Electrical Signature Analysis (ESA)

Electrical Signature Analysis (ESA)

Electrical Signature Analysis (ESA) is a powerful, non-invasive diagnostic solution for detecting and trending motor faults using voltage and current signals. Designed to integrate with InsightCM™, ESA goes beyond traditional phasor and waveform analysis by computing detailed motor-specific features to detect early signs of mechanical and electrical degradation. It provides real-time insights into motor condition without interrupting operation, enabling predictive maintenance strategies and reducing unplanned downtime. ESA is cost-effective, scalable, and easy to implement near Motor Control Centers (MCCs) using existing infrastructure.

Key Features Of The Electrical Signature Analysis (ESA)

• Monitors voltage and current to detect electrical and mechanical faults

• Uses one acquisition device to monitor up to 9 motors on the same voltage bus

• Continuous monitoring with intelligent data gating to minimize bandwidth and storage

• Leverages existing CTs and PTs or allows for direct signal measurement

• Seamless integration with InsightCM™ for trending, alarms, and analytics

• Compact installation near MCCs reduces cable runs and total install cost

Failure Modes Detected

• Rotor bar damage

• Stator faults

• Misalignment

• Mechanical looseness

• Eccentricity

• Bearing faults

• Power quality issues

Efficiency & Scalability

ESA enables cost-effective condition monitoring of multiple motors in a facility using a single data acquisition unit. It minimizes sensing costs by reusing existing protective relay transformers (CTs and PTs), or by using direct measurement where needed. ESA is ideal for large or distributed motor fleets, delivering reliable fault detection with low overhead.

Startup Monitoring

Cutsforth’s ESA system includes intelligent edge gating that captures all critical startup events without overwhelming your network or storage. This ensures accurate fault detection while keeping system resources optimized.

InsightCM™ Visualization Tools

• Trend

• Waveform

• Spectrum

• High-resolution spectrum

• Torque waveform

• Phasor diagram

• Envelope (amplitude demodulation)

• Park-Clarke transformation

Applications

• Pumps

• Fans

• Compressors

• Blowers

• Industrial rotating machinery

• Any critical or frequently cycled motors

Benefits

• Predicts failures before they become critical

• Reduces downtime and maintenance costs

• Easy to deploy with or without existing infrastructure

• Supports predictive and prescriptive maintenance strategies

• Captures startup events in detail without burdening the network

• Scalable solution for monitoring entire fleets of motors