The Difference between Optima 'Blems' & 'Prototypes'

[John Wayland <dat1200@europa.com>]

Hello to All,
     
Ken Lange recently wrote:

>the Optima blems main faults were leaking around the negative 
>terminal.

     As an Optima dealer and as one who also sells a lot of factory
'blem' batteries, I wanted to clarify just what an Optima 'blem' is, as
the above statement is incorrect in its terminology. 
    What Ken refers to as 'blems' were in fact the earliest 'prototype'
versions of the Yellow Top (YT) as it was being developed...these date
back to late '94-early '95.  Optima knew they had a sealing problem with
their first prototypes, and didn't market YTs at the retail level until
they had perfected their design (kudos to Optima). 
    The prototype batteries were resold at very cheap prices with the
stipulations that the batteries were not sealing properly and that they
could have leakage problems at the terminals, that their energy capacity
wasn't as high as Optima expected them to be, and that they were sold
'as is' without a warranty. These earliest YTs are easily identified by
their different case construction, particularly at the base of the
terminals. Each post protruded from a raised round pedestal in the
battery's yellow top that was about 1.75 inches in diameter and about .4
inches tall. On the D750S models, the positive terminal had four tabs of
lead that extended to the outer edge of this round base in a cross
pattern, where the negative post had three tabs in a 'Y' pattern. The
black on white sticker read 'Prototype'. On the D750U models, both the
positive and negative terminals had an exposed rectangular tab of lead
that extended out along the raised side post straps. The top of the
D750S battery's case had four 'finger holes', two along each side of the
battery, and the grey lower part of the case had a long slot for the
battery's handle. When fully charged at room temperature, these
batteries read approximately 12.85 volts. The 'leaker' prototypes have
not been available for several years now. 
      Optima first fixed the leakage problem by using 'O'ring seals at
the terminal. These earliest 'production' batteries had a new top that
lacked the aforementioned terminal pedestals. The posts simply came
straight out from the top with just a small collar of raised plastic at
the terminal's base....no extending lead tabs. The D750U models no
longer had an exposed rectangular tab of lead on the raised side post
straps, now being totally covered right up to the terminal. These second
generation YTs had increased energy capacity as well, as Optima changed
the concentration of the acid so that the battery when fully charged at
room temperature read approximately 13.1 volts. Optima sent me a set of
the early production D750S model (mine were labeled 'Prototype') to test
blast in Blue Meanie. I used these for a little more than two years,
constantly subjecting them to 500-800 amp currents, punnishing  them
with
very deep discharges, and more than 400 'not very nice' cycles.  I had
fantastic results with them with absolutely no leaking. Optima only made
this version for a short time though. 
      The third version had a  redesigned top and the D750S model no
longer had the finger holes along the sides. The terminal collars stayed
the same on the outside, but on the inside Optima eliminated the 'O'ring
seals by using a special formula rubber-like sealant material instead,
and is still using this today. Another small change was in the battery
vent flame arrestors, going from the previous white to a new charcoal
dark grey. The lower case was also changed at this time to where the
slot for the handle has a notch at the bottom to facilitate easier strap
removal. The acid strength remained the same, and the static fully
charged voltage was and still is 13.1 volts.
      Optima is very picky about the quality of the batteries that leave
the factory, and as such, they accumulate 'blems'  over a period of
time. There are two kinds of blems....electrical and cosmetic. I never
acquire the electrical blems and have no interest in them for EV use, or
for that matter, anything else. The cosmetic blems however, are a great
way to get new, full power Optimas at a lower price, with the minuses of
no warranty, the obvious flaws in appearance that constitute being a
cosmetic blem, and a sticker that says 'Blem' or sometimes 'Factory
Second'. When I visited the factory last Summer, I got to know key
people and saw the blem shelf and the types of batteries that end up
there. Some of them have had it pretty rough and have been dropped, have
bends in the cases, deformed terminals, sunken terminals, etc. While I
was there, I made it known that I would not accept batteries in this
condition. Since I buy them by the pallet and buy so many of their
blems, my contacts at Optima now cherry-pick the blems they send me and
most (not all) are pretty nice looking batteries. Sometimes, they look
just about perfect with only a minor scratch or scrape, other times they
look a bit rough with a deep gouge in the edge of the top, or black
marks deep in the plastic.
    Today's Optima YT 'blems' are not leakers and have full power
capacity, but they are an 'as is battery' without a warranty, with a few
nicks and scratches, and a reduced price that makes it easier for EVers
to afford larger quantities of them.
      

See Ya..........John Wayland