benlong 
Electric meter aging test bench
Three‑phase electric meter aging test bench with ZN‑D3000 precision power source. High‑density vertical rack (up to 96 positions), real‑time register monitoring, communication testing (RS485/optical), automatic protection, data logging. Reduces infant mortality, ensures 15‑year service life. IEC/ANSI compliant.
Three‑Phase Electricity Meter Aging Test Bench for Smart Meter Reliability
This reliability-tested electrical tester has been specifically designed to test thousands of three-phase multi-function smart meters for overall quality and endurance in high-volume applications. The tester uses the ZN-D3000 precision power supply to provide consistent voltage/current loads to simulate long-term field usage and to maintain measurement accuracy and structural integrity during ongoing static load. The tester is designed to support multiple simultaneous aging processes using modular connectors mounted on the vertical meter rack, making it an extremely high-density testing solution.
As part of its ongoing measurement process, the system tracks any changes in key indicators: such as dielectric strength, register accumulation (walking test) and communication protocol (IEC 62056 – 21, DLMS/COSEM) stability. The control interface can be used to adjust phase angle, harmonic distortion and load levels more precisely. Real-time data logging and automatic trip protection allow safe testing and historical records to be maintained over a 24/7 testing period. This robust testing regimen meets or exceeds International (IEC, ANSI) testing standards and guarantees 15-year service life under extreme conditions. By improving electronic devices’ rate of infant mortality, the bench provides long-term billing accuracy.
Standard delivery: 45-60 days | ZN‑D3000 power source | High‑density vertical rack
What is an Electric Meter Aging Test Bench?
An Aging Test Bench for Electric Meters is designed to perform accelerated life cycle (burn-in) testing of single-phase and three-phase energy meters using controlled voltages and currents under established environmental conditions (room temperature). By applying the rated voltage and current over an extended time (hours to days), early failures in electronic components, solder joints, and mechanical parts can be identified. A test bench is used with a high-precision programmable power supply (e.g., ZN-D3000), a high-density meter mounting rack with modular connectors, and data logging software. The test bench collects data for walking tests (i.e., register accumulations), communicating stability, and dielectric strength during the aging cycle of the meter. The Aging Test Bench System will also help to lower the infant mortality rate of smart meters and will ensure compliance with IEC 62053-11/22, ANSI C12, or specific customer reliability requirements. As a non-standard, custom solution, this system will be tailored to your specific meter form factor, number of positions (e.g., 24, 48, 96 meters), and communication protocols.
Synchronized three‑phase voltage & current, adjustable amplitude, phase, and harmonics.
Modular connectors for simultaneous testing of multiple meters (24‑96 positions).
Dielectric strength, register accumulation, communication protocol stability.
Overload, over‑temperature protection; CSV/MES export for traceability.
Test Features & System Components
Technical Specifications
| Power source model | ZN‑D3000 (programmable three‑phase) |
|---|---|
| Voltage output range | 0 – 480V AC (phase‑to‑neutral), adjustable– |
| Current output range | 0 – 120A per phase, programmable– |
| Frequency range | 45 – 65Hz, accuracy ±0.01Hz– |
| Harmonic simulation | 2nd – 21st order, programmable amplitude/phase– |
| Number of meter positions | Standard 24, 48, or 96 (customizable)– |
| Communication protocols | RS485 (Modbus, DLMS/COSEM), optical port, pulse output– |
| Monitoring parameters | Register accumulation (walking test), dielectric strength, communication errors, temperature– |
| Protection features | Overload, over‑temperature, short‑circuit, automatic trip– |
| Power supply | 380V ±10% 50Hz (main) | Control: 220V– |
Core Technical Advantages
High‑density parallel aging reduces cycle time
With up to 96 meter positions, the bench significantly accelerates burn‑in testing. Each position is independently monitored, allowing batch qualification without reducing throughput.
Precision ZN‑D3000 source for realistic grid simulation
The integrated power source delivers synchronized three‑phase voltage and current with adjustable phase angles, harmonics, and load levels. This simulates real‑world grid disturbances (voltage sags, harmonics) that affect meter performance.
Comprehensive communication & register monitoring
The bench reads meter registers via RS485 or optical port during the aging cycle, verifying that the accumulation remains accurate under continuous stress. Communication errors are logged for protocol stability analysis.
Automatic safety & data traceability
Real‑time trip protection prevents damage from meter failure. All test data (voltage/current logs, register values, error events) are saved and can be exported to MES or CSV, providing full traceability for ISO 17025 audits.
Customer Success Story – Smart Meter Manufacturer
A major manufacturer of smart meters required reduction of the field failure rate of their three phase meters due to electronic components failing early in their life cycle (infant mortality). In response to this need, Benlong provided a 96-position meter ageing test bench outfitted with a ZN-D3000 power supply and real time register monitoring equipment. Six months after the installation of these test benches:
Within less than 10 months after installation, the customer was able to benefit from the bench’s cost savings by securing a significant utility contract which required compliance with IEC 62053-22 standard.
Applications and Integration
Custom Engineering & Delivery
Request a Custom Electric Meter Aging Test Bench Quote
Provide us with your meter specifications, quantity of testing positions and communication protocol. We will have our engineers provide you with a custom-designed aging bench, using our ZN-D3000 power source along with complete data logging, as well as a comprehensive ROI report.
WhatsApp: +86 150 5837 0007 | Email: xsb@benlongkj.cn | English & Chinese support
Why Choose Benlong for Meter Aging Benches?
- 15+ years designing energy meter test equipment for utilities and manufacturers
- Proven ZN‑D3000 precision power source integration
- High‑density vertical racks (up to 96 positions)
- Real‑time register monitoring and communication testing
- Full traceability – data logging to MES, IEC/ANSI compliance
Typical Custom Bench Includes
Three-phase programmable power source – ZN-D3000, high-density meter rack (can be built to any design), modular test connectors, PLC Control/ HMI, live data logging software, RS485 + optical Port communication modules, overload + over-temperature protection, calibration certificate, installation + training, 1 yr. Warranty.
Frequently Asked Questions
Aging tests, based on a specified voltage and current rate, are applied to meters over a long period of time, like 24 to 72 hours, to identify electronic components (such as capacitors, power supplies, or solder joint connections) that are prone to failure in the field, thus helping reduce infant mortality and guarantee a long useful life of new products.
At regular intervals (hourly for example), the bench will obtain meter register reads via an RS485 or optical port and compute an accumulator for those meter registers to compare against a reference value for drift or communication errors (known as a “walking test”).
Definitely! Both single-phase and three-phase meter configurations will be available; this includes single-phase connection configurations utilizing single-phase power and three-phase connection configurations utilizing ZN-D3000 three-phase source configuration. Backup racks can be created, however they will require separate wiring.
The device can connect using RS485 (Modbus RTU, DLMS/COSEM), an optical port (IEC 62056-21), pulse outputs, or optionally wirelessly (LoRa, NB-IoT). Custom integrations can be made with the device.
Each meter position has an individual circuit breaker or fuse for failure isolation along with overload protection (current limitation), over-temperature shutdown, short circuit detection and ground fault protection.
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