Are you facing the challenge of upgrading the energy monitoring system of an aging industrial park or busy commercial complex without interrupting production? For system integrators, retrofit projects are often more complex than new construction projects due to constraints such as limited space, outdated wiring, and stringent requirements for “zero downtime” installation.
How can you efficiently transform traditional distribution cabinets into smart energy systems that support the Internet of Things (IoT)? This guide provides an in-depth analysis of the core hardware for successful energy management retrofits—open-type current transformers (CTs) and flexible Rogowski coils—and their application strategies.
💡 Why Is “Retrofitting” Key To Modern Energy Management?
Most existing industrial and commercial buildings still rely on traditional mechanical meters or digital meters without networking capabilities. Retrofitting allows you to:
Avoid costly wiring: No need to replace the entire distribution cabinet.
Real-time data acquisition: Upgrade from traditional manual monthly meter readings to second-level cloud monitoring.
Compliance and sustainability: Meet new carbon emission regulations and ESG reporting standards.
⚙️ How Non-Invasive Monitoring Works
The core of modern energy renovation lies in non-invasive monitoring. By combining wireless communication and flexible sensing technologies, you can directly “clip” the monitoring system onto existing wiring.
Renovation Project Workflow:
Flexible Sensing: Depending on cable size and space, select either split-core current transformers (CTs) or flexible Rogowski coils. Rogowski coils can be wound like ropes around thick or irregular copper busbars without disconnecting wires.
Metering: Install compact DIN rail energy meters in the existing tiny gaps of the distribution cabinet.
Transmission: Data is sent to the gateway via LoRaWAN or 4G, completely eliminating long-distance RS485 signal cable cabling.
Analysis: Data visualization, billing management, and load analysis are achieved through a cloud platform.
📊 Core Technical Specifications for Retrofitted Electricity Meters
When selecting hardware for retrofit projects, physical dimensions and compatibility with different sensors are crucial.
| Feature | Retrofit Requirement | Compere Solution (KPM Series) |
|---|---|---|
| Mounting Type | Standard 35mm DIN Rail | Slim design for narrow cabinets |
| Current Input | Split-core CT or Rogowski Coil | Supports 5A to 6000A sensors |
| Communication | Wireless (No wall-drilling) | LoRa / WiFi / 4G / RS485 |
| Data Security | Advanced Encryption | Supports AES-128 / TLS 1.2 |
🔋 Strategic Solutions for Complex Retrofit Scenarios
Old Manufacturing Plants (Long-Range Wireless Coverage)
Pain Point: The factory area is huge, and re-laying RS485 communication cables is extremely costly.
Retrofit Solution: Use LoRaWAN wireless meters. They have strong wall-penetrating capabilities and wide coverage, allowing all production line meters to be connected to the central control room without a single signal cable.
Large Industrial Park Primary Distribution Cabinet (Ultra-High Current Monitoring)
Pain Point: The main cabinet has extremely high current (over 3000A), and the copper busbars are very thick and densely packed, making ordinary rigid current transformers too large to fit.
Retrofit Solution: Use flexible Rogowski coils. Utilizing their open, flexible design, they wrap around the busbars like a rope, and in conjunction with the KPM37’s built-in integrator, they achieve accurate monitoring of ultra-high currents without power interruption.
Commercial Centers and Retail Stores (High-Density Installation)
Pain Point: Frequent tenant turnover necessitates the addition of individual metering within extremely limited distribution boxes.
Solution: Utilize multi-circuit power meters (KPM312). A single device can monitor up to 12 circuits, saving 70% of installation space compared to traditional meters.
Data Centers and Hospitals (Absolute Power Outage Requirements)
Pain Point: Critical loads cannot be installed without power interruptions, requiring extremely high construction safety standards.
Solution: Rogowski coil solutions eliminate the need for physical wiring disconnection, and the output signal is in the millivolt range, eliminating the risk of high-voltage electric shock and ensuring 100% continuous power supply.
⚡ Advantages of Compere Meters in Retrofit Projects
Compere focuses on revitalizing “old” infrastructure with “smart” technology. Our industrial gray rail-mounted meters perfectly match Rogowski coils, aiming to provide global system integrators with the cleanest and most professional retrofit experience. All products adhere to international standards, feature an all-English interface, and meet international engineering standards.
🌍 Meet Us In Cape Town!
Welcome to Enlit Africa 2026, Booth A21, to witness our “Live Installation of Rogowski Coils” demonstration.
❓ Frequently Asked Questions (FAQ) About Energy Retrofit Projects
Q: Can the accuracy of the Rogowski coil meet the requirements for internal accounting?
A: Yes. Our Rogowski coils, used with the KPM37 meter, achieve 0.5s accuracy, fully meeting the needs of industrial-grade energy analysis and cost accounting.
Q: Can I install these meters without interrupting power?
A: Yes. By using our open-type CT or Rogowski coil, you can directly wrap it around a live cable. Only the voltage sampling end requires a simple connection, which can usually be easily done with an existing spare circuit breaker.
Q: Do these meters support my existing system?
A: No problem. Our meters support standard Modbus-RTU and MQTT protocols. We provide a complete register address table to ensure seamless integration with your software platform.
Still have questions?
For a detailed visual guide on how our app-enabled connectivity and electricity flow works, please see our system diagrams above.
