Motor control centers (MCCs) are prone to failures from loose or compromised connections, often at the rear of the bucket or in-drawer joints, which are impossible to inspect without de-energizing. Traditional maintenance methods rarely catch these problems early. Many facilities only discover thermal faults when damage is severe and repairs become expensive. Continuous thermal monitoring (CTM) for motor control centers provides real-time visibility into MCC health, enabling proactive intervention before failures disrupt operations.
The MCC datacard collects sensor temperature data to
activate alarms when a fault is detected
Non-powered sensors attach directly to the critical
incoming / outgoing power connections where they
continuously monitor temperature
A simple LED display provides local and visual
system status
The Eaton Exertherm continuous thermal monitoring for motor control center solution is the most advanced way to detect potentially compromised MCC assets before they fail and cause unexpected operational downtime, or worse, damage. Suitable for retrofit and new build installations, the in-bucket or in-drawer MCC solution provides protection from thermal asset changes where the eye can’t see and the hands can't reach. Our unique ‘fit and forget’ 24/7 electrical infrastructure monitoring technology gives you the peace of mind that your assets are running safely.
Continuous visibility at critical connection points
Monitor hard-to-reach MCC power terminations in real time, where faults are most likely to develop but are difficult to detect.
Simple deployment within MCC environments
Designed for in-drawer and in-bucket installation, supporting both retrofit and new-build applications without complex modification.
Reduced reliance on periodic inspections
Move beyond snapshot-based maintenance with continuous monitoring that captures changes between inspection intervals.
Improved personnel safety
Minimize the need for manual inspection of energised MCC equipment, reducing exposure and supporting safer maintenance practices.
MCC datacard
Collects sensor data
MCC status LED
Displays current monitoring status
MCC sensor loom
Connects to key monitoring points within the MCC
The MCC thermal monitoring ‘In-drawer’ solution can be connected in 3 ways.
Relay only
Local status LED visual with local/remote alarms
Exertherm Thermal Xpert 25
Local graphics on HMI and status LED with local/remote alarms, plus the transfer of raw data via Modbus TCP/IP
Exertherm MCC aggregator
Local status LED visual with local/remote alarms and the transfer of raw data via Modbus 485
Our CTM solution is designed as an OEM‑neutral solution to MCC thermal monitoring, enabling continuous visibility across motor control centre drawers and buckets regardless of manufacturer. It focuses on monitoring the hard‑to‑reach power connections where thermal faults are most likely to develop but are often difficult to detect using conventional methods.
By providing real‑time insight into temperature change at these critical points, it helps teams identify developing issues earlier and improves visibility into fault progression between inspection intervals. Suitable for both retrofit and new‑build MCC environments, the solution integrates easily into existing electrical infrastructure and reduces the need for interaction with energized equipment during maintenance activities to support safer working practices.
From the essentials to the more advanced, these are some of the questions we’re asked most often. Get in touch to learn more about MCC Monitoring Solution.
Our patented MCC solution monitors 24/7, 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:
Our solution supports predictive maintenance planning, keeping your operations safe, efficient, and audit ready.
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