configuration then pressure inserted into\ncalcium are added to the grids to improve strength\nindividual cylinders within the case. This design\nand stiffness needed for manufacturing. These alloys\nprovides the cell's mechanical strength, eliminating\ncan increase plate corrosion, self discharge, internal\nthe need for alloys in the lead.\nresistance, and promote shedding of the active\nmaterial (lead paste applied to grid).\nUsing unalloyed lead extends the life of the\nOPTIMA grid will resist corrosion and last longer\nOPTIMA battery by reducing grid corrosion. The\nAs a result, the battery loses capacity and power.\nWith age, the grids shed their active paste material.\nin high temperature environments.\nengines are harder to start and in cold temperatures.\nThis power loss becomes especially noticeable when\nWhile conventional batteries are adversely affected\nby heat, the effects of heat on a high purity lead\nUsing alloys in the grid sacrifices performance for\nOPTIMA battery are minimal.\nand paste adherence but lowers electrical\nstrength. For example, antimony improves castability\ninternal resistance. This low resistance allows the\nThe use of high purity lead contributes to the low\nconductivity and increases the rate of self discharge\nand gassing.\nto meet the demands of vehicle electrical systems\nOPTIMA to deliver high amounts of power quickly\nWhen a conventional battery is stored for long\nand on-board electronic components.\nperiods without recharging, the alloys in the grid\ncorrode. This shortens the battery's life considerably.\nAnother advantage of using the high purity lead is a\nlow self-discharge rate. The alloys in conventional\nmaterial and the grid, causing a loss of electrical\nbatteries accelerate the reaction between the active\ncharge.\n(See Figure 2)\n(See Figure 1)\nAugust 14, 1996\n\n<<<PAGE 23>>>\n\nCELL DESIGN\nOPTIMA\nConventional battery design\nIndividual cells of the OPTIMA contain only two\npurity lead plates are wound into a tight spiral, and\nplates, one positive and one negative. These thin high\nThe cell of a conventional battery contains several\nplates connected together and suspended in a pool of\nseparator is very thin, allowing for closer plate\nare separated by an absorbent glass material. The\nelectrolyte. Alloys are added to the lead grid to\nincrease its strength and stiffness. Stiffness and\nthe flow of current and lowers the internal resistance.\nspacing. The close proximity of the plates enhances\nstrength are required for the plates to retain the active\nmaterial during operation and to make the plates\nThe porous separator material retains the electrolyte\neasier to work with during manufacturing.\nlike a sponge, preventing the active material on the\nplates from drying out.\nintribute to corrosion, higher internal resistance at\nhile the alloys add strength to the grid, they al\nThe tightly wound spiral allows the use of a very thin\nshedding of active grid material.\nmore winds in the spiral. This increases the amount of\nUsing thinner plates allows\nsurface area in the cell, thus boosting the amount of\nSufficient space between the plates in the cell is\npower generated from the battery. The plate surface\nelectrical shorts. This material falls from the plates\nrequired for shedding of the active material to prevent\nsimilar size conventional battery and utilizes almost\narea of an OPTIMA cell is much larger than that of a\nand accumulates at the bottom of the case.\nthe full height of the container.\nThe extra space results in a larger battery with higher\nAfter the cell is wound, it is pressure-inserted into an\ninternal resistance and lower energy density (energy\nindividual cylinder chamber with a tight interference\nper pound) than the OPTIMA.\nfit. This design increases the strength of the cell and\nprevents the active paste from falling off or shedding.\nmaterial throughout the life of the battery. When a\nThe flat, suspended grids cannot retain the active lead\nThe tightly wound cell resists vibration. There is no\nconventional battery is used in harsh conditions such\nfree space between the plates. This prevents\nas high temperatures or high vibration, shedding of\nmovement of the plates which causes plate to plate\nthe active material increases. This causes a loss in\nshorting and shedding of the active material.\nbattery power and capacity which leads to battery\nfailure. Typically, the battery fails due to loss of\nactive material or plate to plate shorting.\n10\nAugust 14, 1996\ni\n\n<<<PAGE 24>>>\n\nELECTROLYTE:\nOPTIMA\n• Conventional battery design\nThe OPTIMA battery is an absorbed electrolyte,\ngas recombinant battery. All the electrolyte is\nA conventional battery is a flooded system. Flooded\nmaterial between the plates in the SPIRALCELL.\nabsorbed (like a sponge) within the separator\nthe level of the plates. This excess electrolyte is required\nmeans that there is excess electrolyte in the battery above\nto prevent the plates from drying out, which causes\nThe electrolyte consumes approximately 95% of\nsulfation of the active material. This leads to a failure of\nthe voids in the separator material. The remaining\nthe sulfated part of the plate, which reduces the capacity\n5% is left as open space for gas passages.\nof the battery.\npositive plate combines with the hydrogen at the\nDuring the charging procedure, oxygen from the\nGases in a conventional battery collect in the free space\nabove the plates; which are then vented from the battery.\nnegative plate to form water which recombines\nWhen a battery is overcharged, gassing increases. The\ncan be totally sealed. Since the electrolyte is\nwith the electrolyte. Thus, the OPTIMA battery\ngases being vented (hydrogen and oxygen) are very\ncombustible. If ignited, they could cause a battery\nif the case is ruptured or broken.\ncontained within the separator, it cannot leak, even\nexplosion\nA portion of the vented gas corrodes the battery cables\nSince the electrolyte cannot escape via leakage,\nand connectors. This corrosion is often noticeable by the\nevaporation or venting, the plates will not dry out\nappearance of a white powder or blue/green fuzz on the\nand cause loss of capacity.\nterminals.\nBecause the OPTIMA never needs water and does\nThe conventional battery case must contain vents for\nvehicle.\nnot vent, it can be mounted anywhere in the\ngases to escape. If the battery is tipped over or tilted, acid\nwill leak from the vents. If the case is cracked or\nruptured, the acid will spill. Loss of the acid will cause\nshould not be installed in an air-tight space. Some\nGood engineering practices dictate that any battery\nthe conventional battery to fail. The escaped acid can\nalso cause harm to people, equipment, and the\ncharging system fails, causing an abusive\nventilation is necessary in case the vehicle's\nenvironment.\novercharge. Overcharge could cause the\nOPTIMA's internal safety valves to release some\nof the pressure within the battery case. If this\nhappens, some of the internal gases would escape.\nThe sealed, no-venting design eliminates corrosion\nof battery cables, connectors, and vehicle\ncomponents.\nAugust 14, 1996\n\n<<<PAGE 25>>>\n\ni\nFigure 3\nTHE OPTIMA SPIRALCELL\n12\nAugust 14, 1996\n\n<<<PAGE 26>>>\n\n8.\nTHE OPTIMA: FEATURES, FUNCTIONS, AND BENEFITS\nOPTIMA BATTERIES\nFEATURE\nFUNCTION\nBENEFIT\n132*\nGreater plate surface\narea\n• Increases starting power.\n* 800 C.C.A. (cold cranking amps).\n• Recharges more quickly.\nSPIRAL\nStrigger mechanical\nV Withstands vibration thereby increasing life.\n• Eliminates shedding of active material.\n:\n+ Reduces internal shorting.\nCELL\nHigh purity lead grid\n• Reduces corrosion for longer life.\n/ Lower self discharge.\n• Lower internal resistance increases\nDESIGN\nconductivity for more starting power and.\nquicker recharging.\nThinner plates / grid\nV Higher C.C.A. means more starting power.\nV Faster recharging.\nCloser, consistent\nplate spacing\nr More effective chemical reaction increases\nstarting power.\n/ Faster recharging.\nReduced battery size\nV Higher power-to-weight ratio\n• Produces power equivalent to\nconventional batteries several times its\nsize.\nV Fits more vehicles.\nAugust 14, 1996\n\n<<<PAGE 27>>>\n\nCharger:\nAlternátor\nPower\nCurrent\nSupply\nHO\nAbsorbed\nSeparator\nPbO\nElectrolyte\n•\nPb\nH2O\n02\nH2o\nFigure 4\nABSORBED ELECTROLYTE\nFigure 4 shows the absorbent separator material wound between the\npositive and negative plates of the OPTIMA SPIRALCELL.\n14\nAugust 14, 1996\n-\n\n<<<PAGE 28>>>\n\n• •\nOPTIMA BATTERIES\nFEATURE\nFUNCTION\nBENEFIT\nPrecise quantity of\n• Fills approximately 95% of the voids in\n:\nelectrolyte in each\ncell (computer\ncontrolled filling\nprocess)\nsealed battery\nv Proper distribution of acid for efficient\noperation and longer life.\nABSORBED\nAbsorbent separator\nELECTROLYTE\nmaterial\nV Allows hydrogen and oxygen gases to\nrecombine into water, making the\nbattery completely maintenance free.\n& Tightly wound separator material\nprevents internal shorting between the\nbattery failure.\nplates, eliminating a common cause of\n• Voids in the separator material provide\nexpansion capacity in case the battery\nfrom cracking.\nfreezes. This helps to prevent the case\n• No spilling/leaking. Absorbent separator\nruptured.\nretains electrolyte even if case is\nV Allows use of taller plates to better\nutilize case height. This results in more\nplate surface areas and higher power.\nAugust 14, 1996\n\n<<<PAGE 29>>>\n\nFigure 5\n:\nThe completely sealed OPTIMA recombinant battery prevents electrolyte from escaping.\nIt can be mounted in any orientation, even upside down.\n16\nAugust 14, 1996\n\n<<<PAGE 30>>>\n\nOPTIMA BATTERIES\nFEATURE\nFUNCT","truncated":true,"body_characters":83409}