DLG DI-215 User manual

V3
Model：
DI-215(12V)
DI-215A(12V/24V)
AUTOMOTIVE BATTERY
SYSTEM ANALYZER
OPERATING MANUAL
DLG
Diligent Instruments Corporation
Address: 2802 Fanshawe Street Philadelphia, PA 19149
Phone: [phone]
Email: [email protected]
www.diligentinstruments.com
Product distributed in the United States by Diligent
Instruments Corporation and made in China.

1. Brief Introduction
2.Safety Rules And Attentions
3.International Electric Symbol
4.Structure Of Meter
5.Instructions Of Functions
5-1 storage battery voltage mode setting
5-2 storage battery test
5-3 engine system activation load test
5-4 maximum load system test
5-5 charging system test
6.FAQ ……………
6-1 What is the measurement principle of this tester ?
6-2 Can it be affected by the installation of negative current inside the
vehicle?
6-3 Can this tester predict when does the battery become useless?
6-4 Is the CCA value tested by this tester correct?
6-5 What is the difference between the method of this tester and the load
test method?
7.Specification Of Storage Battery
7-1 JIS translation table
7-2 comparison table of DIN/EN
8.Knowledge About Automobile Battery
8-1 the internal resistance of different types of battery differ
8-2 it is unavailable to know the electric quantity of storage battery by
guessing
8-3 some common abbreviation meaning of storage battery standard
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CONTENT
★ DIN－Deutsches Institut für Normung e.V.
Under a cold temperature of 0°F（-18°C）, the Ampere quantity is 9.0V
30 seconds with the lowest voltage, while 8.0V 150seconds.
★ IEC－ International Electrotechnical Commission
Under an average current, every battery cooled in the situation of 0°F （-
18°C）can load the lowest voltage of 8.4Vfor 60 seconds.
★ BSR－Battery Saving Ratio
Under an average current, every battery cooled in the situation of 0°F
（-18°C） can load the lowest voltage of 6.0Vfor 180 seconds.
★ BCI－Battery Commission of International
Under an average current, every battery cooled in the situation of 0°F
（-18°C）~ -20°F（-29℃）can load the lowest voltage of 7.2V for 30
seconds.
19

1
1.Brief Introduction
DI-215 series battery storage testers are used for activated style lead-
acid storage battery, along with checking the following conditions of the
battery, starting up, charging, and electrical loading. With great design, easy
operation, precise reading, complete functions, this tester supply the
readings by a large LCD and hints by sound and light when testing. Precise
circuit and strong digital processing unit make it complete collection of a
series of complicated data and figure out every test data, which availably by
4-wire Kelvin test connection. Besides it strengthens input protection inside ,
in order to prevent such situations as polar reversal connection , over-high
voltage input, poor contact of the test clamps and so on. That makes sure
safer and more convenient when testing.
This tester is the best tool for battery sales, vehicle repair and condition
check of all kinds of lead-acid batteries that used in equipment system
associated with lead-acid battery.
2.Safety Rules And Attentions
This manual includes instruction, operation warning and maintenance. It
is possible to damage the tester without regulations in this manual. This
tester is designed and produced strictly according to GB4793.1 electronic
measurement instrument safety requirement and IEC/EN61010-1 safety
standard. It also reach double insulation over voltage standard CATⅢ 600V
and pollution degree 2 .
(1) DI-215 is available to vehicle of 12V storage battery, DI-215A is suitable
for testing 12V and 24V lead-acid storage battery.
(2) The working voltage of DI-215 is DC 9V to 18V, while that of DI-215A
refers to DC 9V to 35V. Make sure do not check the series connection battery.
(3) The voltage value will be higher than that in the normal situation after the
checked battery being fully charged . Please turn on the headlights for 2 to 3
water), on the contrary shorten its life fast for the reason that it will increase
the acidity of battery water, not the voltage however.
8-3 some common abbreviation meaning of storage
★ RC－Reserve Capacity
Every storage battery has the ability to load averagely 25A electric
perminute and maintains lowest 10.5V more or less in the situation of
80°F(27°C).
★ CCA－Cold Cranking Ampere
With the fixed current, every battery can be cooled in the situation of
0°F（-18°C）~ -20°F（-29°C）for 30 seconds and maintain the lowest
voltage of 7.2V. The unit of CCA is Ampere. For some vehicles, especially
long time used ones, it is hard to start the engine smoothly, and has to be
done twice or for some seconds. Actually the electricity consumes most
when starting the engine. The voltage drops off from the normal value 12.5V
to 10.5V even lower at the moment that large current discharge shortly. The
large CCA is very helpful to start the engine smoothly.
★ CA－Cranking Ampere
The main meaning is very close to that of CCA. The unit is Ampere also.
The temperature under testing is the only one difference between them. CCA
refers to the result that measured under -17.8°C, and CA refers to the result
that measured under 0°C. If there indicates both CCA and CA on the battery,
CCA value is lower for the reason that the lower temperature is, the worse
battery works.
★ AH－Ampere Hour
This is a standard written by Japanese Industrial Standard (JIS). It is
explained that the battery discharges with a fixed ampere for 20 hours along
with over 10.5V. Therefore the value multiplied by a fixed ampere and the
number of hour is Ampere Hour. For example a battery discharges with 5
ampere fixed for 20 hours, its Ampere Hour is 100.
18

minutes, then check the battery when it’s voltage value drop to the normal
value.
(4) Check the insulating layer of the clamps before measuring. Damage,
bareness and disconnection are unacceptable. It is forbidden to use without
covering the rear cover correctly, which can cause electric shock.
(5) Do not use or store the tester in the condition of high temperature, high
humidity, combustibility, explosion and strong electromagnetic field.
(6) Do not change the internal circuit at will in order to avoid damaging the
tester and keep safe.
(7) Wear proper eye mask when testing or repairing in order to avoid some
objects hitting eyes by the engine.
(8) Make sure ventilation when testing or repairing in order to avoid smelling
some toxic gas.
(9) When the engine is working, do not put the tester or accessories beside
the engine or exhaust pipe in order to avoid damaged by high temperature.
(10) Make sure that repair vehicle under the warnings and attentions in the
right procedure written by the manufacturer.
(11)Standard of optional storage battery:
CCA: 100-1700
I E C: 100-1000
E N : 100-1700
D I N: 100-1000
J I S: need to compare CCA with the table
2
17
8. Knowledge About Automobile Battery
8-1 the internal resistance of different types of battery differ
The internal resistance differs because of inconformity of internal
chemical feature even if with the same type battery. It is very small so that we
generallydefine it with unit of milliohm. Internal resistance is a
significanttechnical standard to measure a battery. Normally the battery with
small internal resistance has a great ability to discharge. On the contrary the
battery with large internal resistance has a little ability to discharge.
8-2 it is unavailable to know the electric quantity of storage
battery by guessing
Hydrometer can be used to check the condition of the battery. Battery
water is distilled water and pure sulfuric acid of the proportion of 1.260/20 ℃
to allocate. For a new battery, it is supposed to supply distilled waterwith
reduction of battery water for the reason that the degree of acid is fixed when
the quantity of battery water remain the normal range. Distilled water
supplement can maintain a certain amount of water, but alsothe PH value. If
the battery works normally, in addition to the PH is fixed, the proportion of the
value will be in a certain range.
If the battery finishes charging, the proportion of battery water does not
reach 1.26-1.28, along with the tested voltage under 12.7V, the storage
capacity of this battery has descended. It is impossible to recover its life by
deliberately adjusting the proportion to 1.26 (Increase the sulfuric acid
Battery of small type vehicle
Voltage(V)
Electric(%)
Proportion
>12.7
100% 1.26~1.2 8
12.6
90% 1.2 4
12.4
70~80 % 1.2 2
12.1 50% 1.16
<12 25%<1.13

3
3.International Electric Symbol
4.Structure Of Meter
Introduction of button and clamp
<▲><▼>:increase, decrease,
turn up/down the page
<ESC>:cancel, undo, return
<ENTER>:select, enter, test
the red clamp: positive connection
the black clamp: negative connection
5.Instructions Of Functions
5-1 storage battery voltage mode setting(DI-215A)
Before testing, set the tested voltage according to the type of battery
voltage. Select 12V mode for a 12V battery. Select 24V mode for a 24V
battery. And then head to the following testing :storage battery test, engine
system activation load test, maximum load system test, charging system test.
DC
AC
DC/AC
warning
dangerous voltage(electric shock)
earth
double insulation
fuse
battery
16
Model The same model DIN EN Model The same model DIN EN
54523 54524 220 300 58521 58513 320 540
54537 54545 54801 190 300 58522 58514 320 540
54551 54580 220 300 58815 58821 395 640
54533 54577 54579 220
300
58820
54584 54578 220 300 58827 400 640
54590 210
330 58838 58833
88092 400 680
54827 240
360 59040 59017
59018 360 600
55040 88056
265 450 59218 59219
290 480
55041 55042 220 360 59226 59215 450 760
55044 55414 88056 265 450 59514 320 540
55046 300 510 59518 59519 395 640
55056 320 540 59615 59616 360 600
58515 58527 395 640
55057 54827 88156 320 540 60018 60019 250 410
55068 55069 55548 220 390 60026 58811 440 720
55218 255 420 60044 60038 500 760
55414 55415 55421 265 450 60527 60528 410 680
55422 55566 55040 265 450 61017 61018 400 680
55428 55423 55427 300 510 61023 62529 450 760
55457 265 450 61047 61048 450 760
55529 220 360 62034 62038 62045 420 680
55531 55545 55559L 255 420 63013 470 680
55559 55530 88056 255 420 63545 63549 420 680
55564 55552 55563 255 420 64020 64317 64318 325 550
55564 55565 55548 255 420 64028 64035 520 760
55570 55567 55565L 255 420 64036 460 760
56012 230 390 64317 64318 64323 540 900
56048 56068 56069 250 390 65513 540 900
56049 56069 56073 250 390 65514 65515 570 900
56077 56030 300 510 67043 67045 600 1000
56091 55811 360 540 68032 68034 600 1000
56111 55048 300 540 70029 70038 70027 630 1050
56218 56092
300 510 70036 68040
68021 570 950
56219 56216
300 510 71014 71015
700 1150
56220 280
510 72512 680 1150
56225 56323 300 510 73011 740 1200
56318 56312 56311 300 510
continue table
LCD
button
testclamp

4
5-2 storage battery test
5-2-1 preparation
If the engine is working, please turn off first and switch the key to off
location.
After driving for a while, the voltage value will be higher than that in the
normal situation after the checked battery being fully charged . Please turn
on the headlights for 2 to 3 minutes, then check the battery when it’s voltage
value drop to the normal value.
5-2-2 operation procedure
(1) Make the red clamp connect to the positive polar , and the black to the
negative. Make sure all connections are well contacted in order to void
affected result.
(2) Press <▲><▼>button to select test function, and then press <ENTER>
further. See the picture:
(3) Press<▲><▼>button to select test standard according to the standard of
storage battery. If it is JIS standard, need to check CCA with the comparison
table. Then select CCA(SAE) as the test standard to press <ENTER> further.
See the picture:
(4) According to the value indicated on the battery, press <▲> <▼> button to
adjust the reference value of the battery. Long press <▲> <▼> button to
adjust the number continuously. See the picture:
15
7-2．comparison table of DIN/EN
34B19RS NS40ZAS 270 325 400 80D26R NX110-5 580 580 630
34B19LS NS40ZALS 270 325 400 80D26L NX110-5L 580 580 630
46B26LS 360 145G51L N150L 780 900 1100
48D26R N50 280 360 420 150F51R NT200-12 640
48D26L N50L 280 360 420 150F51L NT200-12L 640
50D20R 310 380 480 165G51R NS200 935 980
50D20L 310
380 480 165G51L NS200L
935 980
50D23R 85BR60K 500 170F51R NX250-12 1045
50D23L 85B60K 500 170F51L NX250-12L 1045
50B24R NT80-S6 390 180G51R NT250-15 1090
50B24L NT80-S6L 390 180G51L NT250-15L 1090
50D26R 50D20R 370 195G51R NX300-5 1 1145
50D26L 50D20L 370 195G51L NX300-51L 1145
55D23R 355 480 500 190H52R N200 925 1100 1300
55D23L 355 480 500 190H52L N200L 925 1100 1300
55B24R NX100-S6 435 420 500 245H52R NX400-20 1530 1250
55B24L NX100-S6L 435 420 500 245H52L NX400-20L 1530 1250
Battery CCA Battery
NEW JIS OLD JIS MF CMF NEW JIS OLD JIS MF CMF
CCA
continue table
Model The same model DIN EN Model The same model DIN EN
52805 52815 180 240 56420 56322 88066 300 510
53517 175 300 56530 56618 56638 300 510
53520 53521 53522 150 240 56618 56619 56620 300 510
53625 53638 53836 175 300 56633 56647 56641 300 510
53646 53621 88038 175 300 56820 56821 56828 315 540
53653 53624 53890 175 300 57024 57029 315 540
54038 54039 175 300 57113 57539 400 680
54232 175 300 57114 56821 88074 400 680
54313 54324 54464 220 330 57218 57219 420 720
54317 54312 88146 210 360 57220 57217 420 720
54437 54466 54459L 210 360 57230 380 640
54459 54434 88046 210 360 57412 57413 57412L 400 680
54469 54449 54465 210 360 57512 57513 57531 350 570
54519 54533 54612 210 360 58515 58424 450 760

5
(5) After adjusting the reference test value of the battery, press <ENTER> to
star testing.
(6) It will display the result after finishing test:
(7) Press <ENTER> to indicate if the test report required to print (refer to 5-6).
Press <ESC> to return step (2) to select test function of the battery.
5-2-3 instruction of test result
★ Normal
Voltage of the battery: 12.41V
Fully charged 100% 12.78V
75% 12.54V
50% 12.30V
25% 12.12V
Totally discharged 11.94V
CCA value 588CCA
Check the condition of battery
When selecting 24V test, CCA equals half of the sum of two groups 12V
Battery CCA Battery
NEW JIS OLD JIS MF CMF NEW JIS OLD JIS MF CMF
32C24L N40L
240 325 400 75D26L F100-5 L
490
34B17R
280 75D31R N70Z
450 540 735
34B17L
280 75D31L N70ZL
450 540 735
34B19R NS40ZA
270 325 400 80D23R 580
34B19L NS40ZAL 270 325 400 80D26L 580
36B20R NS40Z 275 300 360 85B60K 500
36B20L NS40ZL 275 300 360 85BR60K 500
36B20RS NS40ZS 275 300 360 95D31R NX120-7 620 660 850
36B20LS NS40ZLS 275 300 360 95D31L NX120-7L 620 660 850
38B20R NX60-N24 330 340 410 95E41R N100 515 640 770
38B20RS NT60-N24S 330 340 410 95E41L N100L 515 640 770
38B20L NX60-24L 330 340 410 105E41R N100Z 580 720 880
38B20LS NX60-24LS 330 340 410 105E41L N100ZL 580 720 880
40B20L 330 105F51R N100Z 580
40B20R 330 105F51L N100ZL 580
42B20R 330 115E41R NS120 650 800 960
42B20L 330 115E41L NS120L 650 800 960
42B20RS 330 115F51R N120 650 800 960
42B20LS 330 115F51L N120L 650 800 960
46B24R NS60 325 360 420 130E41R NX200-10 8 00
46B24L NS60L 325 360 420 130E41L NX200-10L 800
46B24RS NS60S 325 360 420 130F51R 800
46B24LS NS60LS 325 360 420 130F51L 800
46B26R 360 145F51R NS150 780 920
46B26L 360 145F51L NS150L 780 920
46B26RS 360 145G51R N150 780 900 1100
CCA
32C24R N40 240 325 400 75D26R F100-5 4 90
32A19L NX60-N24L 270 65D23L 420 540 580
26B17R 200 65D26R NS70 415 520 625
26B17L 200 65D26L NS70L 415 520 625
28B17R 245 65D31R N70 390 520 630
28B17L 245 65D31L N70L 390 520 630
28B19R NS40S 245 70D23R 35-60 490 540 580
28B19L NS40LS 245 70D23L 25-60 490 540 580
32B20R NS40 270 75D23R 500 520 580
32B20L NS40L 270 75D23L 500 520 580
295
continue table
14

6
batteries in series.( only DI-215A)
Internal insulation 4.75mΩ
The higher of the CCA value , the lower of the internal insulation
normally.
Remark: Different material of the battery produced by various
manufacturers can cause different internal insulation. So there is no fixed
standard. But there is little difference among the internal insulation of the
battery with the same model from the same manufacturer.
When selecting 24V test, internal resistance equals the sum of two
groups 12V batteries in series.(only DI-215A)
Life: Display the condition of the battery. Suggest replacing the battery
when it shows below 45%.
★ Suggest replacing
The result indicates the battery is bad and remains 32% of life. So suggest
replacing the battery.
★ Life check OK, and voltage check low
<45%
13
The load test method: According to the physical formula R=V/1, test
equipment forcibly make the high permanent DC current ( presently 40-80A
large current is available ) go through the battery shortly ( about 2-3
seconds). And then the tested voltage of the battery can be used to figure out
the internal resistance by the formula.
(1) Just available for large capacitance battery or storage battery. The small
capacitance battery can not load 40-80A large current in 2-3 seconds.
(2) When the large current going through the battery, there comes out
polarization phenomenon from internal electrode, which can cause
polarization internal resistance. As a result it has to be tested in a short time.
Otherwise there is a large error of the internal resistance value.
(3) The internal electrode will be damage generally when large current go
through the battery.
The method of this tester:Battery is actually equivalent to an active
resistance. So we add a fixed frequency and small current to it, and then
sample the voltage value. Eventually the internal resistance can be figured
out after some operation such as rectificationand smoothing.
7. Specification Of Storage Battery
The data in the table is just for reference. Actual value must be referredto the
manufacturer.
7-1．JIS translation table
Battery CCA Battery
NEW JIS OLD JIS MF CMF NEW JIS OLD JIS MF CMF
26A17R 200 55B24RS NT80-S6S 430 420 500
26A17L 200 55B24LS NT80-S6LS 430 420 500
26A19R 12N24-4 200 220 264 55D26R N50Z 350 440 525
26A19L 12N24-3 200 220 264 55D26L N50ZL 350 440 525
28A19R NT50-N24 250 60D23R 520
28A19L NT50-N24L 250 60D23L 520
32A19R NX60-N24 270 65D23R 420 540 580
CCA
295

7
The result indicates the battery is good and full of 100% of life. But only
12.11V left. SO suggest charging.
★ Life check OK, and voltage check over low
The result indicates the battery is OK and remains 73% of life. But only
11.88V left and over low voltage, which can affect the result. At this time it is
better to charge prior to checking again.
5-3 engine system activation load test
5-3-1preparation
If the engine is working, please turn off first and switch the key to off
location.
5-3-2 procedure of operation
(1) Connect the red clamp to the positive polar of the battery, and the black
one to the negative polar. Make sure they are well connected in order to avoid
affected result.
(2) Press <▲><▼>to select activation load test as the picture below:
(3) After selecting the test item, press <ENTER> to display the activation load
test screen as the picture below:
6-2 Can it be affected by the installation of negative current
inside the vehicle?
All the negative currency will affect the result. Therefor please remove
the negative currency prior to checking, in order to achieve the accurate
data.
6-3 Can this tester predict when does the battery become
useless?
The internal resistance of the sealed lead-acid battery is complicated. It
is generated by ohm internal resistance, concentration polarization internal
resistance, chemical reactions internal resistance and interference effect
caused by double capacitance’s charging. The ingredient of internal
resistance and its relative content will change with different test method and
different test moment, which can lead to different tested value of the internal
resistance. And there is no strict relationship between internal resistance (or
conductance) and capacitance of the sealed lead-acid battery. So it is
impossible to predict the life of battery according to a single battery’s internal
resistance. But it can be predicted the life of the battery will be over soon
from the sudden increase of its internal resistance and decrease of its
conductance.
6-4 Is the CCA value tested by this tester correct?
CCA is looked as a control standard with the produce of the battery.
According to the accumulated records, the tested value of new battery is 10-
15% higher than the standard value, and along with consuming of the battery,
the value is getting close to standard, even lower afterward.
6-5 What is the difference between the method of this tester
and the load test method?
12

8
As can be seen in the picture current test voltage is 12.36V, standard voltage
is 9.6V,(for 24V system<DI-215A>, standard voltage is 16V), the lowest
voltage is 12.30V.
(4)Star the engine to make the tester automatically record the lowest voltage
in this process. Normally the voltage of battery will be higher than 9.6V in this
process.(for 24V system<DI-215A>, the voltage should be higher than 16V
when staring up the engine)
(5)Press <ESC> to return step (2).
5-3-3 instruction of engine system test
★ the lowest voltage higher than 9.6V (for 24V system, the reading is over
16V) means good.
★ the lowest voltage lower than 9.6V (for 24V system, the reading is under
16V) means no good.
Please check the relative connections, wire and engine. Also the
terminals of the battery should be checked if rusted.
5-4 maximum load system test
5-4-1 preparation
★ Please star the engine firstly.
5-4-2 procedure of operation
(1) When the engine is working, connect the red clamp to the positive polar
of the battery, and the black one to the negative polar. Make sure they are
well connected in order to avoid affected result.
(12V system)
11
Status
Headlights and
air-condition off ( need to
step the gas pedal when
checking)
Voltage
>13.5
13.2~13.5
13.0~13.2
<13
Data Reference Table
Condition
normal
general
pay attention
check immediately
(12V system)
Headlights and
air-condition on ( need to
step the gas pedal when
checking)
The result can be affected by the defective battery.
13.4~14.6
13.2~13.4
<13.2
normal
pay attention
check immediately
★ If the voltage is lower than 13.30V,(for 24V system<DI-215A>, the
reading is under 26.60V), please check the connections, wires and the
engine.
6. FAQ
6-1 What is the measurement principle of this tester?
The battery will gradually aging with increase of time. The main reason
is that it can no longer generate some effectively chemical reaction because
of aging of the surface of the battery plate. That is why most of the batteries
can longer be used mainly. International Electric and Electronic Engineer
Association(IEEE)formally looks the Conductivity Test as one of the standard
of checking lead acid storage battery. It points out from IEEE standard 1118-
1996 that :Conductivity Test is used to test AC current generated by putting
the known frequency and amplitude AC signal to both sides of the battery. AC
conductivity value is the ratio of AC current signal which keeps same phase
with AC voltage and the AC voltage. This tester is designed from this
principle actually.

9
(2)Turn on all the devices such as lights, warning system , air-condition.
(3)Speed the engine to 2000 rpm and keep this state for 15 seconds.
(4) Press <▲><▼>to select maximum load system test as the picture below:
(5)After selecting the test item, press <ENTER> to display the maximum load
system test screen as the picture below:
As can be seen in the picture current test voltage is 12.86V, standard voltage
is 12.80V,(for 24V system<DI-215A>, standard voltage is 25.60V), the lowest
voltage is 12.80V.
(6)Read the lowest value. If it is high than 12.80V,(for 24V system<DI-215A>,
the voltage is over 25.60V), the system runs normally.
(7)Press <ESC> to return step (4).
5-4-3 There are some problems in the system
★ If the value is lower than 12.80V,(for 24V system<DI-215A>, the voltage is
under 25.60V), please check the engine belt if damaged and the wires if exist
short circuit.
5-5 Charging system test
5-5-1 Preparation
★ Please star the engine firstly.
10
5-5-2 Procedure of operation
(1) When the engine is working, connect the red clamp to the positive polar of
the battery, and the black one to the negative polar. Make sure they are well
connected in order to avoid affected result.
(2)Speed the engine to 3000 rpm.
(3)Press <▲><▼>to select charging system test as the picture below:
(4)After selecting the test item, press <ENTER> to display the charging
system test screen as the picture below:
Figure1 indicates the current test voltage is 13.88V, standard maximum
voltage is 15.00V(for 24V system<DI-215A>, standard maximum voltage is
30.00V), tested maximum voltage is 14.10V.
Figure2 indicates the current test voltage is 13.88V, standard minimum
voltage is 15.00V(for 24V system<DI-215A>, standard minimum voltage is
26.60V), tested minimum voltage is 13.58V.
5-5-3 There are some problems in the system
★ If the voltage is high than 15.00V,(for 24V system<DI-215A>, the reading
is over 30.00V), please check the voltage regulator.
Figure 1 Figure 2