Fluke 6500 User manual

6500
Appliance Tester
Users Manual
PN 2141150
April 2005, Rev 2 12/06
© 2005 Fluke Corporation, All rights reserved. Printed in EU
All product names are trademarks of their respective companies.

LIMITED WARRANTY AND LIMITATION OF LIABILITY
Each Fluke product is warranted to be free from defects in material and workmanship under normal use and service. The warranty period is
two years and begins on the date of shipment. Parts, product repairs, and services are warranted for 90 days. This warranty extends only to
the original buyer or end-user customer of a Fluke authorized reseller, and does not apply to fuses, disposable batteries, or to any product
which, in Fluke’s opinion, has been misused, altered, neglected, contaminated, or damaged by accident or abnormal conditions of operation
or handling. Fluke warrants that software will operate substantially in accordance with its functional specifications for 90 days and that it has
been properly recorded on non-defective media. Fluke does not warrant that software will be error free or operate without interruption.
Fluke authorized resellers shall extend this warranty on new and unused products to end-user customers only but have no authority to ex-
tend a greater or different warranty on behalf of Fluke. Warranty support is available only if product is purchased through a Fluke authorized
sales outlet or Buyer has paid the applicable international price. Fluke reserves the right to invoice Buyer for importation costs of re-
pair/replacement parts when product purchased in one country is submitted for repair in another country.
Fluke’s warranty obligation is limited, at Fluke’s option, to refund of the purchase price, free of charge repair, or replacement of a defective
product which is returned to a Fluke authorized service center within the warranty period.
To obtain warranty service, contact your nearest Fluke authorized service center to obtain return authorization information, then send the
product to that service center, with a description of the difficulty, postage and insurance prepaid (FOB Destination). Fluke assumes no risk
for damage in transit. Following warranty repair, the product will be returned to Buyer, transportation prepaid (FOB Destination). If Fluke
determines that failure was caused by neglect, misuse, contamination, alteration, accident, or abnormal condition of operation or handling,
including overvoltage failures caused by use outside the product’s specified rating, or normal wear and tear of mechanical components,
Fluke will provide an estimate of repair costs and obtain authorization before commencing the work. Following repair, the product will be
returned to the Buyer transportation prepaid and the Buyer will be billed for the repair and return transportation charges (FOB Shipping
Point).
THIS WARRANTY IS BUYER'S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IM-
PLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. FLUKE SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OR
LOSSES, INCLUDING LOSS OF DATA, ARISING FROM ANY CAUSE OR THEORY.
Since some countries or states do not allow limitation of the term of an implied warranty, or exclusion or limitation of incidental or conse-
quential damages, the limitations and exclusions of this warranty may not apply to every buyer. If any provision of this Warranty is held inva-
lid or unenforceable by a court or other decision-maker of competent jurisdiction, such holding will not affect the validity or enforceability of
any other provision.
Fluke Corporation, P.O. Box 9090, Everett, WA 98206-9090, U.S.A.
Fluke Europe B.V., P.O. Box 1186, 5602 BD Eindhoven, The Netherlands.

i
Table of Contents
Title Page
Introduction ....................................................................................................................1
Contacting Fluke ............................................................................................................1
Unpacking the Tester .....................................................................................................2
Safety Information ..........................................................................................................2
Operating Features ........................................................................................................4
Front panel description ..............................................................................................4
Understanding the Pushbuttons ................................................................................5
Understanding the Beeper Sounds............................................................................6
Understanding Displayed Symbols............................................................................6
Powering the Tester .......................................................................................................7
Understanding the Power-up Screen.........................................................................7
Setting Up the Tester: Basic Functions ..........................................................................7
Adjusting the Display Contrast...................................................................................7
Zeroing the Earth Bond Test......................................................................................7
Setting Date and Time...............................................................................................8
Setting the Site/Customer Text..................................................................................9
Setting the USER ID Text..........................................................................................9
Setting Up the Tester: Advanced Functions ...................................................................9

6500
Users Manual
ii
Changing the Access Code....................................................................................... 9
Selecting Fast or Standard Test Mode......................................................................10
Creating/Editing an Auto-Test Sequence .................................................................. 10
Setting Manual Test Limits........................................................................................ 12
Locking and Unlocking Manual Tests........................................................................ 13
Setting the Serial Port Communications Speed ........................................................ 13
Installing - Formatting a Compact Flash Card (Quick Format) .................................. 13
Testing Appliances ........................................................................................................ 15
Aborting a Test.......................................................................................................... 15
Test Modes: Single - Continuous Test ...................................................................... 16
Test Modes: Standard or Fast................................................................................... 16
Using the Auto-Test Mode ........................................................................................ 17
Performing Auto-Tests ......................................................................................... 17
Using the Manual Test Mode .................................................................................... 19
Performing Manual Tests ..................................................................................... 19
Description of the Tests ................................................................................................. 20
Visual Inspection Test ............................................................................................... 20
Bond Test 25A/200 mA (RPE).................................................................................... 20
Substitute Leakage Current Test (ISL) ....................................................................... 23
Touch Current Test (ITC)............................................................................................ 24
Load/ Leakage Current (IPE) Test .............................................................................. 25
IEC Lead Test ........................................................................................................... 27
PELV Test................................................................................................................. 28
Using the Memory.......................................................................................................... 29
Saving Test Results .................................................................................................. 29
Viewing Test Result Records .................................................................................... 30
Viewing Auto-Test Sequences .................................................................................. 30
Deleting Test Result Records ................................................................................... 31

Contents (continued)
iii
Clearing the Memory .................................................................................................31
Printing - Downloading Data...........................................................................................32
Connecting the Printer or the PC...............................................................................32
Printing test results ....................................................................................................33
Printing Auto-tests .....................................................................................................33
Downloading Test Results to a PC ............................................................................33
Transferring Results to Compact Flash Card.............................................................33
Maintaining the Tester....................................................................................................34
Cleaning ....................................................................................................................34
Calibration .................................................................................................................34
Accessories ...............................................................................................................34
Specifications .................................................................................................................35
General Specifications...............................................................................................35
Test Specifications ....................................................................................................36
Power-on Test ......................................................................................................36
Earth Bond Test....................................................................................................36
Insulation Test ......................................................................................................36
Substitute Leakage Current Test ..........................................................................37
Touch Current Test...............................................................................................37
Load/Leakage Test: Load Current ........................................................................37
Load/Leakage Test: Load Power ..........................................................................37
Load/Leakage Test: Leakage Current ..................................................................38
PELV Test.............................................................................................................38
IEC Lead Test.......................................................................................................38
Variation Factor Errors..........................................................................................38

1
6500 Appliance Tester
Users Manual
Introduction
The Fluke model 6500 Appliance Tester (hereafter
referred to as ‘the tester’) is designed to carry out the
following tests to ensure the integrity of electrical
equipment / portable appliances:
•L-N Mains Volts and Mains Wiring test.
•Insulation test (500 V dc).
•Earth Bond test 200 mA and 25A with test lead zero
facility.
•Substitute Leakage Current test.
•Touch Current test.
•IEC Lead test.
•Leakage test.
•Appliance Power and Load current test.
•PELV test
Contacting Fluke
To contact Fluke for product information, operating
assistance, service, or to get the location of the nearest
Fluke distributor or Service Centre, call:
•for UK & Ireland:
[phone]
•for other European countries:
[phone]
Visit Fluke’s web site at:
www.fluke.co.uk
or
www.fluke.com
Register your Tester at: register.fluke.com

Fluke 6500
Users Manual
2
Unpacking the Tester
The tester comes with the items listed in Table 1. If the
tester is damaged or an item is missing, contact the place
of purchase immediately.
Table 1. Shipment Box Contents
6500 Appliance Tester
1 pc. Alligator Clip
1 pc. Test Lead
1 pc. Test Probe for Touch Current
Hard Case
Users Manual (this manual)
Safety Information
The tester must only be used by a suitably trained and
competent person.
Carefully read the following safety information before
using the tester.
Definitions of symbols used
Caution! Risk of Danger. Refer to Manual
Caution! Risk of Electric Shock
Conforms to Relevant European Standard
Double Insulated (Class II) Equipment
Earth Ground

Users Manual
Safety Information
3
Warnings: Read Before Using
To avoid possible electric shock or personal injury,
follow these guidelines:
•If the tester does not power up immediately after
connecting it to the mains outlet disconnect and
verify that the mains outlet is correctly wired.
•Use the tester only as specified in this manual, or the
protection provided by the tester might be impaired.
•The tester shall not be used for measurements in
electrical installations.
•When conducting tests do not touch the appliance as
some tests involve high voltages and high currents.
•Do not use the tester around explosive gas, vapour
or dust, or in wet environments.
•Inspect the tester before using it. Do not use the
tester if abnormal conditions of any sort are noted
(such as a faulty display, broken case, etc.).
•Use only test leads and probes supplied with the
tester, or indicated by Fluke as suitable for the tester.
•Inspect the test leads for damaged insulation or
exposed metal. Check test lead continuity. Replace
damaged leads before using the tester.
•When testing, always be sure to keep your fingers
behind the safety barriers on the test leads.
•Never open the tester’s case because dangerous
voltages are present. There are no user replaceable
parts in the tester.
•Have the tester serviced only by qualified personnel.
•The tester must be properly earthed. Only use a
supply socket that has a protective earth contact. If
there is any doubt as to the effectiveness of the
supply socket earth, do not connect the tester. Do
not use a two-conductor adapter or extension cord;
this will break the protective ground connection.
•The tester has been set for a nominal 240 V ac –
50 Hz operation, it must never be connected to a
higher voltage.
•The tester may only be connected to a correctly
wired mains socket protected for a maximum current
rating of 13 A.
•The mains supply is never to be connected to the IEC
lead test connector or to the appliance test
connector.
•When carrying out Earth Bond tests, regularly zero
the Earth Bond test lead.
•Under certain test conditions the test socket may
have mains potential with a maximum current of
13 A.
•If the tester continuously emits a two tone sound,
you should unplug it immediately as this indicates a
dangerous condition.

Fluke 6500
Users Manual
4
Operating Features
Front panel description
The connectors, controls and indicators of the tester are
shown and listed below.
1 2 3456 7 8
6500 APPLIANCE TESTER
GOGO
STOPSTOP
VISUAL BOND
200 mA
BOND
25 A
INSUL-
ATION
I
SUB
LOAD/
LEAK
I
TOUCH
IEC
LEAD AUTO
£
.
=
+
"
:
*
()
#?/ %&
SHIFT
SPACE
QWE R T
Y
UIO
L
ASDFGHJK
Z
X
CVBNM
1234567890
CAPS
PC/PRINT
YES MEM
NO SET
UP
,
P
SWITCH ON APPLIANCE FOR ALL TESTS
IEC
BOND 25A/200mA
TOUCH P ROBE
INSULATION P ROBE
CLASS II
PROBE PELV
TEST SOCKET
230V 50Hz / MAX 13A
BOND ZERO
Figure 1. Fluke 6500
No. Description
1 Liquid Crystal Display (LCD).
2 Earth bar to zero the Earth Bond test lead.
3 Socket to connect IEC lead for IEC Lead test .
4 Serial RS-232 Port to connect the Fluke printer,
Fluke barcode scanner, or a computer.
5 Socket to connect test lead and crocodile clip for
Earth Bond test.
6 Socket to connect test probe for Insulation test,
Touch Current test, Substitute Leakage test and
PELV test.
7 Socket to connect the appliance to be tested.
8 Slot to insert a Type I Compact Flash Memory
Card.

Users Manual
Operating Features
5
Understanding the Pushbuttons
The table below shows the pushbuttons to control
operation of the tester.
Button Function
VISUAL
Select the Visual Inspection test.
BOND
200mA
Select the 200 mA Earth Bond test.
BOND
25A
Select the 25 A Earth Bond test.
INSUL-
ATION
Select the Insulation test.
I
SUB
Select the Substitute Leakage Current test.
LOAD/
LEAK
Select the combined Load/Earth Leakage
Current test.
I
TOUCH
Select the Touch Current test.
GO
Start /Enter selection.
STOP
Abort the current action and return to idle
screen.
IEC
LEAD
Select the IEC Lead test.
AUTO
Select the auto-test mode.
i
Provide help on the current function.
Scroll up/down to highlight options in screen
instructions ( ).
Move left/right to change options in screen
instructions ( ).
SET
UP
Select the setup menu.
MEM
Store test results or viewing auto-test
sequences.
YES
Confirm a proposed action.
NO
Reject a proposed action.
PC/PRINT
Download/Print test results and auto-tests.
Use capital characters.
SPACE
Type the space character.
Assign special characters to keys.
Enter typed data.
Backspace.

Fluke 6500
Users Manual
6
Understanding the Beeper Sounds
The tester can make several types of beeper sounds.
Sound Meaning
Click A key is pressed.
1 beep A test passed.
2 beeps - A test failed.
- Warning, see display.
- The STOP key is pressed, the
current action is aborted.
Long beep Test will start in continuous
mode.
Continuous two
tone sound
Dangerous condition! Unplug the
unit immediately!
Understanding Displayed Symbols
The following symbols can be displayed:
Caution! Risk of Electric Shock.
Caution! Risk of Danger. Refer to Manual.
ØBond test lead has been zeroed.
Auto-test or manual test failed.
Auto-test or manual test passed.
LMT Applicable limit is exceeded.
The printer/PC is connected.
I II Class I, Class II.
Use buttons .
Lock-out
on
Manual tests are locked out.

Users Manual
Setting Up the Tester: Basic Functions
7
Powering the Tester
The tester will power up when you connect it to the mains
supply. Disconnect the mains plug to power the tester down.
Warning
Read the safety information on page 2 before
powering the tester.
Understanding the Power-up Screen
On power up the display will perform a self-test. During
this test it shows the Fluke model 6500 and the software
version, for example V1.18.
After performing the self test, if all is well, the tester
shows the idle screen:
01/01/06 12:00
Site / customer:
Fluke
USER:
V
LN 241.2 V
V
NE 0.0 V
50.2 Hz
Ø
←date and time
←most recently entered site name
←live-neutral voltage
←neutral-earth voltage
←line frequency
←bond test has been zeroed
If there is an error a self explanatory message will
appear. Follow the screen instructions if an error
message is displayed!
Setting Up the Tester: Basic Functions
This section describes how to set the parameters of the
basic functions.
Adjusting the Display Contrast
To adjust the display contrast, do the following:
1
STOP
Power the tester up OR
press STOP to see the idle screen.
2 Adjust the contrast.
Zeroing the Earth Bond Test
For correct Earth Bond test results you must zero the
earth bond lead to eliminate its resistance:
•when setting up your new tester. Earth Bond tests are
locked out unless the bond zero icon (Ø) is on.
•occasionally, dependent on the condition of the bond
socket and the test lead plug a dirty plug/socket can
result in a significant contact resistance.

Fluke 6500
Users Manual
8
To zero the test lead, do the following:
1
SET
UP
Open the setup menu.
2 Highlight BOND ZERO set.
3
GO
Open the setup menu and follow the screen
instructions:
-Attach the crocodile clip to the test lead
and insert the test lead plug into the
BOND 25A/200mA socket, see fig. 2.
-Firmly attach the crocodile clip to the
BOND ZERO Ø bar on the tester.
Figure 2. Bond Zero Connections
When finished the tester shows the bond zero symbol Ø,
and the resistance value of the test lead, for example
RPE 0.09 Ω. It will subtract this value from bond test
results. As it saves this zero value you will not need to
repeat the operation every time you use the tester.
If the display shows the message RPE > 1.99Ωthe
lead resistance is more than 1.99 and cannot be
zeroed. Earth bond tests will now be locked out.
If the Earth Bond test lead has been zeroed, the idle
screen and the earth bond test results screen will show
the zero symbol Ø, for example:
ØBond test 25A
Setting Date and Time
The tester has a date and time clock. To set the date and
the time, do the following:
1
SET
UP
Open the set-up menu.
2 Highlight DATE/TIME set.
3
GO
Open the next menu and follow the
screen instructions.

Users Manual
Setting Up the Tester: Advanced Functions
9
Setting the Site/Customer Text
To set the site and customer text, do the following:
1
SET
UP
Open the set-up menu.
2 Highlight SITE/CUSTOMER.
3
GO
Open the next menu and follow the
screen instructions.
Please note that the site name is entered
in the first line and the customer name in
the second line (customer name for
reference only).
Setting the USER ID Text
(entry of USER ID for reference only)
To set the USER ID text, do the following:
1
SET
UP
Open the set-up menu.
2 Highlight USER ID set.
3
GO
Open the next menu and follow the
screen instructions.
Setting Up the Tester: Advanced
Functions
This section describes how to set the parameters of the
advanced functions.
Changing the Access Code
The factory set access code is 9999. You need the
access code to enter or edit auto-tests, to lock or unlock
manual tests, and to edit the access code. If you forget
your access code contact Fluke product support.
To change the access code, do the following:
1
SET
UP
Open the set-up menu.
2 Highlight ACCESS CODE set.
3
GO
Open the next menu and follow the screen
instructions.

Fluke 6500
Users Manual
10
Selecting Fast or Standard Test Mode
In the standard test mode the tester provides help
information during the tests. In the fast mode this
information is bypassed where possible to save test time.
See also ‘Test Modes: Standard or Fast’ on page 16.
To select the fast or standard mode, do the following:
1
SET
UP
Open the set-up menu.
2 Highlight FAST MODE set.
3
GO
Open the menu .
4
9999
Enter the access code for example 9999
(factory default).
5
GO
Confirm the access code.
6 Select test mode by arrow key
Creating/Editing an Auto-Test Sequence
The tester is provided with factory programmed automatic
test sequences, see page 18. You can create new auto-
test sequences (max. 50), and edit auto-tests you
created.
To create or edit auto-tests, proceed as follows:
1
SET
UP
Open the set-up menu.
2 Highlight AUTO-TEST setup.
3
GO
Open the User auto-test setup menu.
4
9999
Enter the access code, for example 9999.
5
GO
Accept the access code.
In the next step you must enter a 3-digit test number:
•Enter a new auto-test number to start creating a user
programmed auto-test from scratch (use numbers
from 100 to 999; the numbers 131-142 & 231-240 are
internally reserved numbers).
•Enter the number of a factory programmed auto-test
to make a copy of it, edit the copy, and store it as a
new user programmed auto-test. See page 18 for the
factory programmed tests.
•Enter the number of an existing user-programmed
auto-test to edit the test.

Users Manual
Setting Up the Tester: Advanced Functions
11
Continue as follows:
6
1
2
3
Enter the test number, for example 123.
7
GO
Accept the number.
If you entered a factory programmed
number do step 8 and 9 to make a copy.
If you entered a new auto-test number or an
existing user programmed auto-test number
go to step 10.
8
4 5 6
Enter the number to be assigned to the copy
of the factory programmed auto-test, for
example 456.
9
GO
Accept the new auto-test number and enter
the set-up/instruction screen.
10 Start setting up the test.
11
Use the up/down keys to select the test
parameter(s) to be changed.
Use the left/right arrow key to change the
test parameter
For the test parameters see Table 2.
12
GO
When finished entering the test parameters
exit the set up screen.
13
MEM
To review/edit the test parameters, or
To save the test parameters.
14 Enter a text for auto-test description.
15
GO
Confirm text entry and save auto-test
sequence.
Notes:
1) Auto-test numbers 131-136 & 231-234 are
reserved for pre-programmed auto-tests.
2) Auto-test numbers 137-142 & 235-240 are
reserved for future auto-test updates.
3) User programmed tests are stored in
chronological order and not in numeric order.
4) A standard text will be used when STOP is
pushed during text entry mode.
To view saved auto-tests see ‘Viewing Auto-Test
Sequences’ on page 30.

Fluke 6500
Users Manual
12
Table 2. Test parameters
Test Parameter
Visual check (Skipped) - SELECTED
Bond
Current
Repeat 1)
Limit
Duration
200mA – 25A
R0 – R1 – R2 - R3
0.1…19.9
(Skipped) - 5s….60s
Insulation
Repeat
Safety Class 2)
Limit
Duration
R0 – R1 – R2 - R3
I – II
0.1 M…290M
(Skipped) - 5s….60s
Substitute Leakage
Limit
Safety Class 2)
Duration
0.5mA … 19.5mA
I – II
(Skipped) - 5s….60s
Load/leakage
Limit Load
Limit Leakage
Duration
0VA…3200VA
0.5mA …19.5mA
(Skipped) - 5s….60s
Touch Current
Repeat
Limit
Duration
R0 – R1 – R2 - R3
0.25mA, 0.5mA – 1.9mA
(Skipped) - 5s….60s
IEC Lead
Limit Rpe
Duration 3)
Limit Riso
0.1…19.9
(Skipped) - 5s….60s
fixed at 2 M
Notes:
1) The repeat test parameters R0, R1, R2, and R3
define how many times a test will be repeated.
When you select for example R1, the test will be
repeated once (two tests).
2) The selected class for the isolation test also
applies to the substitute leakage test.
3) The IEC lead test can only be selected if all
other tests, except for the visual check, are
skipped.
Setting Manual Test Limits
To set the manual test limits you need your access code
(factory default 9999).
Do the following:
1
SET
UP
Open the set-up menu.
2 Highlight MANUAL LIMITS
3
GO
Open the next menu and follow the screen
instructions.
To restore the factory set limits press
NO
.
For the test parameters see Table 2.

Users Manual
Setting Up the Tester: Advanced Functions
13
Locking and Unlocking Manual Tests
To unlock/lock manual tests you need your access code
(factory default 9999).
Do the following:
1
SET
UP
Open the set-up menu.
2 Highlight MANUAL TEST lock.
3
GO
Open the next menu and follow the screen
instructions.
Setting the Serial Port Communications Speed
The tester communications speed (baud rate) must
correspond to the communications speed of the
connected printer, barcode scanner, or computer.
To set the communications speed, do the following:
1
SET
UP
Open the set-up menu.
2 Highlight COMMS RATE set.
3
GO
Open the Serial port baud rate menu and
follow the screen instructions.
The Fluke 6500, SP1000 printer, SPScan15 barcode
scanner and Fluke PowerPAT PLUS software are set as
default to communicate at a COMMS RATE of 9600
baud.
It is recommended not to change this setting!
Installing - Formatting a Compact Flash Card
(Quick Format)
You can copy saved test results and user defined auto-
tests to a Type I Compact Flash Memory Card (FAT16
formatted) for backup purposes.
Only data media formatted with FAT16 are supported, i.e.
compact flash memory cards with 32MB to 1GB can be
used.
It is possible to store up to 512 files on a compact flash
memory card, with respect to card memory size
(1 download set = 1 file).
Compact flash cards vary in their specification and some
can cause interface problems with the Fluke 6500, due
the internal CF card design which may change from time
to time.
A document with recommendations of some tested CF
card brands and sizes is provided in the scope of supply
of every tester.

Fluke 6500
Users Manual
14
It is important that you follow the instructions on this
document to verify the compatibility of your compact flash
card together with the 6500 and that your PC can read
the compact flash card file before you carry out testing.
Caution
•Do not remove the card or do not press
the STOP key during a format or a write
operation. This will damage your card!
•Formatting a card will erase all data on
that card.
•Do not force the CF card into the 6500
card socket. If you encounter resistance,
stop and check that you have plugged in
the card in the correct orientation. If you
use force you may damage the card and
the card reader.
To install a card gently insert it into the slot, see figure 3.
To remove the card press the card eject button next to
the slot.
Figure 3. Inserting the CF card
To format the card, do the following:
1
SET
UP
Open the set-up menu.
2 Highlight FORMAT a Compact Flash card
3
GO
Open the Format menu and follow the
screen instructions.
Note:
If the card has an invalid file format (FAT12 or FAT32) a
screen message will prompt you to format the CF card.
If you are formatting a CF card on a PC, please ensure
you format it to FAT 16 (not FAT 32)!