Meter test system "ISKRAMATIC CATS"

GENERAL INTRODUCTION
Contents
1. General description ...................................................................................................................... 3
2. Structure of the system "Iskramatic CATS" ............................................................................... 3
2.2. Iskramatic CATS - connection diagram ...................................................................................... 4
2.3. Functioning of Iskramatic CATS ................................................................................................. 4
2.4. Power source ................................................................................................................................ 5
2.5. Reference standard meter – ANT 310x ....................................................................................... 7
2.6. Meter test bench ........................................................................................................................... 7
2.6.1. Test tunnel with movable racks .................................................................................................. 8
2.6.2. Static test rack ............................................................................................................................ 10
2.6.3. Measuring system ...................................................................................................................... 11
2.6.4. Quick - acting connectors.......................................................................................................... 12
2.7. Personal computer and printer ................................................................................................. 12
2.8. Software CATS............................................................................................................................ 12
2.9. Optional equipment .................................................................................................................... 13
2.9.1. Hand held terminal ..................................................................................................................... 13
2.9.3. ICT ............................................................................................................................................... 14

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1. General description
"Iskramatic CATS" is Computer Aided Test System designed for electricity meter
testing. The system includes all devices that are needed for simultaneous:
➢ Adjustment
➢ Testing, calibration and certification up to 80 electricity meters.

The system has following characteristics:

➢ Modular construction that enables step-by step building or later modernization of
the system.
➢ Enables testing of the meters, classes 0.1, 0.2, 0.5, 1 and 2.
➢ Enables testing of single-phase or three-phase meters (3-wire or 4-wire) for
active, reactive energy. It can also test 4-Q meters. The tested meters can be
electromechanical or electronic.
➢ Enables simultaneous testing of meters with a different meter constant.
➢ The energy comparison method is used.
➢ The reference standard meter is directly connected to the test circuit which
ensures high precision of the system.
➢ Special version of system enables testing with closed links.
➢ Enables semi - automatic adjusting and automatic calibration and certification.
➢ The system is controlled by PC which controls the power source and execution of
different adjusting, testing or calibration procedures.
➢ It enables archiving, processing and transferring of data as well as printing of the
test results.
The structure of the concrete system determines characteristics and possibilities of
the system (for instance: If the single-phase power supply is built in the system, we
cannot expect to test the three-phase meters).

2. Structure of the system "Iskramatic CATS"

Iskramatic CATS system consists of:

➢ Power source.
➢ Reference standard meter.
➢ Test gantry (tunnel) and movable racks or alternatively a static meter rack,
including:
o Measuring places - clamping devices,
o Scanning heads and a support for scanning heads,
o Error meters – calculators,
o Junction box,
➢ Personal computer and printer.
➢ Software CATS.
➢ Optional equipment (a hand-held terminal, additional displays unit, MSVT, ICT
etc.)

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2.2. Iskramatic CATS - connection diagram

Figure 1: CATS connection diagram

2.3. Functioning of Iskramatic CATS

The basic intention of the system is to enable up-to-date and reliable testing of
electricity meters, which includes the usage of energy comparison method. The PC
controls the total system and supervises the test procedures using CATS software.
A very important subsystem of Iskramatic system is the measuring system.
The measuring system consists of:
➢ Reference standard meter (ANT-310x)
➢ Scanning heads
➢ Error meters
➢ Junction box
➢ Personal computer

Operation principle:
Power source supplies energy to the meters under test as well as to the reference
standard meter that is directly connected to the test circuit. That means that the
reference standard receives equal energy as the meters under test. The accuracy
of the reference standard in this way determines the accuracy of the system.

The reference standard meter expresses the measured energy in the form of
impulses that are sent to the error meters.

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The scanning heads are used to get data of the measured energy of individual
meter under test. They read disk revolutions (mark on a disk) or LED blinks. The
impulses from the scanning heads are sent to the error calculators that count the
scanning heads impulses. Error meters receive all the time impulses from the
reference standard meter.
The result of the impulses from reference standard (final number of impulses - initial
number) is sent by error meters over the junction box to the PC where the error of
each individual meter is calculated on a base of comparison between expected
impulses and actually measured impulses of reference standard. The error of each
meter is expressed in % on each error meter and, in the same time, also on the PC
monitor.

2.4. Power source

The power sources used in the system can be:

➢ three-phase or single phase
➢ by power
o portable supplies energy up to 5 meters
o smaller supplies energy up to 20 meters
o medium supplies energy up to 40 meters
o bigger supplies energy up to 80 meters

General features of electronic power source:

➢ enables automatic procedures
➢ does not require stabilized mains
➢ enables choosing of frequency between 45 and 65Hz
➢ test current and test voltage are digitally generated. The digital sinus generator
is incorporated in each amplifier
➢ impulse switching amplifier technology with time discrete control, which is used
ensures high efficiency and low heat losses.

Short introduction of EPS80-3H three-phase power source (for 80 three-phase

meters). It has following characteristics (besides the mentioned ones):
➢ The power source is built in a double 19’’ cabinet
➢ is modularly built and has 3 voltage and 3 current amplifiers
➢ the reference standard meter is built in the same cabinet
➢ it is controlled by PC

The technical data refer to the basic version.

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 Figure 2: Three phase power source

EPS 40 – 3H technical data:

Supply voltage: 3 x 230/400 Vac ± 10% (can be adapted by customer

wishes)
Supply frequency: 50 or 60Hz
Power requirements: 3 x 5 kVA

Voltage outputs: 30 V to 320 V phase sinusoidal voltage or 35 V to 554 V

sinusoidal voltages among phases
Internal voltage ranges: 40 V; 80 V; 160 V; 320 V
Settings: 0.01 V;
Power output: 3 x 800 VA
Accuracy: better than 0.1 % of nominal range
Distortion:  0.5 %
Stability: better than 0.01 % per hour, after 30 min of operation at constant
reference conditions (temperature, humidity, load...)
Protection: overload, short circuit

Current outputs: 1 mA to 120 A sinusoidal current

Internal current ranges: 0.01 A; 0.1 A; 1 A; 10 A; 100 A
Settings: 0,01 mA up to 1A, 0,01 A over 1A
Power output: 3 x 5000 VA
Accuracy: better than 0.05 % of nominal range
Distortion:  0.5 %
Stability: better than 0.01 % (integration time 150 s), at constant
reference conditions (temperature, humidity, ...)
Protection: overload, short circuit

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Output frequency: 45 to 65 Hz, in steps of 0.01 Hz
Accuracy: ± 0.01 Hz

Phase angle: 0 to 359.99º, in steps of 0.01º

Accuracy: better than ± 0.1º

Harmonics: up to the 20th harmonic component at voltage and current

up to the 5th harmonics: max. 40 %
between the 6th and 20th harm.: max. 10 %
the sum of all harmonics: max. 40 %

Efficiency: better than 85 % at full load

Dimensions : 1200 (W) x 1650 (H) x 900 (D) mm

Weight: app. 550 kg

2.5. Reference standard meter – ANT 310x

The “ANT 310x” reference standard meter is integrated in the power source cabinet
and directly connected into the primary circuit. In this way the accuracy of the
reference standard determines the accuracy of the test equipment at the same time.
The measuring accuracy of the ANT 3105(2) three phase standard meter for active
and reactive power is better than 0.05% (0.02) (from measured value).

Figure 3: Reference standard meter ANT 310x

2.6. Meter test bench

Two basic possibilities are usually available for volume meter testing. One is a test
tunnel with movable racks and another is static test rack.
Iskra produces many versions of the racks. They are often designed according to
the customer's demands.
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2.6.1. Test tunnel with movable racks

The tunnel version improves capacities because meters loading and unloading
can be done separately (not in the system). Pre-heating of meters can also be
done on a movable rack out of a tunnel. If additional device for meter starting is
used, starting and running with no load can also be done separately.

The test tunnel

The test tunnel is made of aluminium profiles. The scanning heads and error
displays are mounted on the test tunnel. There are max. 40 measuring places,
twenty on each side in two lines. The scanning heads are set both individually
and collectively. Each scanning head has a support that enables fast - setting
and precise vertical setting. The tunnel is also provided with a mechanism for
fixing the rack with meters.

The movable racks

The meters under test are mounted on movable racks that are also made of
aluminium profiles. There are up to 40 measuring places. The meters can be
fixed on a rack with quick-acting connectors. The rack is connected to a power
source by a special cable with a special connector that enables quick change
of the movable racks.

Considering the number of the meters in the tunnel we are producing

➢ tunnels and movable racks for 40 meters which are normally used by meter
producers (4780 x 1350 x 2380 mm)

Figure 4: Double tunnel (2 x 40 meters)

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➢ and smaller one normally for 20 meters normally used in laboratories

Figure 5: Test tunnel for 20 meters

Figure 6: Movable rack for 20 meters

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2.6.2. Static test rack

Figure 7: Static test rack for 20 meters

A static test rack is recommended for testing of smaller quantities. It is also

made of aluminium profiles and is normally provided with 20 measuring places
- 10 on each side. The scanning heads and error displays are mounted on the
rack. The scanning heads settings are individual. Each scanning head has a
support that enables fast - setting and precise vertical setting. All scanning
heads can be moved up collectively left-right. The meters can be fixed on a rack
with quick-acting connectors. Max. current allowed is 100 A + 20% (basic
version).

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2.6.3. Measuring system

Measuring system consists beside the reference standard meter also:

The measuring system also consists of:
➢ scanning heads that are used for disk mark reading or LED blinks. There
are 3 versions of scanning heads. All of them are made in SMD
technology.
o FG-K scanning head for disk mark reading (electromechanical
meters)
o FG-L scanning head for LED - electronic meters
o FG-LK scanning head for both disk mark and LED

Figure 8: Scanning head FG-LK (and support)

➢ Sensor for optical communications - used for communication with

meter (maximum demand)
➢ Error meter - calculator calculates and displays the error of a single
meter in percentage. They are used also for testing meters with
impulse outputs. Special version is used also for testing
communication registers.
➢ Junction box - links together elements of the measuring system. The
communication processes between scanning heads, a reference
standard meter, error meters and a PC run over the junction box.
Besides this function, the junction box is also used for some other
functions, e.g. switching of tariffs.

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 2.6.4. Quick - acting connectors

Quick – acting connectors are used for quicker and easier connecting of meters
on the test rack. They also decrease the possibility of false connections.

Figure 9: Quick - acting connector - special version

2.7. Personal computer and printer

The personal computer controls the meter test equipment and testing procedures.
It is connected to the power source, reference standard and to the measuring
system.
Intel base with min 19” flat monitor, a laser printer A4, Windows 7 OS and adequate
version of CATS software are usually used.

2.8. Software CATS

CATS software is a modern and modularly built software that operates on Windows
operating system. Its modular construction offers a lot of possibilities for extensions
and for adaptation to the user’s needs. The operation of the program does not
require any special knowledge of electronic data processing; however, knowledge
of MS Windows is required. CATS software is installed on the PC that is used for
controlling all the elements of the Iskramatic system.
CATS software:
➢ Controls and supervises the power source (adjusts voltage, current, phase
angle, frequency, etc.)
➢ Enables displaying of actual values
➢ Enables manual or automatic performing of processes
➢ Controls and supervises simultaneous adjustment, automatic testing and
certification processes of max. 80 electricity meters. The meter constants can
be different
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➢ Enables preparation and storing of testing and calibrating procedures
➢ The results can be displayed, printed (also in the form of a test protocol) and/or
saved
➢ Enables export of data
➢ Enables different priorities of users
➢ Basic version of SW enables also testing of meters with impulse outputs

2.9. Optional equipment

2.9.1. Hand held terminal
A Psion Workabout PRO hand-held terminal with software is used for entering
specific data of the meters (serial number, register counts, etc.). A version of
the hand-held terminal with a bar code reader is also available.

Figure 10: Hand held terminal Psion Workabout PRO

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 2.9.2. ICT
Isolated current transformers enable measuring three and also single-phase
meters with closed links. ICTs transform precisely primary current in to
secondary current with ratio 1:1. Normally ICTs are electronic compensated
current transformers class 0.02% in whole range.

Figure 11: Insulated current transformer

Owing to periodical improvements of product the supplied product can differ in

some details from data stated in prospectus material. Any such difference hasn’t
influence on technical quality of product or system.

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