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Before using OP-1 on batteries that have lost power storage capacity, it is important to know
the condition of the battery that OP-1 is repairing.

CHECKING BATTERY VOLTAGE

Note the battery volts first. For automotive 12V batteries the minimum volts should be
above 10.5Volts and for a 6V battery it should be above 5.25Volts. These parameters for
automotive batteries are valid for a battery that has been removed from service within in
30 days. If the batteries are removed from service for more than 30 days then the volts may
be on lower side. Such batteries should be charged for 2 to 3 hours and then disconnected
from the charging machine. Allowed the battery to settle for 12 hours and then measure the
volts. If the volts are above the minimum requirement as mentioned above, the battery is
subject to further investigations. For traction batteries (forklift batteries etc.) the minimum
volts should be 1.75 per cell.

CHECKING FOR MECHANICAL FAULTS

It is very difficult to find mechanical damage to a particular cell or cells in a lead acid battery.
This is a list of some of the important steps that you can take to find a mechanically
damaged cell.

After you have noted the battery volts and specific gravity in each cell, connect the battery
to a charging machine. Apply the normal charger that you use for your battery, normally it
should be 8 to 10% of batteries rated capacity. Carry out battery charging for 3 hours.
After 3 hours observe the following while the battery is still being charged.

(1) Is there a uniform bubbling or gassing reaction in each cell?

(2) Is there any one or more cells giving a lot of bubbles as compared to other cells?

(3) Is there a notable rise in battery electrolyte temperature of the cell that is excessively
bubbling?

(4) Is the current passing in each cell? If there is no bubbling at all in a particular cell or cells
then that cell has a permanent mechanical failure.

If all the cells are giving uniform reaction and normal gassing is observed then the battery
has a better chance of being fixed.

If one or more cells are giving exceptionally high bubbles or gassing then it is possible
that such cells have heavy shedding of active materials, separator puncture, mechanical
short, or sludge formation at the bottom area. Such cells will not give any improvement
in the specific gravity and will remain same as it was before battery was put to charge. Such
batteries should be discarded.

Most batteries that have been sulfated will give a rise in electrolyte temperature but will
not have uneven gassing in all the cells, such batteries can treated with OP-1.
2 of 3

If you find that there is an improvement in battery volts and gravity in each cell those
batteries should work well with OP-1.

Another simple method of finding the amount of battery sulfation is to find out the
power storage capacity left in the battery. Suppose your healthy battery gives 6 hours
of power at a particular discharge current but due to sulfation it has now come down to
only 1 hour. That means the battery has lost 5 hours of power storage capacity due to
sulfation. Since the battery has still one hour power storage capacity, it confirms that
there is no mechanical damage and the battery can be treated.

ADDING OP-1 TO YOUR BATTERY

Please add the specified amount of OP-1 required as instructed by the ADDITIVE
INFORMATION CHART included in this packet.

CHARGING THE BATTERY

Proceed wtih normal battery charging and continue to charge the battery till full gravity
is observed in each cell and the battery volts reaches above 15.5V for a 12V battery and
7.5V for a 6Volts battery. For traction batteries this should be 2.6volts per cell. For
example for 36volts battery it should be 2.6volts X 18 cells= 46.8 volts minimum. These
are online volts while battery is on the charging machine.

The fully charged battery should then be removed from the charging machine and
allowed to settle to room temperature. When the battery has cooled to room
temperature, note the volts and gravity in each cell. You will find that the battery is
showing more than nominal volts of the battery. All the cells will show at least 1.200
specific gravity in each cell.

DISCHARGING THE BATTERY

A charged battery is required to be discharged for sulfation removal. Discharging can be

carried out using standard discharge testers or dc halogen bulbs. Complete discharge
is recommended. Recharge the battery/discharge the recharged battery for at least 3 to
4 times for complete removal of sulfation.

LOAD TEST OF A BATTERY

After the battery has been cycled for charge/discharge, carry out a load test as per
standard load testing procedure. We strongly recommend that once you find during
the course of battery operations that battery has gradually started to loss power storage
capacity, you must immediately add OP-1 to each cell to prolong the life of the battery
because once the battery begins to lose its power storage capacity and if not treated
there will be faster sulfation and more corrosion of the positive plates resulting in
permanent damage to the battery.
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VRLA, SLA BATTERY (sealed type)

RENEWAL WITH OP-1

In the case of VRLA, SLA batteries, you will find a plastic strip on the top of the battery case.
First remove this strip with the help of a screw driver or a knife. Once you remove the
strip, you will find that there are 3 or 6 (3 for 6Volts and 6 for 12Volts) small vents which
are covered with a rubber cap. Remove the rubber caps from all vents. Then add the
required quantity of OP-1 in each cell. (Quantity of OP-1 required depends on the size
of the battery, add 5 ml OP-1 per cell for 7 ah to 50 ah, 7 ml per cell for 55 ah to 80 ah,
8 ml per cell for 88 to 120 ah, 10 ml for 130 ah to 150 ah, and 12 ml per cell for 160 to
200 ah capacity battery)

After adding OP-1 add distilled water up to plate height in each cell. After water has been
added, shake the battery to and fro for a few times for uniform mixing and then leave the
battery for 24 hours in idle condition during this time OP-1 will go to the battery plates.
After 24- hours carry out normal charging of the battery. Besure not to charge more than
5amps and dont let the battery ever heat or the battery will be no good. Also you will notice
a considerable amount of gas being produced and small amounts of liquid bubbling out
of the battery while charging and discharging, this is perfectly normal and a towell should
be left on the battery to prevent liquid splashing everywhere. The protruding liquid also
contains acid so take caution and avoid eye contact.

The fully charged battery should then be discharged. Repeat 3 to 4 charge -discharge
cycles to remove the sulfation completely.

Once the battery has come to the required level of capacity, close the vents with rubber
caps and reseal the top with the strip using suitable adhesive.
We strongly recommend that all new batteries or in-service batteries be treated with OP-1
to inhibit sulfation for a longer sulfation free battery life. For new or in-service batteries no
cycling is required and doulble of your batteries warranty time will occur.

We have found that many people use higher than recommended amperes or charge the
battery for a longer time than required to charge the battery when the battery capacity
has been going down. We strongly advise not to do so because this practice will further
damage the battery.

We have also found that many people use fast chargers to save the battery charging time,
we strongly advise not to use fast chargers since it will increase the internal temperature
and water loss from the battery. Fast charging could also damage the positive plates.

We welcome your questions and suggestions to improve the way we use batteries.

Gary Shiomi
API alpha product innovation Co.. Ltd
271-3 Tatsugahara Yameshi, Fukuoka, 834-0067
Tel: +81 92 0943-24-1873
Cell: +81 92 090-6779-0430
garysapi@gmail.com
garysapi@yahoo.com
Skype: garyshiomi
OP-1 Additive Information Chart
10cc = A soda capful 5IJT
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Additive information chart

Amp hours No of cells cc’s to be added total cc’s required

to each cell for 1 battery Battery type
5cc Small vehicles
5cc Large vehicles
Golf carts
Mini Bus
Large trucks
and busses

Solar Batteries

Forklifts

Large Industrial
batteries

+ Others