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Authorised distributorElectrical signature analysis (ESA)

ElectroSine – diagnosing motors and pumps through their current, right at the electrical panel

Every mechanical problem in a motor and the machine it drives leaves a characteristic trace in the current and voltage. ESine reads those signals at high resolution and applies machine learning to recognise developing faults – including faults that vibration analysis and routine inspections often miss.

In simple terms: a doctor uses an ECG to see heart problems without surgery. ESine takes the motor's "ECG" right at the electrical panel: worn bearings, misalignment, pump cavitation, windings about to burn out – each condition has its own waveform. Nothing touches the machine, so it suits motors that are remote, at height, submerged or in hazardous areas.
Real-world photos

ElectroSine ESine3 / ESine4 in the field

ESine device installed in an electrical panel
ESine device installed in an electrical panel
ESine electrical signature analysis software
ESine electrical signature analysis software
Industrial motors – the monitored assets
Industrial motors – the monitored assets
Bearing failure – a fault ESine detects through the current
Bearing failure – a fault ESine detects through the current

Photos: PlusSmart Technology (plussmart.tech).

How it works

How ElectroSine works

1stepsInstall the device at the MCC2stepsMeasure high-resolution current & voltage3stepsMachine-learning signature analysis4stepsFaults and trends identified
No sensors on the machineMeasures at the MCC using existing electrical signals – no climbing, no entering hazardous areas, no shutdown.
Electrical and mechanical faultsOne device sees windings, rotor, bearings, misalignment, gearboxes, belts and pump load.
Early detection with machine learningRecognises subtle changes in behaviour that vibration methods or traditional inspections easily miss.
Find energy wasteReduced motor efficiency, poor power factor, VFD harmonics – all directly affect your electricity bill.
Deploy at scaleESine4 continuously monitors many motors through existing electrical connections – suitable for the whole plant.
Combined with PlusSmartPlusSmart engineers translate results into actions, combining them with vibration, oil and VFD data.
Products & modules

What ElectroSine ESine3 / ESine4 includes

ESine3 – electrical signature monitoring at scale

Continuous electrical signal analysis for motors and driven equipment.

  • Uses current and voltage data to recognise developing mechanical and electrical faults
  • No additional sensors needed
  • Early fault detection, condition monitoring, performance insight
  • Lower installation complexity and cost

ESine4 – for complex systems

Advanced electrical analytics platform for multi-asset environments.

  • High-resolution, real-time current/voltage data
  • Full 3-phase analysis: voltage/current imbalance, negative-sequence components, phase loss, phase-to-phase fault location
  • True active/reactive power, NEMA/IEC derating factors
  • Phase sequence, zero-sequence ground faults
Suitable for

Typical equipment and industries

Medium- and low-voltage motorsSubmersible and well pumpsKiln fans, ID/FD fansCompressorsConveyors, crushersMotors in Ex areasMotors at height, hard to accessPlants with many motors
Fault groups ESine detects
RotorCracked/broken rotor bars, end rings, static/dynamic/mixed eccentricity
StatorTurn-to-turn shorts, insulation degradation, coil-to-coil shorts
BearingsOuter race (DE/NDE), inner race, rolling element defects, poor lubrication
MechanicalShaft/coupling misalignment, imbalance, looseness, gear mesh faults, broken teeth, coupling wear, belt tension
LoadPump cavitation, impeller anomalies, torque oscillation, overload, running unloaded
SupplyVoltage harmonics, frequency deviation, VFD harmonics, power factor, voltage sags/swells, poor connections
How to start

Nominate critical or hard-to-reach motors.

PlusSmart will assess them at the MCC and record a baseline dataset – once you have a baseline, every later change becomes visible.

Nominate motors
In-depth technical guide to ElectroSine

MCSA/ESA principles, the broken rotor bar example f(1±2s), derating for 3-phase voltage imbalance per NEMA MG-1, and comparison with vibration analysis.

Read the guide: Motor electrical signature analysis →Read the full technical article on HOANTRANTDH →
FAQ

ElectroSine frequently asked questions

Can it measure motors running on VFDs?

Yes. ESine analyses the harmonics caused by the VFD and separates them from mechanical fault signatures.

How is it different from vibration analysis?

Vibration analysis requires sensors on the machine and mainly sees mechanical faults. ESA measures at the electrical panel, sees both electrical faults (windings, rotor, supply) and mechanical ones, and works on inaccessible machines.

Does the machine need to be stopped for installation?

Installation at the MCC follows the plant's electrical safety procedures; it is often done during routine panel maintenance.

Works with
Contact PlusSmart

Does your plant have pumps that keep failing? Book a free site assessment

We review your existing operating data, identify the highest-risk pumps and propose monitoring that fits your budget. Quotations and lead times are provided directly by PlusSmart Technology – information is always confirmed.

HT
Hoan TranBusiness Manager, Vietnam · PlusSmart Vietnam · View the appointment letter+84 879 848 668 · hoan.tran@plussmart.tech

PlusSmart Technology Pte. Ltd. · 10 Anson Road, #21-07 International Plaza, Singapore 079903 · info@plussmart.tech · +65 8035 1434
Operating in Singapore · Vietnam · ASEAN

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