Condition monitoring from the electrical cabinet
Understand developing faults. Decide what happens next.
SAM4 measures current and voltage at the motor control cabinet to detect changes in motor-driven equipment. Review the measurements and diagnosis with Samotics engineers, then plan maintenance around your site’s operating needs.
Customer results
Named customers, quantified outcomes, and independent verification where available.
Yorkshire Water
£10M+ estimated benefit across the deployment, per Yorkshire Water's own analysis. Contract awarded 2022.
4,000+ pumps monitored from the electrical panel. 15% of inspection trips replaced per year. Submerged pumps that mounted vibration sensors could not practically cover became part of a continuous monitoring programme.
Nyrstar
800% ROI in 11 months.
Zinc smelter assets monitored from the motor control cabinet, without placing sensors in the harsh process environment. SAM4 detected 7 developing faults before failure, including a damaged 10 kV rectifier cable that would have caused more than €1M in equipment damage.
Schiphol Airport
9 of 9 known failures detected, including bearing damage that vibration monitoring did not pick up.
Baggage handling motors monitored continuously across a 12-month trial.
“SAM4 detected possible bearing damage to the gearbox motor, which we had not picked up through our vibration monitoring.”
Need to validate the claims with a peer? Ask us for a relevant customer reference for your asset type or industry. See all customer results · Request a customer reference
The assets that matter most are often the hardest to monitor.
Many of your hardest assets to monitor are also the most critical. Submerged pumps. Enclosed drives. ATEX-zone motors. Rooftop fans. Confined-space equipment.
Mounting sensors on them means shutdowns, scaffolding, specialist access. Manual inspections fill the gap, but only as snapshots: between checks, deterioration develops unnoticed.
At fleet scale, those assets stay effectively unmonitored until performance drops, alarms trigger, or failure occurs.
“In the steel industry, assets frequently operate in conditions that are not hospitable to sensitive sensor technologies. The conveyors at our hot strip mill are a critical part of the production process, but it's virtually impossible to use manual or vibration-based techniques to assess their condition.”
Monitor equipment from the electrical cabinet
Every AC motor is also a sensor. Disturbances anywhere in the motor, drivetrain, or driven asset change how the motor draws current and voltage. The changes are small, but often repeatable. Rotor faults, misalignment, imbalance, bearing degradation, cavitation, and blockage can each leave fingerprints in the electrical signal.
SAM4 captures that signal at the motor control cabinet, analyses the patterns, and detects developing faults early enough for planned action.
Where SAM4 fits. SAM4 is strongest where a fault creates a measurable change in the motor current or voltage signature. The asset fit review tells you where it adds value, and where it does not.
One system: hardware, analytics, and expert review. SAM4 models flag candidate patterns. Samotics reliability engineers review ambiguous detections before they reach your team. Every alert carries the likely fault, severity, supporting evidence, and a recommended action. SAM4 runs standalone or alongside your vibration, SCADA, and maintenance tools. It fills the gap access-dependent systems leave open.
How ESA detects faults See the SAM4 platform Meet the monitoring team
Using SAM4 findings to plan maintenance
See what your team works with.
Start with fleet priorities, open a machine and review the evidence behind a finding. Explore the SAM4 views that support your next maintenance decision.
Explore the SAM4 product tour →Machine condition →Incident evidence →Energy performance →
See where attention is needed
Review which assets are healthy and which need attention. Open the finding to understand the affected equipment, severity and supporting evidence.
Check the fit for your equipment
SAM4 measures from the motor control cabinet. Explore coverage for submerged pumps, enclosed drives and other hard-to-reach assets, including the operating conditions that affect detection.
Detection performance you can inspect
95.5% recall on confirmed fault events. 2.1% post-review false-alert rate. From 2,087 reviewed events in the last 12 months: recall scored on 1,437 confirmed fault events, false-alert rate on 1,402 customer-facing alerts. Performance varies by asset type, fault mode, operating profile, and data quality.
Plan the next maintenance step
Use the diagnosis and recommended action alongside your plant knowledge. Discuss uncertain findings with Samotics and choose the inspection or maintenance response.
The assets SAM4 monitors.
Agitators & mixers
Archimedes screws
Canned motor pumps
Compressors
Conveyors
ESPs
Fans & blowers
LV motors
MV motors
Pumps
Submerged Sewage Pumps
Transmissions
Common questions
ESA reads current and voltage waveforms at the motor control cabinet. SAM4 analyses those signals to detect patterns linked to electrical, mechanical, and operational faults across the motor-driven system.
It can also track load, operating behaviour, efficiency losses, and performance drift. No sensors are mounted on the machine.
SAM4 monitors AC-motor-driven assets such as pumps, fans, compressors, conveyors, transmissions, ESPs, mixers, and motors. Suitability depends on motor type, load profile, operating behaviour, drivetrain configuration, and the fault modes you need to detect. That is why we start with an asset fit review.
Installation typically takes under 60 minutes per asset once cabinet access and safe-working approval are in place. Split-core current transformers clip onto existing cables in the motor control cabinet. Voltage connections require a short de-energisation at the cabinet. No field access to the asset is required.
Installation is fast, but useful monitoring depends on asset fit, operating data, correct configuration, and clear success criteria. The asset fit review covers all four before deployment.
ROI depends on asset criticality, failure rate, downtime cost, inspection effort, and deployment scale. The strongest evidence is customer-reported.
Yorkshire Water estimates benefit exceeding £10M across its deployment. DuPont has prevented €1.7M in costs across 15+ detections. During a 12-month pilot SAM4 detected 12 of 12 developing faults at ArcelorMittal; after rollout to 56 runout-table rollers, a further 27 detections saved an estimated 31 hours of downtime.
SAM4 integrates through REST API or MQTT. Common integrations include SAP PM, IBM Maximo, and other CMMS platforms. Diagnostic reports can be pushed into your existing work order flow, so teams can act inside the systems they already use.
Vibration monitoring provides strong diagnostics on accessible assets where sensors can be mounted close to the machine. SAM4 uses electrical signature analysis to monitor from the motor control cabinet. That makes it useful for assets where mounted sensors are difficult, unsafe, expensive, or impractical: submerged pumps, enclosed drives, hazardous-zone motors, rooftop fans, and distributed fleets.
The two methods are complementary. SAM4 does not replace vibration everywhere. It fills the monitoring gap where access-dependent methods struggle.
SAM4 scores detections by severity, urgency, and confidence. Ambiguous and edge-case detections are reviewed by Samotics reliability engineers before they reach your team. Post-review false-alert rate is 2.1%. Every customer-facing alert includes a diagnosis, severity assessment, supporting evidence, and a recommended action.
Find the assets your current sensors do not cover.
Start with an asset fit review. We map your rotating fleet, identify monitoring gaps, and show where SAM4 is likely to add value. You get an engineer-to-engineer view of fit, limits, deployment effort, and expected business case.