Application Note

Testing of DC Energy Meters

Author
Johannes Baurenhas | johannes.baurenhas@omicron.at

Date
May 4th, 2015

Related OMICRON Product

CMC Test Sets, CMEngine

Application Area
Meter testing

Keywords
DC Energy Meter, CMEngine application

Version
v1.0

Document ID
ANS_15004_ENU

Abstract
DC Meter testing with CMEngine Excel application
 General information

OMICRON electronics GmbH including all international branch offices is henceforth referred to as
OMICRON.
The product information, specifications, and technical data embodied in this application note represent the
technical status at the time of writing and are subject to change without prior notice.
We have done our best to ensure that the information given in this application note is useful, accurate and
entirely reliable. However, OMICRON does not assume responsibility for any inaccuracies which may be
present.
OMICRON translates this application note from the source language English into a number of other
languages. Any translation of this document is done for local requirements, and in the event of a dispute
between the English and a non-English version, the English version of this note shall govern.

All rights including translation reserved. Reproduction of any kind, for example, photocopying, microfilming,
optical character recognition and/or storage in electronic data processing systems, requires the explicit
consent of OMICRON. Reprinting, wholly or partly, is not permitted.
© OMICRON 2015 All rights reserved. This application note is a publication of OMICRON.

© OMICRON 2015 Page 2 of 15

 Content

1 Safety instructions ...............................................................................................................................4

2 General Introduction ............................................................................................................................5
3 Description of the test setup ...............................................................................................................6
3.1 Function of the used devices and accessories ...............................................................................6
3.2 Graphical wiring setup ....................................................................................................................7
3.3 Pictures of the setup .......................................................................................................................8
3.3.1 Picture of the complete test setup .......................................................................................8
3.3.2 Pictures of the single components ......................................................................................9
4 How to use the Excel application ..................................................................................................... 10
4.1 General explanation ..................................................................................................................... 10
4.2 Function of the buttons ................................................................................................................ 11
4.3 Troubleshooting ........................................................................................................................... 12
4.3.1 Wrong CMC connected .................................................................................................... 12
4.3.2 (ENG009 Syntax error) ..................................................................................................... 12
5 Calculation and accuracy ................................................................................................................. 13
5.1 Calculation of the displayed meter error ...................................................................................... 13
5.2 Accuracy of CMC 256plus ........................................................................................................... 13
6 Order details of accessories ............................................................................................................ 14

© OMICRON 2015 Page 3 of 15

1 Safety instructions
This application note may only be used in combination with the relevant product manuals which contain all
safety instructions. The user is fully responsibility for any application that makes use of OMICRON products.
Instructions are always characterized by a symbol even if they are included to a safety instruction.

DANGER
Death or severe injury caused by high voltage or current if the respective
protective measures are not complied.

 Carefully read and understand the content of this application note as well as
the manuals of the involved systems before starting its practical application.
 Please contact OMICRON before you continue the process if you do not
understand the safety instructions, operating instructions, or parts of it.
 Follow each instruction mentioned there especially the safety instructions
since this is the only way to avoid danger that can occur when working at
high voltage or high current systems.
 Furthermore, only use the involved equipment according to its intended
purpose to guarantee a safe operation.
 Existing national safety standards for accident prevention and
environmental protection may supplement the equipment’s manual.

Only experienced and competent professionals that are trained for working in high voltage or high current
environments may perform this application note. Additional the following qualifications are required:
• authorized to work in environments of energy generation, transmission or distribution and familiar
with the approved operating practices in such environments.
• familiar with the five safety rules.
• good knowledge of the CMC test set

© OMICRON 2015 Page 4 of 15

2 General Introduction
The Meter module of Test Universe is designed for testing AC energy meters, but it does not support DC
energy meters. Therefore this CMEngine based Excel application was developed, it allows to perform a DC
load test.
This Application Note explains how to test DC Energy Meters with the enclosed Excel-test-file.
The test file has been tested with the EM4T energy meter from LEM, but may work with other similar energy
meters as well.
The EM4T Energy Meter is a universal on-board energy meter which is used in electric traction units to
measure the exactly consumed and regenerated energy from the train. The meter can measure DC, 16.7 &
50 Hz. This is needed because trains often cross boarders and hence also the energy provider which means
also the frequencies can change from country to country.

The meter error is calculated as the following

ETest Object −ECMC

𝐸𝑟𝑟𝑜𝑟 𝑖𝑛 [%] = ∗ 100[%]
ECMC

ETest Object Energy measured by the meter (test object), set in the "Energy Nominal" entry field of the
Test tab.

ECMC Energy output by the CMC.

© OMICRON 2015 Page 5 of 15

3 Description of the test setup

3.1 Function of the used devices and accessories

CMC
The rooting of the output signals is pre-defined in the CMEngine code and can’t be changed in the Excel
application. This means it is needed to do the wiring as it is described under “3.2 Graphical wiring setup“.

CMLIB A
The CMLIB A is used to connect the low level signal outputs of the CMC with the Signal inputs of the
ISOCON and provide 1 to 5 Volts (with this Voltage span, the ISOCON signal converter provides 4-20mA)
The reason for this connection is because the low-level-outputs have a higher accuracy in this voltage range
as the voltage outputs in the front of the CMC.

ISOCON-6
This Signal Converter is used to simulate the small (mA) currents which are needed for the test object as the
current outputs of the CMC aren’t accurate enough in this range.
The signal converter needs an own power supply and an input voltage (from the low-level outputs of the
CMC (LLO)) which drives the output current. In our case it is configured to output (4-20mA) with an input
voltage from (1-5V). For this voltage the low-level-outputs are used (more details can be found on “3.3.2
Graphical wiring setup“).
For the configuration and calibration of the signal converter a separate application note is available:
“Simulating a 4…20mA Transducer with a CMC Test Set and a Signal Converter”
It can be downloaded from the customer area:
https://www.omicron.at/en/support/customer/knowledge-library/

OSH 256
The OSH passive optical scanning head is needed to detect the status of optical pulse LEDs of the meter.
An adapter cable for direct connection to the external interface connector on the rear of the CMC is included
in the delivery.

© OMICRON 2015 Page 6 of 15

3.2 Graphical wiring setup

Figure1: Schematic test setup with all components

© OMICRON 2015 Page 7 of 15

3.3 Pictures of the setup

3.3.1 Picture of the complete test setup

Figure2: Picture of the complete test setup

© OMICRON 2015 Page 8 of 15

3.3.2 Pictures of the single components

Figure 3: ISOCON-6 connection Figure 4: EM4T Meter connection

© OMICRON 2015 Page 9 of 15

4 How to use the Excel application

4.1 General explanation

After the wiring of the setup is finally done, please open the attached Excel file. This file contains three
sheets. The first one is “Test Object” where all needed information regarding the test object can be entered.
The fields “Tested accuracy” and “Test date” gets automatically entered after the test is successfully
finished.
The second sheet contains the graphical wiring setup.
The third Sheet is “Meter-Test” where the needed values have to be entered to start the test.

The first thing which has to be done is to enter the needed values under settings. In the example below the
corresponding values have already been entered.
Nominal current/voltage (prim) is needed for calculating the nominal Energy.

Nominal current/voltage (sec) is linked direct to the CMC outputs which are connected to the meter, here it
is advisable to double check the value before starting the test.

Pulse/Rotation is in our case 3 imp/kWh. This means for every kWh the LED of the meter blinks 3 times.

Settling time for this time (at the beginning of the test) the CMC outputs current but doesn’t measure the
pulses, because the meter need a few seconds to warmup.

Test pulses defines the duration of the test. As soon as the CMC has counted the amount of entered pulses
the test is finished and the actual values are calculated automatically.

© OMICRON 2015 Page 10 of 15

4.2 Function of the buttons

As all values are entered correctly, the test can be started.

Associate CMC: if there is a CMC connected to the PC (over ETH or USB) the software will find it and
connect to it automatically, the corresponding CMC type and serial number are added under Test Device.

AuxDC on/off: By clicking this button the CMC outputs immediately 110V per default, the voltage output
stops by a second click on the button.

Start: Starts the test. Secondary values of nominal voltage and nominal current are used for the test.

Stop: Stop the signal output of the CMC test set's analog immediately.

Protocol Export: This button collects all information which is entered in the Excel application sheets (Test
object detail, Wiring and a screenshot of the application) and merges them into a PDF file. Therefore Adobe
Reader has to be installed.

Figure 5: Excel application user interface, sheet “Meter-Test”

© OMICRON 2015 Page 11 of 15

4.3 Troubleshooting

4.3.1 Wrong CMC connected

If there are more than one devices connected to the PC, the program will always connect to the one which is
the first one in the “Test Set Association“ of Test Universe. To avoid connection problems it is recommended
to connect only one device directly to the PC.

4.3.2 (ENG009 Syntax error)

It can happen that by pressing the “Start” button a popup window opens and the following error message
occur “(ENG009) Syntax Error”. This problem is regarding a not accepted comma as a decimal symbol, just
change the comma (,) to a dot (.) and the application will run fine.
Therefore open “Region and Language” in the Windows Control Panel. Then under “Additional settings“ the
“Decimal symbol” has to be changed.

Figure 6: Region and Language settings Figure 7: Customize Format settings

© OMICRON 2015 Page 12 of 15

5 Calculation and accuracy

5.1 Calculation of the displayed meter error

ETest Object −ECMC

𝐸𝑟𝑟𝑜𝑟 𝑖𝑛 [%] = ∗ 100[%]
ECMC

ETest Object Energy measured by the meter (test object), set in the "Energy Nominal" field of the Test tab.

ECMC Energy output by the CMC.

5.2 Accuracy of CMC 256plus

Nominal Values are used for calculation (1A current outputs, 5V LLO outputs):

Guaranteed max. error of the current outputs

Error < 0.015 % of rd. + 0.01% of rg.+ ErrorDCoffset = 0.15 mA + 0.125 mA +0.3 mA= 0,0575%

Guaranteed max. error of the LLO outputs with calibrated ISOCON-6

Error = ErrorLLO + ErrorISOCON = 0.025%+0,05% = 0.075 %

© OMICRON 2015 Page 13 of 15

6 Order details of accessories

SEM 1 Scanning Equipment for Meters

SEM 1 contains the OSH 256 passive optical scanning head and an adapter cable
for direct connection to the EXIF connector on the rear of the CMC test set.
Order number: [VEHZ1158]

CMLIB A Set
The CMLIB A Set includes the CMLIB A and the 16-pole-LEMO cable to connect to
the low-level outputs of the CMC test set.
Order number: [VEHZ1105]

BNC to 4 mm (0.16 in) banana cable

Order Number: [VEHK0005]

More details can be found on our website:

https://www.omicron.at/en/products/all/secondary-testing-calibration/accessories/

Signal converter
For these tests the ISOCON-6 signal converter from IMO Precision Controls has been used.
Further details can be found on the manufacturer’s website: http://www.imopc.com/

© OMICRON 2015 Page 14 of 15

Support
When you are working with our products we want to provide you with the greatest possible
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