MotorPulse module

Many motor failures develop gradually and present warning signs before a breakdown occurs. But with hundreds or thousands of assets, often located in noisy or hard-to-access areas, these signs are often missed. MotorPulse continuously monitors asset health via its electrical waveform to identify developing issues early, giving maintenance teams time to investigate, order replacement parts, plan repairs and address problems before they lead to unplanned downtime or production disruptions.

MotorPulse helps maintenance teams focus resources on assets that require attention based on its condition instead of relying solely on fixed maintenance schedules. By identifying developing issues early, organizations can reduce emergency repairs, avoid secondary equipment damage, better plan maintenance activities and make more effective use of labor and spare parts.

Motor and pump issues often develop gradually, causing equipment to consume more energy long before a failure occurs. Problems such as bearing wear, stator winding degradation, cavitation, and operating away from the pump’s best efficiency point can all reduce system efficiency and increase energy costs. MotorPulse helps uncover emerging motor and pump issues early, enabling teams to restore equipment to optimal condition, improve efficiency, and reduce energy costs.

MotorPulse is well suited for industries that depend on the reliable operation of motor-driven equipment, including industrial, data center, critical infrastructure, and logistics. Any operation where motor failures can impact productivity, service continuity or maintenance costs can benefit from improved motor health visibility and foresight.

MotorPulse predicts bearing and stator winding faults up to months in advance.

MotorPulse can be used with low voltage AC induction three-phase motors greater than 1hp with any type of motor control.

By detecting pump cavitation, MotorPulse provides early warning of abnormal operating conditions that can ultimately lead to eroded impellers, damaged pump components, reduced efficiency, and ultimately lead to pump failure if left unchecked.

By continuously estimating pump flow, head, and efficiency – all from the motor current signature – MotorPulse enables maintenance and engineering teams to identify operating inefficiencies, uncover the root causes of degradation, and keep pumps running closer to their optimal operating point.

Traditional vibration monitoring systems can generate false alarms when normal changes in load or operating conditions affect vibration levels. MotorPulse reduces alarm fatigue by recognizing changes in motor load and operating conditions, automatically accounting for those variations during its analysis, and then distinguishing normal operating changes from actual developing equipment problems.

In addition, rather than overwhelming maintenance teams with excessive threshold-based alerts, MotorPulse focuses attention on progressive faults for specific failure modes. This helps maintenance teams avoid chasing false alarms and prioritize the issues most likely to affect equipment reliability, uptime, and efficiency.

Yes! MotorPulse modules can easily be retrofitted into existing low voltage motor control cabinets. This helps organizations add motor health visibility and predictive insights for the equipment they already have. 

MotorPulse measures the motor current through integrated pass-through CTs for motors rated up to 136 A, with support for external CTs on larger applications up to 800A. These integrated CTs continuously capture high-resolution waveform data without the need for vibration, temperature, or other external sensors mounted on the motor.

MotorPulse is designed for rapid time to value. Simply enter the motor nameplate information and, for pump applications, the pump curve profile to configure the module in the embedded web user interface. Then allow MotorPulse’s automated machine learning engine to train on normal operating conditions in less than two days. Once the training is completed, MotorPulse continuously delivers predictive motor and pump health insights, while also continuously learning as the motor is operated at different loads based on the application or season.

MotorPulse is certified to UL 61010-1 and UL 61010-2-30 safety standards for electrical measurement and control equipment and carries CE compliance, supporting safe installation in motor control panels and enclosures.