ABB now offers the option of integrating Electrical Signature Analysis capabilities (ESA) into their ACS880 variable frequency drives. This development, expected to be globally available in November 2025, makes condition monitoring simpler and more scalable than ever.
Industrial teams want to protect and optimize their motor-driven assets. But enabling remote condition monitoring often means installing extra sensors, running cables, and scheduling downtime. These barriers force many manufacturers to delay or skip monitoring entirely, increasing the risk of unplanned shutdowns and business impacts.
Monitoring by using the drive as the sensor
Together with ABB, we’ve explored how to deliver ESA monitoring capabilities for the entire powertrain directly from the drive. This sets a baseline for applications like pumps and fans and gives a better view on the health status of the powertrain. ESA, when integrated in the drive, requires no additional installation work, and no disruption to industrial processes.
This meant rethinking how ESA standalone solution works at a fundamental level. We looked at how to extract the right data directly from the drive, process it reliably, and deliver the same actionable insights ESA is known for. ABB’s new control unit (UCU) that’s used on the ACS880 drive, currently being rolled out, enabled this breakthrough in data generation from the drive. While ABB drives are capable of monitoring their own health and providing condition-based maintenance recommendations, the integration of ESA enables monitoring from the drive of the connected rotating equipment as well. This unique set-up offers complete visibility into both the drive and the equipment it controls (like pumps, fans and conveyors). After thorough testing, refinement, and successful piloting, the solution is now ready to be rolled out to early adopters in selected countries.
Jasper Hoogeweegen, CEO of Samotics, said: “We believe this is the future of condition monitoring: built-in, effortless, and scalable. By embedding Samotics’ ESA capabilities into ABB’s variable frequency drives, we’re empowering industrial teams to unlock the value of their data and take control of asset health.”
Oswald Deuchar, Global Head of Modernization at ABB Motion Services, added: “Industrial players are increasingly shifting from reactive maintenance to data-driven approaches. By working closely with Samotics and combining our analytics capabilities in our drives, customer data-driven decision making will be enhanced, for added impact and higher asset performance.”
No trade-off on insight or accuracy
You may wonder if a drive-based solution can truly deliver the same depth of analysis as a standalone ESA solution. The answer is yes. The integrated version uses the exact same analytics engine as the standalone system, drawing directly on high-quality electrical data from the drive.
The system detects anomalous behavior in motors (e.g. rotor bar issues, bearing faults, misalignment and unbalance), gearboxes, belts and couplings, as well as in driven equipment (e.g. cavitation in pumps), and process-related inefficiencies.
So, while the setup is much easier to deploy, the insights are just as powerful.
How this changes daily operations
With ESA now embedded inside the ABB drive, teams can access continuous, remote monitoring data with integrated services from the manufacturer (ABB) itself. ESA sets a good baseline for applications like fans, pumps and conveyors, everything from within the drive. When more complex applications like compressors or crushers need to be monitored, the ESA baseline needs to be enriched with other monitoring techniques, such as vibration. We expect to gain insights on a wider range of assets and faults by combining ESA with vibration analysis.
The system is built to work in industrial conditions, and is particularly beneficial in dusty, wet, submerged or hostile environments.
What’s next
Today we have introduced the concept to a limited set of countries. The global launch is expected in the last months of 2025. In the meantime, customers can already pre-order the integration of ESA into ABB’s ACS880 variable frequency drives. This will secure availability and installation before the end of the year.
Beyond the ACS880, the concept is also available on modernized (upgrade/retrofit) ACS600 and ACS800 drives.
Join our limited early adopters list
We’re now opening up a limited early adopters program for industrial teams who want to be first in line to use the integrated solution in the field. This group will get priority access to the technology after the official launch in November. This means you will be up and running before the end of the year.
Spots are limited, so if you’re interested in joining the early adopters list, please leave your details via the form below.
Sign up for the early adopters list below
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