Motor Control Centers: Thermal Monitoring Solution

Motor Control Centers (MCC) are known to be prone to failure caused by loose or compromised connections. The joints most susceptible to faults are typically at the rear of the MCC bucket/in-drawer, and impossible to access for inspection without de-energizing (especially in-drawers). Many facilities don’t realize they have thermal issues until it’s too late, and damage has already occurred, which can be inconvenient and costly.

Yes. Exertherm's MCC solution can be used for both new build motor control centers as well as retrofit existing assets. 

Annual thermography inspections are typically conducted annually, which is less than 1% of a monitoring cycle. This approach relies on luck to detect a failure during an inspection. It also exposes maintenance personnel to safety risks whilst inspecting. In addition to this, the detection of compromised joints is more challenging when assets are deenergized. The use of thermal imaging to detect temperature rise in a cooling joint can give unreliable results that are not indicative of the true state of a connection under load.

To achieve a true operational likeness, inspections need to be performed whilst equipment is energized rather than de-energized due to connections cooling down. As personnel carry out inspections, actively seeking out problematic electrical joints, they become exposed to the potential safety risks resulting from loose connections.

Our patented MCC solution monitors 24x7, 365 days a year, and delivers 100% ‘always on’ uptime visibility for critical connections. The solution enables early detection of overheating joints, which are an early indicator of electrical component degradation.

The MCC solution is simple to install in new build or retrofit in existing equipment. The sensors operate as a standalone system, and use an algorithm to identify abnormal temperature rise before an electrical failure occurs. The solution also enables real time baseline data to be captured to provide trend analysis. 

Permanently installed sensors remove the need for personnel to engage with energized equipment to carry out condition assessment, minimizing safety risks.

Traditional inspections typically require equipment shutdown to allow physical access, which can not only give unreliable results, but result in the inconvenience of downtime and lost productivity.

Our ‘fit-and-forget’ thermal sensors offer a smarter alternative:

• 24x7 real-time insights to help reduce unplanned downtime
• Compliant by design with key safety standards such as NFPA 70B
• No shutdowns - no recalibration - no ongoing maintenance

Our solution supports predictive maintenance planning, keeping your operations safe, efficient, and audit ready.

Because it works, continuously. Continuous Thermal Monitoring (CTM) provides always-on, real-time insights that periodic inspections simply can’t match. That’s why every major OEM now recommends it as the standard for predictive maintenance helping facilities reduce risk, improve uptime, and stay compliant.