How to properly restore a maintenance-free battery

general information

When trying to understand how to open a Varta battery, it is necessary to clarify the main design features of this unit, its placement in the car and the subtleties of dismantling. To accomplish this task, you need to prepare the following tools and available means:

1. Spanners.
2. Pliers.
3. Instructions for the car.
4. Latex gloves.
5. Sandpaper.
6. Brush or scraper.

To determine where the battery is located, it is enough to carefully examine the engine compartment by opening the hood. If a visual inspection does not bring any results, you need to study the instructions again. Now that the battery has been found, you should make sure that the upcoming dismantling will be easy and quick. In some cars, these units are secured with additional fasteners and equipped with protective covers.

Having seen how the battery is secured, you can begin to remove it.

In most cases, the role of the latch is performed by a metal strip placed on top of the battery and connected by two rods. In some cars, the component is fixed deep in the socket, so it is simply not possible to get to it without a socket wrench and serious investment of time and effort. Before the upcoming work, you need to protect yourself with rubber gloves.

Next you should check the battery terminals. There are two types of batteries used in modern cars:

1. With top terminals.
2. With side terminals.

In the first case, dismantling is carried out using a regular wrench with a suitable size. If there are spring clamps, the wires are removed using pliers. If the terminals are located on the side, then you need to use combination or socket wrenches as a working tool.

Having prepared the necessary devices, you can begin to unscrew the protective covers and latches. The first step is to remove the negative wire from the terminal, which is required to prevent accidental short circuit when in contact with the metal body of the vehicle. After this, you can remove the positively charged wire. The polarity of the battery is indicated on its case in the form of “plus” and “minus” . The main thing is not to confuse anything.

Then it remains to pull out the battery by the handles or corresponding recesses for transportation.

Specifications

The Varta d59 car battery is a maintenance-free type of battery. It has a capacity of 60 ah and a starting current (cold cranking current) of 540 A. The polarity is reversed with the positive terminal on the right. The terminals are also standard 19 mm positive and 17.5 mm negative. The battery has the following dimensions: 242x175x175 millimeters and weighs 14 kilograms.

The main advantages of this model include its body, made of high-quality plastic. It is highly resistant to low and high temperatures, which helps maintain its overall integrity even under the harshest operating conditions.

The overall power density of the VARTA 560410054, which uses innovative PowerFrame technology, far exceeds that of conventional car batteries sold in domestic auto stores. The unique method of creating a battery lattice, patented by the Czech company, called PowerFrame, is responsible for increasing the overall resistance of the battery to damage as a result of exposure to strong starting current, as well as strong vibration that occurs while the vehicle is moving.

Important points

After dismantling the battery, you need to pay attention to the condition of the wire terminals and the unit itself. Often these parts oxidize, becoming covered with a white coating. If such a defect is present, it is enough to treat the surface of the battery with sandpaper. It is also necessary to inspect the seat of the device.

If there are various technical contaminants in it, you need to go through it with a scraper or brush.

At any stage of dismantling, it is important to remember safety rules. Under no circumstances should you smoke near the battery, light matches or a lighter, or come into contact with an open flame source. Such an impact can cause damage to the unit, and in the worst case, ignition of vapors from leaked acid.

If there is a serial number, model name and other technical characteristics on the battery cover, it is recommended to photograph them or write them down on a sheet. The fact is that this data can significantly simplify the upcoming purchase of a new battery.

Maintenance free models

It is no secret that many car batteries cannot be refurbished due to their design features. For motorists who do not want to constantly think about the current state of the power source, this option looks attractive. However, most domestic drivers are accustomed to independently monitoring their car and servicing it in the garage.

As you know, closed batteries are designed in such a way that they cannot be opened, since there are no corresponding fasteners on the structure body.

If you want to dismantle the battery and restore its functionality, it is enough to use certain tricks and tools.

All internal components of the power supply are housed in a durable housing. If we talk about serviced models, they have open access to containers with liquid electrolyte, so the technician can easily take them out, add acid and carry out a number of other activities.

As for maintenance-free devices, they are equipped with a smooth surface, and the entire upper part is located directly under the cover, which protects it from technical contamination. This design can be removable with latches, or monolithic. In the latter case, it is welded to the body by heat welding. Closed batteries often have monocaps.

To open a maintenance-free unit, you need to prepare several tools. If the cover fastening is located on the grooves, it is enough to carefully unclip the fasteners and dismantle the element. You may need to use a flathead screwdriver for this task.

If the assembly is hot pressed, it will not be easy to remove. Any careless actions can lead to damage to the part, so it is better not to dismantle this element in order to maintain its integrity. But if this is not possible, and removal is necessary, it is carried out using a screwdriver, drill or awl. It will not be possible to completely remove the cover, but it is quite possible to make several holes for further work.

How to charge a maintenance-free car battery

So, if a classic battery can, subject to precautions, be charged with almost any direct current source (the simplest “old-fashioned” method is a light bulb with a diode connected in series, connected directly to the mains), then a maintenance-free battery requires a stabilized voltage source that has the ability to limit and control the charging current .

, the voltage should not exceed 14.5-14.8 V. A working battery in this case receives a current determined by its internal resistance - being maximum at the beginning of the cycle, it gradually decreases. This is the basis of the operating principle of automatic chargers - when the current drops to a level of 200 milliamps, the charging cycle is interrupted.

If the charger exceeds the specified voltage, then in parallel with charging the battery, the decomposition of the water included in the electrolyte will begin. In the case of maintenance-free batteries, this is especially dangerous because it is impossible to see the “boiling”: in a classic battery, the process of gas formation is visible through the turned-out plugs, but here they either cannot be turned out or are covered with a battery cover.

Video: How to charge a calcium car battery - RIGHT! Just something complicated

When a maintenance-free battery is significantly discharged, almost all of the sulfuric acid from the electrolyte is consumed by reacting with the plates of the cans, and in fact between them there is water with a small admixture of lead salts and acid. An attempt to connect a charger without current limitation will result in rapid electrolysis of water, and by the time charging begins, its level will decrease. Several such cycles will lead to premature failure of a maintenance-free battery.

Read also: Photos of radio components that contain gold

Therefore, the charger must be able to limit the charging current - for a standard charging cycle, a current that does not exceed 1/10 of the numerical value of the battery capacity in ampere-hours is considered safe. For common 55-amp batteries, the current should not exceed 5.5 A, for 75-amp batteries - 7.5, and so on. If the charger does not have a smooth adjustment of the maximum current, then the nearest lower value is set. When connecting a charger to a severely discharged battery, the current should be limited to half that of a normal cycle.

There are two principles of operation of chargers:

1. DC charging;
2. and impulsive.

In the first case, the device regulates the voltage at its terminals, ensuring that a given current flows through the battery. In the second, the device delivers short pulses, interrupting them when the maximum current is reached - since the electrochemical processes in the battery have a certain inertia, the current does not increase instantly.

Each charging option has its own advantages - pulsed charging “revitals” a discharged battery faster, but the standard charging cycle is slower than when charging with direct current. At the same time, simple automatic devices without a pulse mode are often unable to start charging a discharged battery. Therefore, the best choice for charging a maintenance-free battery is either a device with a forced pulse mode, or one that automatically turns it on at the beginning of the charging cycle.

Primitive chargers, which do not have the ability to limit the current and automatically turn off when it decreases, can be used to charge maintenance-free batteries only as a last resort.

Buying a new one or repairing an old one is a dilemma for car owners whose battery has failed. For owners of modern maintenance-free batteries, it would seem that the choice is clear - buy. Ingenuity and knowledge of battery design will help extend the life of a “dead” energy source.

Winter is a real test for car enthusiasts. A working car may not start in the morning if the battery misfires. If you purchased a maintenance-free one and it let you down, don’t be upset, you can charge it, check it and continue using it.

Subtleties of autopsy

If the task is to maintain a closed battery, it must be done taking into account several subtleties. When a motorist wants to remove lead from a non-working unit (for example, for hunting or fishing), there is no need to be afraid of breaking the body with a hammer or any other object, but before doing this, you must first drain the acid solution.

If you want to extend the service life of the battery, you need to carefully make holes that will provide access to containers with electrolyte. The following steps should be followed step by step:

1. Remove stickers from the surface of the case.
2. Carefully inspect the structure. Given the tightness of the lead-acid model, it should retain the factory stampings of the plugs.
3. Using an awl, drill or any other tool, make small holes in the desired location.

Varta battery

Varta batteries are widely used due to their high quality and affordable price. Information - how to remove the cover from the Varta battery will be useful to many car owners.

Everything is clear with the serviceable Varta batteries; if desired, they can be opened; all you need to do is have a tool available. As for Varta's maintenance-free batteries, their entire upper part is protected by a cover. This design can be removable or monolithic. With a monolithic design, the top cover is “seated” on a heat seal. Is it possible to remove this Varta battery cover?

Battery VARTA SILVER

You will need a tool to remove the top cover. If the cover is fastened using grooves, you need to undo the fastening and dismantle it. When the battery is pressed in, it is difficult to disassemble it. Careless actions may damage the battery. Therefore, it is better to refuse to dismantle the Varta battery in order to preserve its integrity.

It turns out that the cover from the Varta battery cannot be removed. However, if to service the Varta battery it is necessary to add working fluid, this can be done using a drill, awl or screwdriver.

Although it will not be possible to remove the cover, it is quite possible to drill holes for adding liquid.

To do this, do the following:

• the Varta battery case is freed from stickers;
• on the lid you need to find the stampings of the plugs;
• Using an awl or drill, holes are made in these places.

Restoring a non-working part

It is no secret that productive and long-term operation of a battery significantly deteriorates its performance properties. As a result, after a certain period of time, the car owner is no longer satisfied with the performance of his vehicle. If your car has a sealed battery, there is no need to rush to throw it in the trash and buy a new unit. Knowing how to open a Varta d43, c15 or any other model battery, you can restore it in the near future.

First you need to dismantle the cover, following the established diagram. After this, access to the working components of the battery will be open, so any repair work will not take much time.

Closed battery models are equipped with an electrolyte level change indicator. Most modern devices have a translucent body or labels that provide free control of the solution flow in containers. To check the current level, you can use a regular tube, syringe or other object that is inserted inside the jar. The optimal volume of solution is 10−12 mm of substance above the plates.

It is important to take into account the fact that the electrolyte level and its density are the most important parameters of the normal condition of the battery. To determine the current characteristics, it is enough to use a hydrometer. You can also take a syringe, insert it into the hole and withdraw the acid from the container. Then you need to pour it into the device and track the readings. If the fluid density is too low, the battery will not be able to function fully.

Where is Varta Blue Dynamic d59 used?

The Blue Dynamic D59 battery (ETN code 560 409 054) was developed specifically for use in modern passenger cars with standard electrical equipment without a start-stop system.

The Varta D59 battery has received official approval for use in cars from the most famous automobile brands.

Such car batteries are characterized by high reliability even in the most severe operating conditions. Thanks to the use of innovative technologies, batteries in the Blue Dynamic model line are able to maintain a normal charge level for a long time, even during prolonged exposure to the street in very low air temperatures, which is especially important for residents of the northern and eastern regions of our country. In cold weather, this model provides 10 percent more powerful starter rotation current than other car batteries, which makes it easier to start both gasoline and diesel engines.

In addition, the robust body design guarantees increased resistance to vibrations, which is important for our less-than-ideal roads.

Step by step guide

There are many reasons why motorists become interested in how to remove the cover from a Varta battery. If there is a need to perform such an action, you need to remember that each stage may have its own difficulties. To avoid disappointment in the future, it is better to study the working nuances in advance.

Before disconnecting the car battery, you must review the service manual in detail. Some modern machines are equipped with a special lever that turns off the unit. There may also be a shield with a toggle switch on the body. To quickly and efficiently disable the device, it is important to read the manufacturer's manual. By the way, there are also cars that do not support disconnecting the battery. Instead, they require parallel installation of a new part to replace the old one.

To avoid sparks jumping during dismantling, it is better to install a special fuse on the vehicle. It is mounted at the output, with a negative charge. As at all other stages, it is important to be careful and attentive here, since any mechanical damage can break the seal, and the crack formed will become a place for the leakage of a liquid substance - electrolyte.

Manufacturer Exide

The manufacturer of Exide batteries is the international concern Exide Technologies, which includes several large industry enterprises located in different countries of the world. The origins were the American Electric Storage Battery Company, created back in 1888.

Advertising stand

Exide Technologies today is a recognized world leader in the production of rechargeable batteries. Continuous improvement of production, development of new technologies and vigilant control allow the corporation to maintain the trust of leading vehicle manufacturers.

Safety precautions

If you want to remove the battery yourself, you should not forget about basic safety precautions. Absolutely forbidden:

1. Throw the device on the ground or allow it to fall into the open hood.
2. Turn the knot over with sharp movements.
3. Press firmly on the terminals and try to place them on the terminals.
4. Completely pouring the liquid out of the battery will lead to unpleasant consequences in the form of sediment that has accumulated at the bottom for a long time floating up, as well as clogging of the holes.
5. Use force when dismantling or reinstalling the system.
6. Work with a discharged device in cold conditions, at sub-zero temperatures.
7. Add electrolyte or any acid to the battery yourself. The only liquid that can be added is distillate.

When dismantling, it is enough to use two wrenches of the appropriate size. You also need to take a rag or brush to thoroughly clean the interior from dirt.

If at any stage an electrolyte spill occurs, it will be necessary to apply a neutralizer to prevent the reaction from activating.

When working with an acid battery, it is necessary to prepare the alkali in advance. To do this, you can use a solution of 10 percent alcohol or soda. Alkaline batteries are treated with acid. It is recommended to carry out such actions outdoors or in a well-ventilated garage.

Compliance with the basic rules of battery maintenance will allow you to restore a non-functioning unit in a short time and without much effort. If you know how to open the Varta battery with your own hands, then the need to contact a service center for help will automatically disappear.

Modern power supplies for cars require less and less human participation during operation. Maintenance-free batteries do not need to be topped up with water or electrolyte throughout their entire operating life. If the owner likes the battery, but the indicator indicates that the resource is exhausted, is it possible to restore the battery? How to open the battery and get the lead plates for fishing?

What can happen when opening the case?

If you open the battery case, this will lead to the fact that the water from the electrolyte will constantly evaporate and the battery will need to be refilled as if it were being serviced. Disassembling the battery in any way will void the warranty . For modern products, the manufacturer's warranty can range from 12 to 36 months.

Important! If the battery is under warranty, then before opening it and repairing it yourself, take it to a service center, maybe they can help you there.

Disassembling a battery is not always possible without chips getting into its housing. In addition, during operation of a battery opened in this way, dust and dirt may get inside the cans. Foreign objects inside the case, to put it mildly, do not contribute to increasing the service life of the product.

Do you have any questions, haven’t been able to solve the problem, or have something to add to the article? Then write to us about it in the comments. This will help make the material more complete and useful!

Is it possible to disassemble a maintenance-free battery?

The maintenance-free nature of the power supply is attractive for those who do not want to worry about the condition of the power source once again. At the same time, many are accustomed to monitoring all elements of the automotive system. It is traditionally believed that a closed battery cannot be opened. Indeed, there are no technical holes on the body of such batteries. However, if you want to make a car battery serviceable or remove lead from it, then you can disassemble a maintenance-free power supply. To do this, you will need some tools and knowledge of safety rules.

What types of lids are available?

The contents of any car battery are enclosed in a housing. Serviced batteries are distinguished by the ability to gain access to the banks and, if necessary, add electrolyte or distilled water. The maintenance-free closed-type battery is characterized by a smooth surface of the housing. To avoid any contamination, the upper part of the battery is retracted under the cover. It can be removable - with latches or monolithic - heat welded to the body. Most often, a closed type battery has a monocap.

What tools are needed for opening

To gain access to the filler holes, even if they are filled at the factory to the surface level of the case, you must remove the cover from the battery. How to open the battery cover? If it is on the grooves, then carefully unclip the fasteners and remove the element. You may need a flathead screwdriver.

A hot pressed part will not come off easily. During its dismantling, there is a high probability of the part breaking. Therefore, we do not recommend removing this type of element. However, if you wish, you can try to break the integrity of the part using an awl, screwdriver or drill. You will not remove the cover completely, but you will be able to make holes for further operations.

Why does such a question arise at all?

Everything is also simple - when charging the battery, when the battery is already completely “saturated”, this happens in all six “banks”. Accordingly, if you charge such a battery, the seething will only intensify with each passing hour - the caps are not unscrewed, and therefore pressure is created inside, which can damage the plastic case!

However: – the housings, as usual, are designed for such pressure and can withstand even many hours; you are unlikely to recharge for more than a few hours - this can only harm the batteries.

How to open a maintenance-free battery

There are not many ways to open a closed-type power source, and they depend on the intended purpose. If you need lead (for hunting or fishing), then you don’t have to worry about opening the battery and just break its case.

In order to extend the life of the battery, you need to make holes that will give access to the banks.

• Remove the stickers from the surface of the battery.
• Carefully inspect the body. Since the sealed lead-acid battery was filled at the factory, stamping of the plugs remained.
• Take an awl, screwdriver or drill and carefully make holes in place of the bays.

This simple procedure requires care, but allows you not to purchase a new power source, but to restore the functionality of the existing one.

Reviews

Maxim 42 years old Excellent battery, I recommend it to all my friends, in three years of use it has never failed. Only after the car had been idle for a week in severe frost did it have to be charged.

Alexander, 30 years old I have Warta batteries on all three cars, everything is fine. The cars start easily even in the most severe frost, which is very important in my region of residence.

Vyacheslav 25 years old The battery is really good, the only negative is that it is considered maintenance-free, but with the right skill you can get to the plugs and fill in new electrolyte.

How to turn a maintenance-free battery into a serviceable one

The time comes and the car owner is no longer satisfied with the characteristics of the battery. If you have a sealed battery, you shouldn’t throw it away and buy a new one. You can make it serviceable if you open the lid using the method we described above. This will allow you to carry out a number of procedures necessary to maintain the functionality of the power source.

The ability to check and change the electrolyte level is one of the signs of battery serviceability. Closed batteries are equipped with an indicator that allows you to see the electrolyte level. Some containers are made of translucent materials or have markings that help you keep track of the amount of solution in all jars. The electrolyte level can be checked using a special tube or syringe by inserting them into the holes made in the lid. The normal amount of solution corresponds to 10–12 millimeters of liquid above the plates.

Do not forget that not only the acid level, but also its density is an important characteristic of battery performance. Data on the density of the solution can be obtained using a hydrometer. Take a syringe, insert it into the hole on the lid and take the electrolyte from the jar. Pour into the hydrometer and watch the readings. Too low a density (less than 1.22 g/cm3 at temperatures up to +6) does not allow the battery to work fully and indicates a small amount of electrolyte and the need to replenish it. Increased density or insufficient level of solution requires adding distilled water.

Battery hydrometer.

Read more about the process of adjusting density in our article: How to use a hydrometer correctly.

Check the electrolyte level using a transparent tube.

Please note that excessive concentration of electrolyte leads to tragic consequences - sulfation and destruction of the plates.

The figure shows the electrolyte density values ​​under various conditions.

After completing the work of adding water or acid solution, the holes in the lid must be sealed with sealant.

Solite battery

Korean Solite batteries are popular due to their wide range of models and reasonable prices. The batteries have good performance and excellent quality. Unfortunately, Solite batteries are maintenance-free, but this is not a problem. You can add working fluid to the battery, measure the density with a hydrometer and charge the battery using the above method.

There are hundreds of training videos on the Internet on how to perform the technical correctly. servicing a maintenance-free battery. During the maintenance process, do not forget about safety measures when performing this type of work. It is prohibited to throw the unit, turn it upside down, completely pour out the working fluid from it, etc.

How to open the varta battery cover

The German company Varta was founded in 1887 and since then has been producing and repairing all types of batteries. Currently, the German company Varta is rightfully considered a leader in the production of rechargeable batteries of all types. The batteries are manufactured in 6 factories in 5 European countries.

Varta car batteries produced are used by European car manufacturers for installation in new cars. More than 20 million Varta batteries are produced per year, which in foreign currency equivalent amounts to more than half a billion euros.

Varta is an abbreviation (Vertrieb, Aufladung, Reparatur Transportable Akkumulator) - in other words Sales, Charging, Repair of Transportable Akkumulator.

Advantages of VARTA batteries

• Since 2002, the South American company Johnson Controls has been creating Varta starter batteries.
• Does not require topping up water during the entire service life (completely maintenance-free).
• Greater operational safety due to the labyrinth design of the lid.
• The Silver Dynamic series batteries have a 30% increased starting current.

VARTA SILVER DYNAMIC – the greatest power for the greatest demands.

The top product of the dynamic TRIO series impresses with its internal features: reliable power supply with a very large number of power consumers, very high cold start performance even in extreme conditions and the largest reserve capacity. The power properties exceed the requirements of international car manufacturers.

Advantages of SILVER dynamic

VARTA BLUE DYNAMIC is a powerful all-rounder.

Safety precautions

• We strongly recommend using protective equipment when disassembling the power supply. It is strictly forbidden to turn over or shake the jars. This may cause a short circuit.
• If the battery cover is secured with fasteners, be careful not to break them. In the event of a breakdown, the part will have to be glued, and this does not guarantee safe operation of the power source.
• If you want to split the battery using a tool, choose special products that will help protect your eyes from splinters.

Can we safely say that a maintenance-free battery can be made into a serviceable one? Of course, a closed battery can be remade! If the purpose of opening the battery is to extract lead for fishing or hunting, then by observing a number of precautions, you can easily do it with just a hammer.

The development of electrical energy storage systems using chemical processes helps create truly useful maintenance-free devices, thereby significantly simplifying the life of motorists. On the other hand, the slightest innovation in battery design is immediately used by companies selling car batteries to effectively present the undeniable advantages of their products.

From advertising slogans, new battery designs looked like they did not require human intervention for normal operation. A more than attractive offer, especially if a person already has negative experience with servicing and charging batteries.

What does a maintenance-free battery mean?

The main task in servicing batteries of classical design was to maintain the specified density and electrolyte level. High temperature and overcharging forced periodic replenishment of water losses in the battery banks. The first maintenance-free batteries appeared in the United States in the early 1980s. Thanks to the use of an alloy with a calcium content of up to 0.1% and tin up to 0.12% for the fittings of electrodes and jumpers instead of lead, it was possible to significantly, almost six to seven times, reduce the intensity of gas evolution and self-discharge. Water losses were small and did not require replenishment for more than two years. The market has dubbed such structures “maintenance-free.”

Modern designs of maintenance-free batteries appeared on the markets of the USA and Western European countries in the late 90s. After numerous experiments, a multicomponent high-purity alloy was developed, which already contained additives of silver, aluminum, calcium, tin, and antimony.

Specifications

Varta Blue Dynamic D43 was developed using the most modern German technologies for vehicles of all classes. It refers to maintenance-free batteries. The capacity is 60 Ah, and the cold cranking current is 540 A. The polarity is straight. The battery dimensions are 242x175x190 mm with a total weight of 14.34 kilograms with filled electrolyte. ETN: 560 127 054.

The battery uses PowerFrame technology, which significantly increases service life, increases starting current and reduces energy consumption. This makes it possible to start the engine even in the most severe and cold conditions. The rate of destruction of the mesh from shaking and corrosion is also reduced.

The main distinctive advantages of Varta Blue Dynamic D43:

• Complete environmental safety;
• Increased starting current in comparison with the main competitors;
• Reasonable cost taking into account the highest quality and long service life;
• Providing an official guarantee from the manufacturer;
• Application of new technology in the manufacture of the internal structural lattice of the battery. This helped to increase its reliability even with constant exposure to vibration while the vehicle was moving on an imperfect road surface;
• Full compliance with high European standards and requirements set by global automakers;
• The use of a new chemical formula of the electrolyte, which improved the battery's resistance to negative temperatures and reduced its self-discharge rates.