Revenue Grade Watt-Hour Meters

Watt-Hours Meters are devices that measure the amount of electricity used by a residence or business location. Use relays to remotely disconnect energy and are assembled on a plastic base

CURRENT TRANSFORMERS

Falco designs and develops Current Transformers (CTs) for Watt-Hour meters that meet the precision and mechanical requirements of the application. CTs are engineered to comply with the relevant ANSI and IEC standards, encompassing all requirements for accuracy and external influences.

Different CT configurations are offered including potted, pin, or lead out terminations, as well as with the embedded primary conductor. A magnetic shield can be incorporated to mitigate the core saturation caused by unwanted external magnetic fields such as tampering attempts.

State-of-the-art calibration panels for electricity meters enable us to test linearity across various power factors and temperature ranges from -40°C to +85°C, along with DC tolerance assessments. This capability allows us to optimize our current transformers in terms of size, performance, and cost.

Falco CTs are utilized in various single and three-phase electricity metering systems that require accuracy. They are applicable in residential and industrial environments.

AC Current Transformers

  • Current range up to 400A
  • Customized current ratio from 1:100 up to 1:4000 or more upon request
  • Class 0.2 accuracy per ANSI C12.1, ANSI C12.20 and IEC 62053-22
  • Customized rectangular and Toroidal shapes to meet any footprint application
  • Shielded options against external magnetic fields are available
  • Assistance for UL-listing, UL-recognized components, or CE-marked option

DC Tolerant Current Transformers

  • Current ranges up to 200A
  • Full and partial DC tolerance per IEC 62053-21
  • Class 0.5 accuracy per IEC 62053-21
  • Customized rectangular and Toroidal shapes to meet any footprint application
  • Shielded options against external magnetic fields are available
  • Assistance for UL-listing, UL-recognized components, or CE-marked option

Single Phase AC CT

AS0W01

Features
  • Single-phase application
  • Nominal current: 200A
  • Current ratio: 1 to 3000
  • High accuracy: 0.2 Class per ANSI C12.1
  • Shielded enclosure against external magnetic fields for anti-tampering
Single Phase AC CT

Three Phase AC CT

AS0W02

Features
  • Three-phase application
  • Nominal current: 320A
  • Current ratio: 1 to 2000
  • High accuracy: 0.2 Class per ANSI C12.1
  • Epoxy sealed
Three Phase AC CT

RELAYS

Relays are extensively utilized in ANSI and IEC compliant electronics watt-hour meters. This product supports smart meters featuring remote disconnection capabilities, enabled by the incorporation of latching relays and revenue-grade CTs within assemblies. Falco manufactures relays in Mexico and CTs in all facilities.

Relay Assembly

RA0W01

Features
  • According to ANSI or IEC
  • Socket (type “S”) or Bottom-connected (type “A”)
  • Meets UL2735 for safety
  • CTs can be incorporated
Relay Assembly

BASE ASSEMBLIES

Includes the plastic base, current terminals, current transformers, wire harnesses, and the relay.

Falco controls the entire manufacturing process, which includes injection molding, metal stamping, tin plating, terminal crimping, welding, and CTs. Final testing is automated using image recognition software. Units are serialized with a 2D label or laser-engraved, and the associated test data is stored for traceability and analysis.

The bases for our electricity meters are extensively utilized in ANSI and IEC-compliant electronic watt-hour meters. These bases support smart meters featuring remote disconnection capabilities, enabled by the incorporation of latching relays within the assemblies. Falco manufactures meter bases at its facilities in China and Mexico, facilitating efficient shipping to markets across Asia, Europe, and the Americas.

Meter Base Assembly

MSAW01

Features
  • According to ANSI or IEC for physical aspects
  • Socket (type “S”) or Bottom-connected (type “A”)
  • Made to meet UL2735 for safety
  • Single and Polyphase bases
  • Fully automatic system for inspection
  • Current transformer, wire harnesses, plastic and metal parts produced by Falco
  • Latching relay assembly
Meter Base Assembly

COMPLETE METER ASSEMBLY

Complete smart watt-hour meter assembly

Smart Watt-Hour Meters accurately measure electrical energy consumption while enabling utilities and energy providers to monitor, manage, and control electrical service

Smart watt-hour meter assembly detail

Falco provides turnkey manufacturing solutions for complete smart watt-hour meters, integrating component manufacturing, PCBA, final assembly, calibration, serialization, and testing into a streamlined manufacturing solution.

Our vertically integrated capabilities include current transformers, magnetics, stamped and plated components, injection-molded parts, wire harnesses, switching relays, PCB assemblies, and final meter integration. This extensive in-house manufacturing capability enables Falco to provide customers with greater supply-chain control, consistent quality, competitive cost, and scalable production for utility and smart-grid applications.

Meter configurations can be customized to meet specific residential, commercial, and industrial applications.

Residential Smart Meters

  • Switched and non-switched configurations
  • Multiple current ratings and meter forms
  • Integrated revenue-grade current sensing
  • Residential and light-commercial applications
  • Custom configurations available

Commercial & industrial Smart Meters

  • Switched and non-switched configurations
  • Single- and multi-phase configurations
  • Revenue-grade metering capability
  • Commercial and industrial applications
  • Custom configurations available

CAPABILITIES

Metal Stamping

Metal Stamping

110–160 ton stamping capability with in-house tooling maintenance for meter blades, terminals, bus bars, brackets, and other precision metal components.

Plating

Plating

Automated barrel plating capability, including tin and copper passivation, supporting high-volume production of electrical components.

Injection Molding

Injection Molding

Thermoplastic molding from 180–420 tons and thermoset molding up to 320 tons, supported by in-house mold maintenance.

Resistance Brazing / Welding

Resistance Brazing / Welding

Precision electrical-resistance joining processes for strong, repeatable, highly conductive electrical connections.

PCBA Manufacturing

PCBA Manufacturing

Surface-mount (SMT) and through-hole (THT) manufacturing capabilities for meter electronics and control assemblies.

Revenue-Grade Current Transformers

Revenue-Grade Current Transformers

  • Full range 20A – 320A
  • Accuracy 0.1 – 0.5
200 A Double-Pole Latching Relay

200 A Double-Pole Latching Relay

  • Designed for smart meter disconnect applications
  • High-current switching capability
  • Designed and validated to applicable meter requirements
  • ANSI compliance
Wire Harness Manufacturing

Wire Harness Manufacturing

  • UL-recognized wire harness capability
  • Automated wire cutting, stripping, and crimping
  • Custom harness design and manufacturing
Final Assembly & Traceability

Final Assembly & Traceability

  • Design for Manufacturing (DFM)
  • Lean manufacturing processes
  • Controlled assembly and torque verification
  • Full product traceability
  • Custom serialization and laser marking
End-of-Line Testing

End-of-Line Testing

  • Automated electrical testing
  • Current and voltage verification
  • Dielectric / Hi-Pot testing
  • Meter accuracy verification
  • Functional testing
  • Automated data collection and traceability
Calibration

Calibration

Each finished meter undergoes automated calibration and accuracy verification prior to final inspection and packaging. Test results can be recorded and linked to the meter's unique serial number to provide complete manufacturing traceability.