Engineering Instruction 6/1

Pages:
15
Title Date Issued :
03 September 2007
Electricity Meters And Associated Equipment
Supersedes:
None

Prepared By S. Sabao (O&CE) Review / Approved Date

Checked By B. Siso (DSM)

Approved By P.J. Simoyi (OD)

1. SCOPE

This Engineering Instruction has been issued with the intention of making all Engineering staff
conversant with the installation, care, checking and examination of the various types of meters
and associated equipment encountered in ZESA’s undertakings. These include all indicating,
integrating and recording metering and associated equipment installed in Power Stations, Sub-
stations and Consumers’ cubicles or premises. Reference is also made to the certification of
meters, at the consumer’s request, ‘off-circuit testing’ and routine testing of meters.

2. ASSOCIATED EQUIPMENT

Equipment connected to meters e.g. potential transformers, current transformers, Phase shifting
devices, resistance units, etc, must be regarded as associated equipment and may not necessarily
be interchangeable with other similar units.

Where it is possible it is essential that meters be tested with their associated equipment; and
where it is not possible, the associated equipment must be separately tested.

3. HANDLING, CARE AND STORAGE OF METERING EQUIPMENT

All metering equipment must be handled with great care if accuracy is to be

maintained. Jolting, jarring and vibration are the chief causes of departure from Meter Test
calibration values. Suitable boxes must be provided by the Meter Test Section for
transportation by road or rail. Damp packing material must not be used, as this is liable to
cause severe damage to the meters.

Foam rubber mats, covered with dark material to prevent deterioration, or foam plastic
approximately 25mm thick, provides adequate protection to metering equipment during
transportation.

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 Approved storage facilities for tested meters and metering equipment must be provided by
all district depots, permitting the meters to be stored vertically on racks, or horizontally on
shelves; the former being preferable.

4. TYPES OF METERS IN SERVICE

At present the following types of meters are in use in the Authority’s

Undertakings :

 Three-phase Programmable Meters :

 Spectra – 3Ph 3W (110V, 5A)
 Spectra – 3Ph 4W (230V, 5A)
 Enermax – 3Ph 3W (110V, 5A)
 Enermax – 3Ph 4W (230V, 5A)
 Enermax – 3Ph 3W (110V, 1A)
 Premier – 3Ph 4W (230V, 5A)
 Apex Statistical meters – 3Ph 3W (110V, 1A)

 Disc-type (Ferraris) meters :

 kWh meters – 3Ph 4W ( 380V/230V, whole current)
 kWh meters – 3Ph 4W ( 380V/230V, CT-operated )
 kWh meters – 3Ph 3W (550V)
 Maximum Demand kVA & kW (3Ph 3W, 110V & 550V)
 Maximum Demand kVA & kW (3Ph 4W, 380V/230V)
 kWh meters – 1Ph 2W

 Prepayment meters ( Single-phase)

 Cashpower 2000
 Cashpower Suprima

Maximum ratings for whole current meters are as follows:

 Single phase – 200/250V, 80A
 Three-phase, 4 wire – 230/380V, 100A and 160A
 Three-phase, 3 wire – 550V, 100A

For higher current ratings current transformers are employed.

Special cyclometer dials (instant change or impulse type) will be fitted almost exclusively
to all future purchases of electricity meters in preference to clock dials. These cyclometer
dials indicate whole numerals only. Friction troubles are virtually eliminated due to the use
of light acrylic resin rollers and improved bearings.

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 State-of-the-art Programmable, time-of use, meters have been installed for the metering of
large consumers requiring a Demand-Energy tariff.

Summation metering is employed for the metering of large consumers with more than one
point of supply. For the demand tariff this method of metering is essential to take into
account load diversity and obtain the correct summated maximum demand.

The Authority uses two types of summation meters:

a) Summation meters using summation current transformers
b) Summation meters, which receive impulses from individual feeder meters.

5 CURRENT AND VOLTAGE TRANSFORMERS

Large consumers are usually metered by means of HV metering equipment. This employs
current and voltage instrument transformers of suitable ratio and working voltage. The
meters are connected to the secondary circuits of the transformers, the train gears and
multiplying constants taking into account the CT and VT ratios.

Current and voltage transformers are used for the following reasons:

a) To insulate the metering equipment from HV supply

b) To transform primary HV voltages and load currents to secondary values well
within the design limitations of electricity meters.

The nominal ratio of transformation of voltage and current is always a standard ratio as laid
down in BS 3938: 1965 and 3941: 1968, for current and voltage transformers respectively.
For example, an 11000V/110V voltage transformer has a ratio of 100:1; and a 100/5A
current transformer has a ratio of 20:1.

All instrument transformers have ratio and phase angle errors, which vary with the change
of burden in the secondary circuit.

6. TESTING OF METERS

6.1 METER CERTIFICATION

A meter is certified when it has:

a. been tested and calibrated in accordance with the Clause 5.3 for Electricity Meters.
b. Been sealed by a person authorised to do so
c. Not been in service for longer periods than those stated below for different types of
meters.
 All single-phase kWh meters shall have a certification period of 12
years.
 All poly-phase kWh meters to have a certification period of 10 years
 All types of maximum demand meters to have a certification period of 8
years
 All impulse metering and other special metering equipment to have a
certification period of 3 years.

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6.2 LAPSING OF CERTIFICATION

The certification of a meter shall not be valid :

a) For longer than periods given in 5.1 c.
b) If it bears any signs of interference or tampering with seals, or the meter has been
subjected to rough handling, e.g. broken glass, damage to case, or other visible
defects.
c) In the case of meters used for temporary installations, after 6 months from date of
certification.
d) After a storage period of 2 years.

6.3 LIMITS OF ERROR

The limits of error for a Class 2 kWh meter are laid down on page 620 of the Federal
Government Notice No. 404 of 1961, Electricity (Supply) Regulations 1061 Act 8/56, part
VI, Standards of Measurements, Sub-Heading, Measurements of Electricity, Clause 60,
Sub-Clause (3), being 3% plus or minus.

These limits of error are not applicable to programmable meters since they are now Class 1
and Class 0.5. The acceptable limits of error for these meters shall be +/- 2% and +/- 1.5%
respectively.

A point to note is that in due course these regulations will be reviewed.

6.4 PHASE ROTATION

All poly-phase meters are tested for connection to a supply of standard phase rotation.

6.5 INSULATION TESTS

Insulation resistance is tested with a 500V D.C. insulation resistance tester, after which the
meter insulation is subjected to a flash test of 2 000V A.C. which shall be sinusoidal or
approximately so, at a standard frequency for the period of one minute.

6.6 CT SECONDARY CIRCUITS

Extreme care must be taken to avoid open-circuiting the secondary winding of a current
transformer whilst current is flowing in the primary circuit as this could result in a very
high voltage building up across the terminals with the attendant danger of electric shock
and possible break-down of winding insulation. CT characteristics might also be impaired
due to the core becoming magnetically biased resulting in incorrect registration or
indication of metering connected to the circuit. This bias can be rectified and the CT
returned to normal by Meter Test Section.

6.7 TESTING METERS “AT CONSUMERS’ REQUEST”

Where direct-connected meters are concerned, a check meter of similar voltage and current
rating must be installed in series with the meter in question, and left in circuit until such
time as the consumer advises that he is satisfied with the readings obtained. This work is to
be undertaken by District Staff.

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 Meters connected to the secondary circuit of the instrument transformers are to be treated
in the same manner as above, except that the connection for the check meter will be taken
from the meter test block.

In the event of a District Manager having doubts as to the capability of local staff to
undertake this work, the matter may be referred to either Harare or Bulawayo Meter Test
Section, for assistance.

If the difference in readings between the two meters is within the prescribed percentage
limits of +/- 3% (for a Class 2 meter) and +/- 2% (for a Class 1 meter) then the check meter
may be removed. If, however, the meter being checked is found to have errors beyond the
prescribed percentage limits, the faulty meter must be removed and despatched to either
Harare or Bulawayo Meter Test Section.

Check meters required for the above-mentioned tests must be requisitioned from either
Harare or Bulawayo Meter Test Section Stores.

Staff at both Meter Test Sections has been instructed to treat such orders as urgent. In the
case of a consumer being dissatisfied with the results obtained by using a check meter as
described he can request to have the meter removed for test, at either the Authority’s
Harare or Bulawayo Meter Test Calibration Laboratories. Should he prefer to have the
meter tested by an independent authority, this can also be arranged.

Both Meter Test Sections require prior advice of a meter to be tested at a consumer’s
request. If advice does not precede arrival of such a meter, it is possible that the meter may
be overhauled shortly after receipt, making it impossible to conduct the required “off-
circuit” test, to obtain “As Found” errors. The meter should be clearly labelled stating the
reason for its return.

Head Office must be kept fully advised of any action taken.

5.5 “OFF-CIRCUIT” TESTS

The following meters must be “off-circuit” tested at either Harare or Bulawayo Meter Test
Section on removal from service, and seals in all cases must be intact:

a) All impulse metering equipment

b) A consumer’s meter that, in the opinion of the District Manager, should be “off-circuit”
tested.

Before despatch to the Test Section concerned, meters described in any of the above clauses,
must be adequately labelled, stating that an “off-circuit” test is required.

5.6 TERMINATION OF CERTIFICATION PERIOD

In some instances, possibly due to the type of installation, location, or other circumstances, it
may be considered inconvenient, difficult or impossible to remove a meter for re-certification. In
such cases the Test Section catering for the district concerned must be notified. On such advice
being received, Meter Test Staff will either test and re-certify the meter on site, or other
arrangements will be made for its overhaul and re-calibration. Meter Test Section will issue a
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new meter certification docket on completion. It must be stressed that the responsibility for
advice of such an installation lies with the district concerned.

The responsibility for ensuring that meters do not remain in service beyond the certification
period lies with the District Manager in charge of the district office concerned.

5.7 CERTIFICATION DOCKETS AND LABELS

Dockets are issued by Harare and Bulawayo Meter Test Sections for retention as district records,
and indicate certification dates of meters issued to them by one or other of the Calibration
laboratories.

If the dockets are not received within a reasonable period after receipt of certified meters, the
Test Section concerned must be notified as their receipt should normally precede the arrival of
the meters to which they refer.

A self-adhesive label bearing the certification date is also gummed on top of each certified meter
before issue. This label must not be defaced or removed.

4. SEALING OF METERS

6.1 METER COVER

The Meter Test Section responsible for testing the meter always seals the meter cover and the
seals may on no account be broken by district staff, unless special permission to do so has been
granted by Meter Test Section. THE ONLY EXCEPTION to this rule will be in the case of a
meter being so badly damaged (by internal flashover) that the cyclometer reading is obscured,
due to carbon deposit on the interior of the meter window. The fact that the meter cover seals
were broken for this purpose must be entered on the meter docket notifying removal of the meter
from service.

6.2 METER TERMINAL COVER

This must be sealed by district staff on completion of installation of the meter, to prevent
tampering with terminal connections.

6.3 SEALING OF ASSOCIATED EQUIPMENT

This may be performed by Meter Test Section or district staff; depending on the design of the
equipment concerned. No sealing point must be left unsealed by district staff.

7.1 SEALING PLIERS

All meters issued by both Harare and Bulawayo Test Sections will bear seals embossed ZESA
plus a number preceded by a T. Sealing pliers employed by district staff will always bear a
distinctive serial number in addition to the letters ZESA.
A record of all sealing pliers issued to districts throughout the Authority is kept at Harare Meter
Test Section.

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In the event of a pair of sealing pliers being irretrievably lost or damaged, the respective Test
Section must be immediately notified.

5. INSTALLATION OF METERS

7.1 METER CUBICLES, PANELS AND BOARDS

Care must be taken to install meter cubicles, panels and boards, remote from sources of
vibration, dampness, heat, excessive dust, corrosive liquids and fumes which are liable to impair
accuracy or cause physical damage to metering equipment.

7.2 INCOMING MAINS

Test poly-phase incoming mains for standard phase rotation with a phase-rotation meter. THIS
IS IMPORTANT.

7.3 DIRECT CONNECTED METERS

Check potential links for loose connections. Check that the line and load leads are firmly held by
the terminal block pinching screws. Seal the terminal cover.

7.4 CT AND VT-OPERATED METERS

After the installation of the meter the Senior Customer Services Officer, or similar official must
check the work. In order to facilitate checking, all information is to be entered on a CT METER
INSTALLATION card, form E. 102 a copy of which is attached, and the completed card sent to
Head Office. Copies of these cards may be obtained from Head Office.

The following procedure is to be adopted:

a) The entire installation is to be checked against the correct Meter Connection Diagram and the
Drawing number entered on the form.
b) All primary and secondary connections must be checked for tightness. Where fitted, ammeter
selector switch contacts must be checked.
c) The insulation resistance of current and potential circuits must be checked with a 500V
insulation resistance tester or similar instrument. Each circuit should be earthed at one point
only.
d) With the installation energised, the voltage must be checked at the meter terminals and the
phase rotation at the meter terminals checked for standard phase rotation.
e) With the installation on load, the secondary current should be checked using clamp-on
portable ammeters or tong-testers, where possible. If necessary, use should be made of
ammeter selector switches or test terminal blocks, where fitted.

Under NO circumstances must the secondary winding be open-circuited while on load. (see
Section 5.6)

f) The direction of rotation with only one potential element at a time energised must be noted.
In three element meters this is done by disconnecting the voltage from two phases at a time.
In two element meters the voltage is disconnected from the Blue phase to give potential

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 across Red to Yellow only and from the Red phase to give potential from Blue to Yellow
only. The Yellow phase voltage is not disconnected.

In three element meters the direction of rotation will always be forward; but in two element
meters it is possible for the meter to rotate slowly in a reverse direction under poor power
factor conditions when only the red element is energised.

g) An estimate of the power factor should be made by one of the methods outlined in
Engineering instruction 6/2, and entered on the card.

h) All equipment should be sealed, including the test terminal block, terminal covers, fuses,
phase shifting transformer, etc.

Please note that it is essential that all metering installations at 11kV and above must be checked
and certified correct by a member from the Meter Test Section as soon as possible after
commissioning. However, the work must still be thoroughly checked by the Senior Customer
Services Officer as mentioned above, and the card forwarded to Head Office.

7.7 CHANGE OF CT RATIO

All metering installations where the CT ratio is changed are to be re-commissioned completely
and a completed CT METER INSTALLATION card, Form E 102, sent to Head Office.

The respective Test Section must be contacted before making any change of the CT ratio. This is
to ascertain the correct primary linkage, if provided, and the secondary terminals to be used; and
also to check that the correct constants are programmed into the metering. All this ensures that
the database at the Test Section is kept up to date.

It is important to note that metering units employed on ZESA’s supply system vary in their mode
of obtaining the required CT ratio. There are three different types as follows:

TYPE A
The required CT ratio may be selected from a range of CT secondary terminals which are
marked accordingly and the CT primaries are not altered in any way.

TYPE B
In these units linking the HT primary CT windings in series or parallel effects the change of
ratio. These are normally dual ratio units. Only one set of secondary terminals is provided which
serves either CT ratio.

TYPE C
This unit is somewhat more complicated and has provision for linking the CT primary windings
in series or parallel, as well as specially marked CT secondary terminals. This scheme provides
three different CT ratios; for example, 60/5A with the primary links in parallel and 30/5A and
15/5A with the primary links in series, the secondary windings being centre-tapped to obtain the
additional ratio.

NB: Connection diagrams applicable to the above types of metering units will be issued for
inclusion in the meter diagram booklet.

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6. METER FAULTS

8.1 POTENTIAL COILS

Almost without exception, faults to which meters in service are prone will cause a drop in
consumption. The most prevalent source of trouble is an open circuited potential coil.

Should a sudden fall in consumption occur, particularly during the lightning season, HT and LT
potential fuses should be examined in the case of CT and VT operated meters. Should a fuse be
damaged, and on replacement cause no change in disc speed or in the case of a digital meter
cause no change in the displayed units, the meter must be considered faulty. This fault would be
due to an open circuit in the potential coil, it being understood that the element concerned is
carrying current.

Direct connected meters may be checked by opening the potential links and checking the disc
speed to ensure that each element is producing torque.

1000 watt, 20/230V, meter loading units suitable for testing 220/230V single-phase and
220/380V 3Ph 4W meters to ensure that each element produced torque when loaded, are
available ex-Test Departments, if required.

A further device is in use, employing a neon indicator lamp for installation with 220/380V, 3Ph
4W three element meters only. Depression of a push button indicates whether the potential coils
of the meter with which the device is inter-connected are healthy, partially so or completely
faulty.

A connection diagram and operating instructions are issued with each unit.
If a meter is not in circuit, continuity of potential coils may be checked by means of a megger or
continuity tester.

In the case of a meter becoming faulty, the reason, if known, must be noted on the meter docket
concerned.

NOTE: In the case of 3Ph 3 Wire meters with standard phase rotation
connection, the red element ceases to produce torque at 0.5pf
lagging. Below this value the torque is reversed.

8.2 INSULATION FAILURE

This trouble is usually obvious as the meter will almost invariably have flashed over between
phases, or to earth if housed in an earthed metal case. Direct connected meters will cause the
main switch to trip. Potential fuses may blow on replacement in the case of CT or CT and VT
operated meters.

8.3 ERRATIC ROTATION

A meter disc may rotate erratically due to some obstruction in the brake or electro-magnetic gap.
This is not a likely fault, however, as prior and subsequent to calibration, Meter Test staff before
sealing meters, carefully examines meter elements. An intermittent open circuit in one or more
potential coils will also cause erratic rotation of a meter disc.
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 8.4 LARGE VARIATION IN kWh CONSUMPTION OR KVA MD

The Finance Department will query a large variation in a consumer’s consumption, or maximum
demand, as it may be an indication that the metering equipment concerned has become during
the preceding month.

A variation beyond the limits of accuracy (+/- 3%) between the “Main” and “Check” meters of a
duplicate metering installation, should be investigated immediately by the district office
concerned.

8.5 ACCURACY IN DOUBT

Should there be the slightest doubt regarding the accuracy of metering equipment, for any
reason, Test Department must be informed without delay. This will ensure the institution of
immediate investigation; otherwise the Authority will lose a considerable amount of revenue.

7. METER REGISTERS AND CONSTANTS

9.1 MULTIPLYING CONSTANTS

A meter may be direct reading or the cyclometer reading may require a multiplying constant. In
the latter case, the constant will be clearly marked on the dial or in proximity thereto as in the
following example:

R x 20 – signifying the multiplication of the reading by 20

A constant is usually employed in the case of CT or CT and VT

operated meters.

In the case of programmable meters the constant is included at the

programming stage such that the displayed reading will be the actual
kWh or KVA. The programming is the responsibility of Meter Test
Section staff only.

9.2 METER REGISTERS

The lowest value cyclometer wheel or a direct reading register may have a value greater than 1
kWh per division, and this should always be checked as one or more 0’s may have to be added to
the meter reading as shown in the following examples:

1 kWh per division, meter reading 4 961

10 kWh per division, meter reading 49 610
100 kWh per division, meter reading 496 100

It is very essential that the value of the lowest value digit be carefully checked.

8. MAXIMUM DEMAND METERS

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10.1 A number of makes of meters are at present being utilised by
ZESA for the purpose of measuring the consumer’s kVA and/or
kW maximum demand.

10.2 MD METER OPERATION

Digital programmable meters have since replaced all the analogue MD meters with the manual
rest friction pointers; as well as the maxi-prints and printo-meters. Their operation is thus
different from that of the mechanical meters.

The programmable meters use the sampling method. This is where data is sampled every second
or minute, depending on the manufacturer’s specification, and this is then integrated over a
period of 30 minutes (ZESA tariffs use 30 minutes for the demand integration period). The
demand integration period defines the time interval between resets of the rising demand.

The highest MD value reached within the 30 minutes integration block is the one captured and
displayed on the meter on a specified register. This takes place over a specified billing period
(usually one calendar month) and then the highest maximum demand reading within the period
will be captured in the appropriate register. The data from the meter is obtained after the meter
has been downloaded using an opto-coupler together with a programmable data retrieval unit.

The bulk of the MD consumers are on a monthly MD tariff. However, there is a handful that is
on a daily MD tariff. In the case of the latter, the highest MD reached on each day is captured.
Metering staff has the responsibility of submitting this information to the respective Accounts
Sections in the various districts, for billing purposes.

Load profiles can be printed for specific periods in case there will be queries either from the consumer
or ZESA.

The programmable meters have the ability to register the kVA maximum demand correctly at all
power factors.

Should any of the programmable meters appear to be mal-functioning, the respective Meter Test
Section must be advised immediately. NO ATTEMPT at repairing or re-programming is
permitted for the districts.

9. GENERAL

11.1 TEST DEPARTMENT RESERVATIONS

Any work on metering installations involving impulsing meters, both ordinary and statistical.

11.2 METER WIRING DIAGRAMS BOOKLET

Each undertaking should be in possession of a meter wiring diagram booklet issued by the
Test Department. It contains a complete list of connection diagrams of meters used on
ZESA’s undertakings.
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 The booklet is revised periodically by Test Department.

11.3 SPECIAL DIAGRAMS

Special wiring diagrams not included in the Meter Connection Diagrams Booklet (11.2) will be
provided by Test Department on request.

11.4 METER TRANSACTIONS

All possible transactions between District Staff and consumers, concerning meters, are to be
found on Form A.56. This form is issued by the Stationery Department in book form and deals
with “Installations”, “Replacements”, “Disconnections”, “Change of Tenancy” and “Change of
Tariffs”. The form is self-explanatory.

Three copies, white, pink and green are for despatch to Head Office; the yellow one goes to the
District Office and the fifth copy which is blue, is retained by the Senior Customer Services
Officer.

11.5 ZESA (ZEDC) SERIAL NUMBER

Each meter is allocated a ZESA (ZEDC) serial number, usually stamped or printed on the name
or property plate. Only the ZESA (ZEDC) number must be used as a reference in any subsequent
correspondence concerning it.

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