Exceeding Max Starts per Hour

A Critical Predictor of Equipment Failure

Understanding Excessive Start Cycles

In industrial and commercial electrical systems, motors and other rotating equipment are designed to operate within specific parameters, including the number of allowable starts per hour. When equipment exceeds its maximum recommended start cycles, it undergoes increased mechanical and electrical stress, leading to premature wear, overheating, and potential failure.

At Volta Insite, our InsiteAI technology detects excessive start cycles in real time, alerting facility managers before damage occurs. This predictive insight allows for proactive interventions, reducing unplanned downtime and extending equipment lifespan.

Why Exceeding Max Starts Per Hour is a Problem

Exceeding the recommended number of starts per hour can result in:

Increased Wear and Tear

Frequent starts and stops generate additional mechanical stress, causing accelerated degradation of components.

Overheating & Insulation Breakdown

Repeated inrush currents raise temperatures, leading to insulation failure and increased risk of electrical faults.

Higher Maintenance Costs

Increased cycling means more frequent servicing and replacements, adding unnecessary expenses.

Reduced Equipment Lifespan

Motors, compressors, and other assets fail prematurely due to excessive thermal and mechanical stress.

How InsiteAI Detects and Prevents This Issue

Volta Insite’s predictive maintenance platform continuously monitors electrical patterns to detect excessive start cycles. Our AI-driven insights provide:

Real-Time Alerts – Immediate notifications when equipment exceeds safe operating limits.

Root Cause Analysis – Identification of operational issues leading to excessive starts, such as improper control settings or fluctuating demand.

Automated Trend Reporting – Historical data tracking to identify recurring problems and prevent long-term damage.

Preventative Actions with Volta Insite

By integrating InsiteAI, businesses can:

• Set automated thresholds for allowable start cycles.

• Identify and correct control system malfunctions.

• Reduce stress on motors, compressors, and pumps.

• Lower maintenance costs and extend equipment life.

Protect Your Equipment with Predictive Maintenance

Excessive start cycles are an early warning sign of equipment failure. With Volta Insite, you can detect and prevent this issue before it leads to costly breakdowns. Contact us today to learn how our predictive maintenance solutions can protect your assets and keep your operations running smoothly.