Asset maintenance solutions
Continuous thermal monitoring solutions
Eaton Exertherm continuous thermal monitoring solutions
Eaton Exertherm continuous thermal monitoring (CTM) is a leading-edge solution that provides an alternative to infrared (IR) thermography surveys to detect electrical issues.
Thermal sensors help to protect critical electrical infrastructure from expensive failures, reduce costs and unplanned downtime, and increase personnel safety. Add to this the acceleration of IIoT, making condition monitoring sensors essential to the acquisition of data to future-proof your most important asset: power.
What is continuous thermal monitoring (CTM)?
Eaton Exertherm continuous thermal monitoring (CTM) can predict up to 70% more failures in electrical assets than inspection.
CTM is the next technology step from periodic maintenance that is important for implementing condition-based monitoring practices. It is a solution that enables data capture for analysis, allowing trends to inform predictive maintenance, enhance personnel safety and extend critical electrical equipment reliability.
CTM supplements or complements traditional periodic IR imaging surveys and other maintenance practices, enabling electrical maintenance teams to predict failures, safeguard electrical equipment, and optimize performance.
Benefits of continuous thermal monitoring (CTM)
Reduce the likelihood of electrical failures and improve operational stability with 24/7 monitoring
Reduce electrical fire or explosion risk resulting from arc flash due to compromised electrical assets
Minimize human interaction with potentially faulty assets to increase personnel and on-site safety
Lower the need for additional costs and the unnecessary intrusion of unplanned maintenance
Help protect critical electrical assets
Build a more sustainable and resilient electrical infrastructure by identifying the symptoms of electrical power failures.
Future-proofing electrical assets with CTM eBook
A solution for your industry
Leverage CTM to help data centers digitize electrical asset maintenance and deliver more reliable services. See how the CTM solution can improve oil and gas industry safety.
Why choose Eaton Exertherm CTM?
Eaton is a leading provider of 24/7 thermal condition monitoring for electrical infrastructure, successfully installed worldwide by all major OEMs. We deliver complete OEM-neutral solutions for LV/MV switchgear, motor control centers, transformers and more. We’re so proud of our proven reliability we even offer a zero maintenance lifetime guarantee.
Contact one of our experts to learn more about our solutions for predictive maintenance solutions.
Frequently asked questions
From the basics to the more advanced, here’s a few questions we get asked a lot. If your question isn’t answered here please contact our sales team.
1.Why are Eaton Exertherm CTM sensors hardwired, not wireless?
The most important issue is that wireless sensors create a potential threat to critical infrastructure operations because such systems are hackable. Eaton sensors avoid any cyber security risks
Sensors described as wireless often have a very limited transmission distance – sometimes as low as 30 cm (SAW technology)
Wireless sensors require antenna to pick up the wireless signal –usually several antennas will be required per vertical column
The antenna are hard wired! - so perceived savings are actually not available
Wireless sensors operate on a limited number of frequencies – which can result in confusion if antenna pick up two sensors on same frequency – causes commissioning problems
The wireless systems can only normally be commissioned on-site
Wireless sensors require power to transmit the signal – that creates problems such as battery replacement costs / insufficient power to generate energy harvesting on LV equipment / requirement for re-calibration etc.
Eaton sensors avoid ALL these issues + Eaton sensors come with a Lifetime Warranty/ zero maintenance guarantee – something wireless sensors cannot guarantee
2.What integration options are available?
Raw data can be exported from Eaton Datacards in Modbus 485 protocol
Raw data can be exported in Modbus TCP/IP via use of a converter or via the Eaton EXT25 HMI module
Local and remote dry contact relays can be utilised via the Eaton EXT25 module
The MCC thermal monitoring solution enables remote alarm via dry contact relay / export of raw data via Modbus 485, or export of raw data in Modbus TCP/IP via the Eaton EXT25 HMI
The MCC thermal monitoring solution also provides a drawer/ bucket face mounted status LED to indicate Green = OK; Yellow = Warning level alarm; Red = Critical level alarm
3.Where would Eaton Exertherm CTM sensors be installed?
Bus joints of line and load side of main incomer air circuit breakers
Line and load side of bus couplers / tie breakers
Optional shipping split bus joints
Line side main incomer ACB
Incoming + outgoing power terminations fits inside the drawer/ bucket
Dry resin core transformers
HV both ends of coil terminations
Input / output cable terminations
Incomers (line and load side)
Bus couplers/ tie breakers,
Critical cable terminations
Motor Control Centers (MCC)
Battery connections into UPS
4.What is the ROI of installing Eaton Exertherm CTM sensors?
Independent research indicates that there will be generic savings of circa 12% on current Opex maintenance costs. In addition, 24/7 condition monitoring will detect approx. 70% more failures in advance of the failure than periodic inspections. This will save on repair and replacement of equipment + associated downtime costs. The combined effect will produce circa 30% overall savings when compared to periodic inspection maintenance regime.
Calculations for typical 10 x switchboards with 5 columns per board indicate total savings of circa $250,000 over lifetime (20 years) of equipment.
There is also the opportunity cost of not utilising condition monitoring. These include lost opportunity to increase safety by removing people from a place of potential risk to perform inspections.
Perhaps the greatest lost opportunity of not utilising condition monitoring will be the loss of the ability to collect 24/7 data of uniform quality for subsequent analysis to obtain the benefits of IIoT. Every piece of electrical equipment e.g. LV/MV switchboards, MCC, transformers etc which is built without the inclusion of sensors is building in obsolescence.
5.Why should I change from periodic thermal inspection to continuous thermal monitoring (CTM)?
There are a number of reasons which can be summarised as:
Thermal inspections on electrical equipment are normally undertaken annually – that is one day out of 365 – less than 1% – which means a high dependence on luck to detect a failure condition in advance of the failure
Thermal inspections are not integrated into SCADA / BMS computerised systems and so cannot provide alarm notifications, trending, analysis, etc.
The thermal inspection temperature measurements are highly dependent on the quality of thermal camera and operator, thus data produced is not of a uniform quality. Further, thermal window infrared transmission deteriorates over time, making accurate indications of Go / No Go situations unreliable
Eaton sensor technology provides proven accurate and reliable data of a uniform quality
The IIoT “revolution” will globally transform the way electrical infrastructure is procured, operated, and maintained across all major industries. Installing sensors to create the data for subsequent analysis is a key part of the IIoT jigsaw since No Sensor = No data!
ALL major OEMs now advocate the use of thermal condition monitoring over periodic inspection
The continuous thermal monitoring solution
A rise in temperature is the main symptom of a faulty joint or connection that can result in major power failure in your mission critical environment. Eaton Exertherm thermal monitoring enables fault detection and predictive analysis of electrical temperature data 24x7. We provide a comprehensive solution for low-voltage (LV) switchgear, medium-voltage (MV) switchgear, bus duct, motor control centers (MCC) and dry transformers, increasing efficiency and performance of your electrical infrastructure as an integral part of your predictive maintenance plan and IIoT strategy.
Applications for Eaton Exertherm CTM solutions
Continuous thermal monitoring for bus duct Continuous thermal monitoring for bus duct
Continuous thermal monitoring for bus duct
Continuous thermal monitoring for lv switchgear Continuous thermal monitoring for lv switchgear
Continuous thermal monitoring for lv switchgear
Continuous thermal monitoring for mv switchgear Continuous thermal monitoring for mv switchgear
Continuous thermal monitoring for mv switchgear
Continuous thermal monitoring for motor control centers Continuous thermal monitoring for motor control centers
Continuous thermal monitoring for motor control centers
Continuous thermal monitoring for dry type transformers Continuous thermal monitoring for dry type transformers
Continuous thermal monitoring for dry type transformers
Continuous thermal monitoring for lv transformers Continuous thermal monitoring for lv transformers
Continuous thermal monitoring for lv transformers
Continuous thermal monitoring for tap off / end feeder box Continuous thermal monitoring for tap off / end feeder box
Continuous thermal monitoring for tap off / end feeder box
Thermography vs monitoring
Discover the difference between periodic thermographic inspection and continuous thermal monitoring.
A current electrical inspection typically uses periodic thermographic scans to check temperature.
Predictive maintenance: Continuous thermal monitoring is the always-on sensor solution.
Explore the Exertherm product portfolio
Browse the complete range of Exertherm continuous thermal monitoring solutions, sensors, interfaces, and ordering references to support specification and project planning
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Explore continuous thermal monitoring: insights and case studies
Explore key insights and real-world case studies that demonstrate how this technology enhances safety, efficiency, and reliability in various industries.
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资料来源：企业官网公司简介（复核日期：2026-10-07）。