Electrical Signature Analysis

Turn Electrical Signals into Early Warnings

Protect Your Industrial Equipment with Advanced Electrical Signal Analysis

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Electrical Signal Analysis (ESA)

ESA measures 3-phase current and voltage signals from fixed- and variable-speed motors to detect subtle changes that reveal developing equipment faults. By analyzing variations in these signals, it can identify issues such as insulation breakdown, rotor bar defects, or load imbalances long before failure occurs. This non-intrusive method leverages existing electrical circuits to provide continuous, cost-effective monitoring that delivers early warning of both electrical and mechanical problems — offering a powerful, scalable way to improve reliability and reduce unplanned downtime.

Failure Modes Detected

  • Bearing issues
  • Load Imbalance
  • Rotor bar damage
  • Misalignment
  • Insulation breakdown
  • Mechanical looseness
  • Stator faults
  • Power quality issues
  • And more…

Customer Testimonials

“Cutsforth provided the high quality and individual detail that customers have learned to expect from a focused and dedicated subject matter expert. The close attention to detail resulted in our finding and repairing several other problems that could have been the root cause of past collector ring and brush problems.”

T.P.
Principal Engineer
Large East Coast Power Producer

"More informed replacement schedules optimize asset lifetime and performance, thereby reducing operational costs and business risk from unexpected failures."

Ethan Smith
EIT, Capital Planning Engineer
San Jose Water

"This is the first time I had a job from a company with unmatched response time, highly professional technicians, and more than 100% service satisfaction."

K.P.
Electrical Engineer
Consulting Company

InsightCM™: Catch Hidden Motor and Generator Faults Fast

InsightCM provides powerful tools for displaying and analyzing ESA measurements and waveforms, including:

  • Trend
  • Waveform
  • Spectrum
  • High-Resolution Spectrum
  • Torque Waveform
  • Phasor Diagram
  • Envelope (Amplitude Demodulation)
  • Park Clarke

Measurement Capabilities

How It Works

  • Uses current transducers (CTs) and potential transformers (PTs) for simple, cost-effective installation
  • Works across low-, medium-, and high-voltage motor applications
  • Monitors fixed-speed or variable-speed motors

A More Efficient Solution:

  • Up to 9 fixed-speed or up to 4 variable-speed motors on a single bus with one acquisition device
  • Installation near Motor Control Centers (MCCs) minimizes cable lengths and costs
  • Never miss a startup with continuous monitoring with intelligent edge gating that minimizes network bandwidth and storage

Additional Resources

Webinar: Discover Electrical Signature Analysis
Case Study: San Jose Water Reduces Operational Costs with Electrical Signal Analysis (ESA)
Webinar: Introduction to InsightCM

Electrical Signal Analysis FAQs

What is Electrical Signature Analysis (ESA)?

ESA is a non-invasive monitoring method that uses voltage and current signals to detect electrical and mechanical faults in motors and generators.

What types of issues can ESA detect?

ESA identifies rotor bar defects, eccentricity, misalignment, bearing wear, insulation problems, and other early-stage faults.

How does ESA differ from vibration monitoring?

Vibration tracks mechanical movement; ESA reads electrical patterns. Together, they provide a fuller picture of motor and generator health.

How does ESA relate to MCSA?

MCSA (Motor Current Signature Analysis) is a subset of ESA focused primarily on current signals. ESA expands on MCSA by analyzing both voltage and current, providing broader diagnostic insight into electrical and mechanical faults.

Does ESA require installing new sensors?

Often no — Cutsforth can use existing CTs and PTs for electrical measurements. If those aren’t available, ESA can be measured directly.

Can a single system monitor multiple motors?

Yes. One ESA acquisition unit can monitor up to nine fixed-speed motors or four VFD-driven motors.

Is ESA suitable for all voltage levels?

Yes. ESA works with low-, medium-, and high-voltage motors and generators.

How does ESA help reduce downtime?

By spotting abnormal electrical patterns early, ESA alerts teams to developing faults before they cause failures or trips.

Does ESA work with variable frequency drives (VFDs)?

Yes. Cutsforth’s ESA system is designed to analyze both fixed-speed and VFD-driven machines.

Can ESA integrate with InsightCM?

Absolutely. ESA data flows directly into InsightCM for trending, analysis, alarms, and unified condition monitoring.

How does ESA support maintenance planning?

It provides clear indicators of fault severity and progression, helping prioritize repairs and avoid unnecessary maintenance.