3rd Edition
By: John .1. WiUiam, MSEE
President
Consumertronics Co.
Includes STOPPING POWER METERS 2ND EDITION, SPM ADDENDUM
And More!!
STOPPING POWER METERS is divided into two distinct bodies. The first body
covers watt-hour energy meters, how they work, how they are adjusted, and
the errors they produce. The second body is devoted to various techniques of
slowing do~,vn and stopping power meters.
This pamphlet is comprehensive, lengthy and full of valuable information.
Indepth theoretical knowledge is not required to understand and utilize it.
However, a very good practical electrical and electronic background and
know-how is a must. NOTE: The utility meter attached to your home or
business is a watthour meter - not a power meter.
CAUTIONS AND DISCLAIMERS
DO NOT USE THESE METHODS ON ANY METER BELONGING TO A UTILITY.
Completely isolate your utility meter from your personal meter with an
isolation transformer and/or heavy filtering. As hr as we know, the legality
of applying load control methods that incidentally make the utilityowned
meter underregister has not been legally tested. However, assume that the
law will take as dim a View of doing this as it does if you actually physically
tamper with the meter. It is ironic that many law enforcement agencies on
one hand can't seem to do enough to plea# utility big-shots while blithely
ignoring the many and extreme aimes committed by utilities upon the
citizenry. Fortunately, most juries savvy this perversity of the law and act
accordingWe must firmly state that we are totally against breaking the law in any
fashion and that WE FORBID ALL ILLEGAL APPLICATIONS..Also, no licence#
is granted under the copyright and/or patent rights of Consumertronics Co.
or anyone else. And, although we have made every reasonable effort to
provide accurate, reliable and useful information, we assume no
responsibility whatsoever for errors or omissions.
Be careful and know what you are doing. Induced currents can injure or kill
and mistakes can also cause# property damage. All circuit diagrams are
simplified; add fuses and circuit breakers as required.
WATTHOUR METERS
There is nothing magical or sacred about watthour meters.
Like any high-grade scientific instrument designed to accurately
measure an electrical parameter (energy, in kilo-watthours)
under specific operating conditions and an ideal environment,
they lose accuracy when their operating and environmental
conditions are less than ideal and thru the process of aging.
Watthour meters measure electrical energy consumed in a
dynamic load by using the principle of the 2-Phase induction
motor. IN FACT, IF THE ROTOR DISK WAS
RESTRAINED, THE WATTHOUR METER BECOMES A
CONSUMERTRONICS CO.
Copyright ~ 1979 John J. Williams ana
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ROTOR ASSEMBLY ~_ Rotor Plate - Fig. 1: Basic Elements of the Typical Induction Watthour Meter. The four
major manufacturers of watthour meters are: 1 ) General Electric. 2)
Sangamo. 3) Westinghouse. 4) Duncan.
The common inductance watthour meters design principle has remained
unchanged since 1925, but there have been some improvements in devoting,
roil design compenr, tion, otc., since then. To maintain accuracy watthour
meters must b calibrated frequently. Utilities u ually limit this recallibration
to: I) Full-Load Adjustment. 2) Light-Load Adjustment. 3) L~ Adjustment.
I~ FULL-LOAD ADJUSTMENT
The Full-Load Adjustment rating of most home and small business m~rs is 5
to 30 amps, printed on meter face. At a loss of some accuracy, most modem
meters are capable of measuring energies of up to 600% Full-Load Rabng.
This adjustment is made at full load and unity PF. It is done by assuring that
the braking magnets are of suitable strength. Then, by carefully varying
their positions, from thedisk or by adjusting the positions of the magnetic
shunts that lie between their Pob faces and the disk, by turning the
adjustment wh~l that has an "F" and "S" on it until disk speed is accurately ~t.
NOTE: In some cases the "S" direction speeds the meter up while the "F"
direction slows it down ~Duncan Meters). This opposite notation is designed
to fool and Fnalize meter tamFrers. This is the main adjustment that the
utility will make when either you or it is concerned about the meter's
ccurac~
2) LIGHT-LOAD ADJUSTMENT
Under light loads (10% of Full Load), meter performance becomes nonlinear.
This results from friction, lack of linearity
~
~ Registration Dials~
J ~
P ~
~REGISTER ASSEMBLY;
in the generation of driving torque as a function of load current;, and the
presence of torques due to the potential flux acting alone caused by the lack
of symmetry of the stator with respect to the disk. Uncompensated, meters
usually overregister under light loads. However, due to voltage coil flux
irregularities, it has not been uncommon for meters to run backwards under
li~ht loads. Slots and holes have ben put in the disks of modern meters to
prevent the disk from moving at all under very light loads ~less than 1% Full
Load). This adjustment essentially adds a controlled torque due to the
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other uulnerabilitie~
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P. 3
voltage flux alone sufficient to provide the correct disk sFed for 10% unity PF
loads. Compensation torque is provided by adding a shaded-pole loop known
as the Light-Load Plate. The necessity of this adjustment is apparent if the
disk turns in either direction when there is no load. This condition is known
as "meter aeeP- 3) LA~ AD,~USTMENT
Since the voltage coil has some resistance, the voltage flux lags line voltage
by less than 90~. A compensatory lag coil (See Fig. 11 or plate is provided to
adjust the lag so that it is as close to 90as possible. This adjustment is made
at 0.5 lagging PF. When the lag is out of adjustment, it almost always results
in underregistration, but it is hardly noticeable unless the PF is small. Any
lag adjustment made to inaea# disk sFed at lagging PF will decrease its speed
for leading PF (capacitative load). Often, the Light- Load and Lag
Adjustments are provided by the same mechanism. A radial motion provides
the Lag Adjustment while a circumferential motion provides the Light-Load
Adjustment.
WATTHOUR METER INACCURACIES
Utilities are fond of boasting that watthour meters are accurate to within ~1%
of actual consumption under conditions where load currents vary from 0.3%
to 400% and voltage from 80% to 120% of rated values, PF from 0.2 lagging
to 0.2 leading, and temperatures from -40 C to ~75 C. In my opinion, that
claim is utterly false. In reality, this is the very best case error for precise
ly
calibrated meters under laboratory conditions. Under the above "field"
conditions, cumulative error for a calibrated meter can be as high as 10096
under small loading conditions and higher than 10% under normal
home/business loads WITHOUT having made any effort to "fool" the meter.
These errors can result in either your or the utility's favor. When it favors
the utility, you'll never hear about it, and you will undoubtedly never collect
a dime for past overpayments. When the error is in your favor, if the utility
notices, you probably will b billed on a guessed-estimate arbitrarily
determined by the utility to adjust your costs upwards. And your meter will
b recalibrated or replaced by one more favorably calibrated for the utility,
andlor you may b monitored by a pole meter. However, unless you take the
initiative and even chronically complain, the utility will seldomly adjust an
overregistering meter to read the correct amounts.
Meter errors are caused by a number of factors, many of them interrelated.
These errors exist even when the meter is precisely calibrated. They are
accentuated when the Full-Load, Light Load and/or Lag adjustments are
required. No scientific instrument remains accurate if not frequently and
precisely calibrated, particularly an instrument in continuous outdoor use.
Wear, deterioration, temperature, humidity, dirt, electromagnetic fields and
vibration always take their toll. Meters usually spend years in operation,
AND SOMETIMES EVEN DECADES, between calibrations. Errors didn't matter
so much when rates were fair, such as in the 1960s and early 1970s.
However, few people can now afford to pay for their actual consumption much less for errors that are compounded by the Fuel Adjustment rip-off.
METER ERROR SOURCES
I) TEMPERATURE ERROR
Meters read high between O and 8~F and low thereafter. Error accentuates
with decreasing PF and alone can be as high as 4% at 0.5 PF. The main cause#
of this error is the increase in the voltage coil lag at low temperatures
(temporary error) and demagnetization of the braking magnets permanent
error) at high temperatures. ALL PERMANENT MAGNETS DEMAGNETIZE
WITH TIME, THE RATE OF WHICH IS DETERMINED BY TEMPERATURE, TIME,
QUALITY, AND ELECTROMAGNETIC FIELD EXPOSURE. The demagnetization of
braking magnets ALWAYS results in rotor speed-up and over registration I
2) FREQUENCY ERROR
Lille frequency seldomly varies more than ~ IX from 60 ~or 50) Hz. a 10%
variation of line frequency can result in a 1% or more error, particularly for
high PFs. Meter reads high at low frequencies ~to a point) and low at high
frequencies. Meter ~can perform erratically when harmonically rich
waveforms ~eg rectified sine wave) is applied to it at appreciable energy
levels. Error is higher for low PF loads at low frequency.
3) VOLTAGE ERROR
Generally, line voltage k stable to within+10% of rated. In cases of
overvoltage, watthour meters read substantially low due to significant AC
damping that results in some braking. This phenomenon is called "overload
droop" and is slightly higher for low PF. Watthour meters read slightly high
when voltage is low.
- 4) VERY HIGH OR VERY LOW LOADING
Very low loading almost always favors the utility, even for compensated
meters, up to the point where the meter stops turning. This error can
possibly be as much as 100% of actual consumption. Very high loading of
meter results in 'overload droop." For low PF, the meter almost always
reads high no matter the actual consumption.
6) METER DISSIPATION
Meters dissipate about IA watts on a continuous basis. Furthermore, if the
disk stops turning, 22-24 watts is required just to restart it. For the dubious
privilege of letting the utility monitor your electrical consumption, it costs
you about one KWH Fr month in meter dissipation alone.
6) VIBRATION AND SHOCK
Vibration and shock will uncalibrate any scientific instrument - including
watthour meters, causing it to either underregister or overregister. Thus, if
your meter is located where earthquakes have occurred, near heavy
machinery, or near high traffic flows, your meter may be put out of
calibration in a very short period of time.
The effects of most of these error mechanism are summarized in Fig. 2.
This section is dedicated to slowing down, even stopping power meters
without physically tampering with them or applying externally pnerated
power, and~ while consuming substantial power. WE MUST STATE
CATEGORICALLY THAT NO METHOD IS PROVIDED FOR ILLEGAL
APPLICATION WHATSOEVER. THIS INFORMATION IS PROVIDED FOR
EDUCATIONAL AND INFORMATIONAL PU RPOSES ONLY. WE ARE
ABSOLUTELY AND TOTALLY AGAINST BREAKING THE LAW IN ANY FASHION.
Any attempt to tamper with a utility meter is almost definitely illegal. It is
unclear to me whether the legal definition of tampering includes load control
methods. Some utilities define it ~:
"Tampering means any unauthorized interference with the Company's
equipment, including meters or other property, which would reduce the
accuracy of the measurement, or eliminate the measurement of the
electricity taken by any Customer or person on the premises, or any
unauthorized connection of a meter."
alter, frequency techniques are applied to the current thru the mster. Mixed
frequencies, ie rectified sine wave, will cause the rotor to behave erratically,
and if its energy is high enough, rotor sFed will drastically slow down and
may evenstop. Harmonically-rich waveforms require more energy to stop a
meter than DC or RF, simpy bcause most of its harmonic energy is in
freqwncies not very far from 60 Hz. Fast load surges will be far
underr~istered primarily due to he rotor inertia.
CAUTION: Line and induced volta~s can killl For all ehctrical projocts, be
certain that all circuit components induding wiring, can more than handle
worse case voltages currents and powers before proceeding to construct any
drcuit. U# sensible, safe and accurate wiring techniques and procedures, as
well as good judgment, at all times. YOUR SAFETY IS TOTALLY UP TO YOU.
If you do not have a power or KW-HR meter to practice on, either can be
obtained legally. KW-HR meters can be obtained by mail from ENGINEERING
ASSOCIATES, 7567 Rt. 49A East, Dept. C, Arcanum, OH 453C4. They sell a real
nice, rebuilt. Iike-new, GE 1-14, 5 Amp, 115 VAC KW-HR meter for ONLY
$2011 Owner's narne is Charles C. Littell, Jr.. (513) 692-5641 .
In our figurss, ~ represents line neutral, and ~7 represents earth ground
(ussd to ground cases in three wire 120 VAC systems). PIV designates peak
inverse or reverse voltap, or DC working voltap for capacitors. All figures are
simplified circuit diagrams. Add fu#/drcuit breaker protection as required.
In addition, all meters should have tNnsient suppression. Cl of Fi~s. 6 and 7
do a good job. For better transient suppression, GE, Schenectady, NY, does
excellent work in this area with very good GEMOV 19 Varistors. Transient
suppression is required to assure long lasting,rare-free psrformanres of
semiconductors, capacitors and other components. Even without our
methods, good transient and riwle eliminstion protects induction motors and
transformers, and shields applianres from utility ripde control of them. Our
RIPPLED OFF pamphlet explains transients, ripde, and utility apdiance and
Peak Demand Meter control in detail.
I) DC LOADS
DC Loading is the hardest to accomplish but it is the most effective method.
If you have induction motors or transformers~ they will also be adversely
affected by any DC that reaches them. C=500 uf, 25 PIV min. L=1000 turns
rriin., insulated wire on'about a l" soft-iron core. As with all suggested homemade inductors, keepwell insulated and don't U# a core that can be touched
(eg leg of a drill press). Cl are PaFr-Oil typss or Fig. 1 lelectrolytics, and a
re
1000 to 100,000 uf, 400 PIV, depandin~ upon load reactance. See Fiq. 3.
With the DC Method, three major problem areas have ari#n. Some are finding
that the Cl (Blocking Capacitors) are very expensive, overly bulky or difficult
to realize, even with the Fig.ll arrangement. The# capacitors are required
ONLY IF you apply the DC Method with other loads #nsitive to DC excitation
(induction motors and tNnsformers tend to saturate) simultaneously running
off the same meter. This problem is simply solved by running all your DC
experiments with all the #nsitive loads disconnected. With a DC current of
about 5 Amps, a substantial permanent decrea# in meter indication will
result with time due to permanentlyinduced malfunctions.
Problems involving the kickback of rectified AC into the DC power supply are
evident. We u#d a very heavy duty charger (like that found in garages) and
didn't ob#rve any malfunctions. Fig. 4 illustrates two approaches of
overcoming this problem, making it possible to realize this method with a
smaller, home-type auto-battery charger.
The Fig. 3 circuit only affeas the current coils of the meter. This is becau# th
e
meter's voltage coil is across the outputs of the two rectifiers. To get the
voltage coil into the act, we used the circuit of Fig. 5. We obtained
satisfactory results with both approaches, but customers prefer the Fig. 5
approach.
Be careful when using the DC mathod. Other meters sharing the same power
transformer #condary will also be slowed down. However, becau# the loads
on any other meters will probably not be DC isolated, havoc could result in
their operations.
Stoppin~ Power Meters
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Fig. 5: Alternate DC Method. Voltage Coil (VC) is in the Q DC circuit. CCs are
Current Coils of meter. C and C1s, same as n Fig. 3. Rs are 120V heater
elements. Rect. is 1N1198A. See ~S
teYt
Fig. 6: Frequency Method using capacitative coupling. C is between 0.01 and
0.001 uf, 400 PIV. C1=2' uf polypropylene. L=100 turns. See text.
~,~ RG SB or 5 ~, ~
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Other
Clr
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P. 7
technique is easier to apply than the DC Method and can be more effective.
In fact, it can be made so effective that it would permanently wreck your
meter by disrupting its carefully balanced mechanical system and/or by
shorting out the voltage coil windings. The result of this damage can usually
be physically observed - the meter either fails to indicate or its action is
erratic often with scraping sounds. "The Flasher" managed to accidentally
wreck his utility meter in this fashion. Why utilities would react to this in an
hysterical
manner is beyond me since they cavalierly inject line ripple onto your power
line with no regard to the destructive effects it has on YOUR equipment and
on YOUR lifel
As with the DC Method, we suggest that you disconnect all other AC loads
from the rneter's circuit.
We used a commercial photoflash unit alled a SYNCHRO TESTER (National
Camera, Inc., 2000 West Union Ave., Englewood, Colo.). Check with your
amera store on vsrieties. Our unit outputs about 400 Volts, 1 to 50 msec.
duration per "flash."
The circuit of Fig. 13 would work just as well. Plate transformers are cheap
surplus items. You should be able to control voltage level with a rheostat.
The storage capacitor discharge can be controlled by an electromechanical or
solid state relay (SSR~ or even a telegrapher's key. The former two can be
electronically controlled to provide consistent and programmable results.
Voltage level duration and repetition rate should initially be low anri slowly
inaeased until the desired results are realized. Patience and perserverance
are musts to get optimum results and to gain valuable experience and
knowledge about meters.
Mkter
240 V~C
PhotoFln~h
CircUl t
Fig. 12: Our infamous Magno-Brake Technique. C-5.0 uf 600 PIV. Ls are same
as Fig. 6. C1=50 uf, 600 PIV polypropylene or other "poly" type upacitors.
R211~wirewound with bolt insert, 50 Watts. See text.
z . 1 H ~ r
lOK ~ lOW~tt 0.02 ufl
n U ~
C~p. Control
~nk Circuit
Xfrm~.
Fig. 13: Simple, effective home made "photoflash" circuit. Points A and B
correspond to Fig. 12. The minimum stepup value of the plate transformer is
250 VAC. Transformers with higher step-up voltages result in a greater
dramatic effect on meters. Be sure that other circuit components can easily
and safely handle the voltage and power produced by whatever transformer
you choose. See text.
When using any of the four methods desaibed, different timing schemes can
be used. For instance, there may be some Friods that you find it highly
advantageous to stop or even reverse your power meter while restoring it to
P. 8
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