AEMC 6503 User manual

MEGOHMMETER
6501
6503
ENGLISH User Manual
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

Statement of Compliance
Chauvin Arnoux®, Inc. d.b.a. AEMC®Instruments
certifies that this instrument has been calibrated
using standards and instruments traceable to
international standards.
We guarantee that at the time of shipping your
instrument has met its published specifications.
An NIST traceable certificate may be
requested at the time of purchase, or obtained
by returning the instrument to our repair and
calibration facility, for a nominal charge.
The recommended calibration interval for this
instrument is 12 months and begins on the date of
receipt by the customer. For recalibration, please
use our calibration services. Refer to our repair
and calibration section at www.aemc.com.
Serial #: ________________________________
Catalog #: 2126.51 / 2126.52
Model #: 6501/ 6503
Please fill in the appropriate date as indicated:
Date Received: _________________________________
Date Calibration Due: _______________________
Chauvin Arnoux®, Inc.
d.b.a AEMC®Instruments
www.aemc.com
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

Table of Contents
1. INTRODUCTION...................................................... 3
1.1 International Electrical Symbols...................................... 4
1.2 DenitionofMeasurementCategories............................ 4
1.3 ReceivingYourShipment................................................ 5
1.4 OrderingInformation ....................................................... 5
1.4.1 AccessoriesandReplacementParts ................. 5
2. PRODUCT FEATURES ............................................. 6
2.1 Description ......................................................................6
2.2 Features.......................................................................... 6
2.3 Model6501ControlFeatures ......................................... 8
2.4 Model6503ControlFeatures ......................................... 9
3. SPECIFICATIONS.................................................. 10
4. OPERATION .......................................................... 12
4.1 Auto-ranging .................................................................12
4.2 SafetyCheck-VoltageTest.......................................... 12
4.3 InsulationResistanceTesting(MΩRange)................... 12
4.3.1 TestVoltage...................................................... 13
4.3.2 SpotTesting...................................................... 13
4.3.3 RatioTesting..................................................... 14
4.4 SuccessfulInsulationResistanceTesting ..................... 14
4.5 UtilizationoftheGuardTerminal(Model6503) ................... 15
4.6 InsulationMeasurement-Connections ........................ 17
4.7 InsulationResistanceonMotors................................... 21
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

5. MAINTENANCE..................................................... 24
5.1 Warning........................................................................ 24
5.2 Cleaning........................................................................ 24
5.3 FuseReplacement........................................................ 25
RepairandCalibration..................................................................26
TechnicalandSalesAssistance ................................................... 26
Limited Warranty .......................................................................... 27
WarrantyRepairs..........................................................................27
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

MegohmmeterModels6501/6503 3
CHAPTER 1
INTRODUCTION
Warning
Thesesafetywarningsareprovidedtoensurethesafetyof
personnelandproperoperationoftheinstrument.
• Readtheinstructionmanualcompletelyandfollowall
safetyinformationbeforeoperatingthisinstrument.
• Safetyistheresponsibilityoftheoperator!
• Testsaretobecarriedoutonlyondeadcircuits!Check
forlivecircuitsbeforemakingresistancemeasure-
ments(safetycheck).
• Thesemegohmmetersareratedfor600VCATIIor
300VCATIII-PollutionDegree2.
• TheMegohmmeterModels6501/6503aresources
ofhighvoltage,asisthesampleconnectedtothem.
Allpersonsperformingorassistinginthetestsmust
employallsafetyprecautionstopreventelectrical
shocktothemselvesandtoothers.
• AEMC
®
Instrumentsconsiderstheuseofrubbergloves
tobeanexcellentsafetypracticeeveniftheequipment
isproperlyoperatedandcorrectlygrounded.
• Whentestingcapacitancesamples,makesurethat
theyhavebeenproperlydischargedandthattheyare
safetotouch.Dielectricinsulationsamplesshouldbe
short-circuitedforatleastvetimestheamountoftime
theywereenergized.
• Usetheleadssuppliedwiththemegohmmeter.If
defectiveorused,replacebeforetesting.
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

4 MegohmmeterModels6501/6503
1.1 International Electrical Symbols
This symbol signifies that the instrument is protected by double or
reinforced insulation.
This symbol on the instrument indicates a WARNING and that the
operator must refer to the user manual for instructions before
operating the instrument. In this manual, the symbol preceding
instructions indicates that if the instructions are not followed, bodily
injury, installation/sample and product damage may result.
Risk of electric shock. The voltage at the parts marked with this
symbol may be dangerous.
In conformity with WEEE 2002/96/EC
1.2 DenitionofMeasurementCategories
CAT I: For measurements on circuits not directly connected to
theACsupplywalloutletsuchasprotectedsecondaries,
signallevel,andlimitedenergycircuits.
CAT II: For measurements performed on circuits directly
connectedtotheelectricaldistributionsystem.Examples
are measurements on household appliances or portable
tools.
CAT III: For measurements performed in the building installation
atthedistributionlevelsuchasonhardwiredequipmentin
xedinstallationandcircuitbreakers.
CAT IV: For measurements performed at the primary electrical
supply (<1000V) such as on primary overcurrent protec-
tiondevices,ripplecontrolunits,ormeters.
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

MegohmmeterModels6501/6503 5
1.3 ReceivingYourShipment
Uponreceivingyourshipment,makesurethatthecontentsarecon-
sistent with the packing list. Notify your distributor of any missing
items.Iftheequipmentappearstobedamaged,leaclaimimme-
diatelywiththecarrierandnotifyyourdistributoratonce,givinga
detailed description of any damage. Save the damaged packing
containertosubstantiateyourclaim.Donotuseaninstrumentthat
appearstobedamaged.
1.4 Ordering Information
Megohmmeter Model 6501.....................................Cat. #2126.51
Includes a soft carrying case, two color-coded leads, two insulated
alligator clips, test probe and user manual.
Megohmmeter Model 6503.....................................Cat. #2126.52
Includes a soft carrying case, three color-coded leads, three insulated
alligator clips, test probe and user manual.
1.4.1 Accessories and Replacement Parts
Replacement soft carrying case................................Cat. #2126.71
Replacement leads (black and red), alligator clips
(black and red) and one safety test probe (6501)......Cat. #2126.72
Replacement leads (black, red and blue), alligator clips (black,
red and blue) and one safety test probe (6503).........Cat. #2126.73
Replacement Fuse - 0.2A, 600V HPC (6501) ............Cat. #2970.95
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

6 MegohmmeterModels6501/6503
CHAPTER 2
PRODUCT FEATURES
2.1 Description
The AEMC® Models 6501 and 6503 are compact, self-contained
hand-crankedmegohmmeters.Theyarepracticalanddependable
instruments designed for a broad range of plant and eld service
applications,suchasacceptancetestingandpreventivemaintenance
ofwiring,cables,switchgear,andmotors.Theeasyhand-cranked
operationprovidesasteadyrectiedDCvoltageoutputacrossthe
entirerangeforconsistentlyreliablereadings.
Thesemegohmmetersincorporateabuilt-ingeneratorandacon-
stantDC voltagecircuittoprovideastableoutput andgivedirect
insulationresistancereading.
TheModels6501/6503haveauniqueauto-rangingfeaturewhich
expands the scale by x10 and almost doubles the scale length.
Whenthepointerreachesneartheendofscale,theauto-ranging
featureactivates,returningthepointertothebeginningofthescale
withthex10redLEDindicatoron.
Insulation resistance is indicated with a rugged taut-band meter
movement on a logarithmic scale. The indicator scale is easy to
read.
2.2 Features
• Measuresinsulation at500V, resistanceand continuity(Model
6501)
• Threetestvoltages:250V,500V,1000V(Model6503)
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

MegohmmeterModels6501/6503 7
• Testvoltageconstantacrosstheentiremeasurementrange
• AutorangingMΩ,kΩandΩranges(Model6501)
• AutorangingMΩranges(Model6503)
• Designedforharshenvironments:offshore,mining,heavy-duty
eld,industrial,andmilitaryuse
• Compact,self-containedpackage;foldingcrank
• Largedirectreadingscale
• 600Vtestvoltagerange(safetycheck)
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

8 MegohmmeterModels6501/6503
2.3 Model6501ControlFeatures
kΩ
Ω
M
V
x 10
5
0
1
2
6
7
10
V
FUS
1
2
3
4
5
10
20
10
20
30
0.5
50
(500V)
(1mA)
(5mA)
ΜΩ
2!C
42
300
0
100
200
400
500
600
Ω
κΩ
4
3
8
9
40
0
Ω
MEGOHMMETER
Model 6501
INSTRUMENTS
®
600V CAT II / 1000V CAT I !
123
4
5
6
7
8
9
Figure 2-1
1. Line(-)terminalBlack
2. Fuse0.2A
3. Earth(+)terminalRed
4. AmberLEDilluminateswhenpropercrankspeedisattained,
indicatingpresenceofselectedoutput
5. Foldawayhandle
6. Mechanicalzeroadjustmentscrew
7. Rangeswitch-safetytestrstonMΩ/Vrangeto600VAC
8. Autoranging:RedLEDilluminateswhenreadingneedstobe
multipliedx10toobtainthetruevalue(MΩ,kΩ,Ωranges)
9. Securityngerrestisolatesusershandfromterminalswhile
givingarmgripduringanoperation
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

MegohmmeterModels6501/6503 9
2.4 Model6503ControlFeatures
MEGOHMMETER
Model 6503
INSTRUMENTS
®
V
500V
1kV
250V
x 10
300
0
100
200
400
500
600
V
G
20
15
30
40
50
100
200
500
50
20
10
5
4
3
2
1.5
10
1
(1kV)
(250V)
(500V)
ΜΩ
2!C
42
600V CAT II / 1000V CAT I !
123
4
5
6
7
8
9
Figure 2-2
1. Line(-)terminal-Black
2. Guardterminal-Blue
3. Earth(+)terminal-Red
4. Green LED illuminates when proper crank speed is attained,
indicatingpresenceofselectedtestvoltage
5. Foldawayhandle
6. Mechanicalzeroadjustmentscrew
7. Rangeswitch-Safetytestrston600V/V~rangeto600VAC
8. Autoranging:RedLEDilluminateswhenreadingneedstobe
multipliedx10toobtainthetruevalue(MΩrange)
9. Securityngerrestisolatesusershandfromterminalswhile
givingarmgripduringanoperation
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

10 MegohmmeterModels6501/6503
CHAPTER 3
SPECIFICATIONS
MODELS 6501 6503
ELECTRICAL
Insulation Tests
Test Voltage 250V
500V
1000V
−
0.5 to 5.5MΩ; 5.5 to 200MΩ
−
1 to 11MΩ; 11 to 500MΩ
1 to 11MΩ; 11 to 500MΩ
10 to 110MΩ; 110 to
5000MΩ
Short Circuit
Current
5mA (max)
Accuracy 2.5% of Scale Length
Resistance Tests
Measurement
Range
(Auto-Ranging)
0 to 45kΩ; 45 to 500kΩ−
DC Test Current 1mA constant, 500V max −
Accuracy 2.5% of Scale Length −
Automatic
Discharge
5s/µF 8s/µF
Continuity Tests
Test Voltage
5mA constant, 10V max −
Measurement
Range
(Auto-Ranging)
0 to 9Ω; 10 to 100Ω−
Accuracy 2.5% of Scale Length −
Fuse Protection 0.2A, 600V HPC 6x32mm −
Voltage Tests/Safety Check
Voltage Range 0 to 600VAC
Frequency 45 to 450Hz
Accuracy 3% of Scale
Input Impedance
100kΩ(approx)
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

Megohmmeter Models 6501/6503 11
MODELS 6501 6503
Scale
Direct reading on all ranges; 3"(76mm), black on white
Test Voltage
Indicator
Amber LED indicates proper
test voltage and crank speed
NOTE: If the LED is not ON during
testing, the reading is not valid
Green LED indicates proper
test voltage and crank speed
NOTE: If the LED is not ON during
testing, the reading is not valid
Auto-Range
Indicator
Red LED indicates Auto-Range;
multiply MΩ, kΩ& Ω
readings x 10
Red LED indicates Auto-Range;
multiply MΩreadings x 10
Power Source
Hand-cranked, heavy duty brushless alternator and
solid state rectification and amplification for stable voltage;
test voltage reached at 140rpm (approx)
Meter Movement
Rugged taut band suspension
MECHANICAL
Dimensions
4.7 x 4.4 x 5.3" (120 x 111 x 135mm) with lid
Weight
2.5 lbs (1.1kg)
Terminals
“+” Line (red); “–” earth (black);
accepts standard 4mm safety plugs
ENVIRONMENTAL
Temperature
Reference
Operating Range
Storage Range
68 to 79°F (20 to 26°C), 30 to 50% RH
14 to 113°F (-10 to 45°C), 0 to 75% RH
-4 to 176°F (-20 to 80°C), 0 to 90% RH
SAFETY
Sealed
IP54 with lid, IP52 without lid
Rating
EN 61010-1, 600V CAT II; 300V CAT III; Pollution Degree 2
Double Insulation
Yes
CE Mark
Yes
*Specications are subject to change without notice
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

12 MegohmmeterModels6501/6503
CHAPTER 4
OPERATION
4.1 Auto-ranging
How it works:Whenthepointerreachesapproximately90%ofthe
fullscalelength,theauto-rangeistriggered,theredauto-range(x10)
LEDlightsup.Thepointergoesbacktothebeginningofthescale
andresumesitstravel.Thereadingsshouldbemultipliedby10when
thex10LEDison.
4.2 SafetyCheck-VoltageTest
Beforemeasuringinsulationresistance,conrmthatthesampleis
fullydischarged(particularlyindielectricandcapacitancesamples)
andthatthesampleisnotconnectedtoanenergizedcircuit.
Toperformthevoltagetest,settherangeselectiontoVMΩ(Model
6501) or 500V MΩ (Model 6503), connect and read on the red
voltage scale (600VAC max). DO NOT CRANK. If measuring on
aDCcircuit,thepointerwilldeectbutthemeasurementmaybe
inaccurate.
4.3 InsulationResistanceTesting(MΩRange)
Aftercheckingforalivecircuit(seesafetycheck),selectthetestvolt-
ageandconnectthemegohmmeter.Severalconnectionexamples
areillustratedfurther.CrankthehandleuntiltheAmberLED(Model
6501) or Green LED (Model 6503) on the upper right-hand side
lights,ensuringthattheselectedtestvoltagehasbeenreached.
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

MegohmmeterModels6501/6503 13
4.3.1 Test Voltage
Nopublishedstandardtellswhichvoltagetochooseforanygiven
winding. However, published recommendations could be summa-
rizedasfollows:
Rated Voltage of Motor Test Voltage
Below 115 250V
115 250 or 500V
230 500V
460 500 or 1000V
4.3.2 Spot Testing
Asageneralruleinspottesting,testvoltageshouldbeapplieduntil
novariationinreadingisnotedfor15secondsorappliedforaxed
60seconds.Oncapacitancecircuits,crankingforuptoaminuteor
moremaybenecessarytofullychargethesample.Whatminimum
valueshouldbemeasured?TheIEEEstandardN°43-2000states
thatitisimpossibletospecifythevalueofinsulationresistanceat
whichawindingwillfailelectrically,butonmotors,minimumread-
ingsgenerallystatedare:
Rated Voltage R minimum
250 or less 2 MΩ
460 2 MΩ
There is no xed gure for determining what is good and bad in
resistancereadings,butagoodguidewouldbe1MΩforeveryone
hundredappliedoperatingvolts,asaminimumgure.Thisapplies
to motors and transformers. When the insulation resistance gets
thislow,anelectricalbreak-downcanbeexpectedatanytimeand
rewindingorreplacingshouldbeconsidered.
It is not unusual for a winding to be 10 to 100 times the recom-
mended minimum value (IEEE standard 43-2000: Recommended
Practice for Testing Insulation Resistance of Rotating Machinery),
butthisvarieswithtemperatureandhumidity.
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

14 MegohmmeterModels6501/6503
4.3.3 Ratio Testing
In time resistance reading (Dielectric Absorption Ratio), readings
are taken at 30 seconds and 60 seconds to obtain the dielectric
absorptionratio.
 Insulationresistance@60s
 Insulationresistance@30s
Thistestisusefultoincreasetheaccuracyofspottesting.Ingen-
eral,aratioof1.25:2orbettershouldberequired.Aratiobelowthis
indicatesthatrepairisprobablyneeded.
Rememberthat aDCinsulationtestmaybeusedforacceptance
testing,butismorecommonlyusedtocheckthegradualdeteriora-
tionofequipmentoveritslife.Consultyourequipmentmanufacturer
forspecictestortestvoltageifnotknown.
Insulationresistancedecreaseswithmoisture,temperatureandage
andshouldberecordedovertimeatagiventemperatureandcor-
rected.
4.4 SuccessfulInsulationResistanceTesting
• Checkwiththeequipmentmanufacturerforfactoryinsula-
tionresistancereadings.
• Donotrelyoninsulationresistancetestingaloneasproof
ofwindingconditions.
• Donotexpectthesamevalueforallpartsofallmachines.
• Observeconsistenttesttimeduration,recognizingthat
totalcurrentthroughinsulationundertestwillvarywith
time.
• Correctallreadingsproperlytoastandardreferencetem-
perature(seeIEEEstd#43-2000,Temperature Correction
Curve).
• Knowwhatyouaretesting.Isolatethepieceofequipment
fromothercircuitry.
• Watchtrendsratherthanrelyingonsingle“spot”readings.
=DielectricAbsorptionratio
(DAR)
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

MegohmmeterModels6501/6503 15
4.5 UtilizationoftheGuardTerminal(Model6503)
G
A
D
B
C
A = Insulation
B = Shield
C = Conductor
D = Exposed surface
Figure 4-1
Guardterminalsareusefulwhenmeasuringhighresistancevalues
andforstabilizingreadings.
Whentestingtheinsulationattheendofacable,itisnecessaryto
eliminatetheerrorfromsurfaceleakagewhichoccurs,particularly
athighresistancevalues.Thepurposeoftheguardterminalisto
provideathirdterminalwithinthepathofthesurfaceleakage“D”.
ConnecttheinstrumentasshowninFigure4-1.
Ifthereisnoshieldat“B”,useacopperwirewoundseveraltimes
aroundtheexposedsurface“B”.(Note:Ifashieldisnotavailable
and you do not make up a shield around “B” and connect to the
guardterminal(-),themeasurementwillbeerroneousandleadto
confusionastothecable’sstate.)
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

16 MegohmmeterModels6501/6503
Iftheguardterminalisnotconnectedat“B”,theinstrumentmea-
sures the current “I” owing through the insulation and a surface
leakagecurrent“i1”.SeeFigure4-2.
To EARTH
terminal
I
To LINE
terminal
NO CONNECTION
to Guard terminal
A
B
C
Ry
Rx
Rz
Rx: resistance through insulation
Ry: surface resistance
Rz: surface resistance
i1
Figure 4-2
Whentheguardterminalisconnectedat“B”,theinstrumentmea-
suresthecurrent“I”andnotthesurfaceleakagecurrent“i1”,which
is not included in the measurement. See Figure 4-3. This type of
measurementwillgivethetruevalueoftheresistance“Rx”,provid-
ingthe“Ry”and“Rz”arenottoolow.
To EARTH
terminal
I
To LINE
terminal
To Guard terminal
A
B
C
Ry
Rx
Rz
Rx: resistance through insulation
Ry: surface resistance
Rz: surface resistance
i1
Figure 4-3
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

MegohmmeterModels6501/6503 17
4.6 InsulationMeasurement-Connections
Figures 4-4 shows the connections to measure the insulation of
one conductor to the other conductors. The cable should be dis-
connectedatbothendstoavoidleakagethroughswitchboardsand
panels.For theModel6503,theconnectiontotheguardterminal
isusedtoeliminatetheeffectsofsurfaceleakageacrossexposed
insulationatoneendofthecable.RefertothesectiononUtilization
oftheGuardTerminal(§4.5).
G
Cable Insulation
Conductor Under Test
Cable Insulation
6501
6503
Conductor Under Test
Fus
Figure 4-4
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]

18 MegohmmeterModels6501/6503
Figures 4-5 shows the connections for testing insulation from a
supplyconductortoground(motorframe).
Cable Insulation
Conductor Under Test
Figure 4-5
www.GlobalTestSupply.com
Quality AEMC Products Online at: [e-mail]