The Value of Imaging Technology Throughout Data Facilities
Using thermal and acoustic cameras for condition monitoring allows operations managers to detect overheating equipment, energy inefficiencies, or asset irregularities before they lead to system failure and unplanned downtime
The explosive growth of artificial intelligence (AI), cloud computing, and real-time data processing has companies scrambling to expand data centers to meet demand, and with this expansion, the task of maintaining system uptime becomes increasingly complex.
Today’s data centers are designed to support AI-native workloads, which can require up to 50 times more power and cooling than traditional applications. With so much mechanical, electrical, and electronic infrastructure concentrated under one roof, overheating becomes a major concern—not only due to energy inefficiency but also because overheating can trigger cascading server failures, data loss, and service disruptions.
High-Tech Maintenance Inspections
Ensuring the continued operation of power distribution systems and cooling infrastructure for data centers is essential to maintaining uptime, preventing mechanical and electrical failures, and avoiding outages. These systems often heat up before they fail, and traditional inspections using infrared thermometers or fixed sensors may miss critical hot spots.
While these measure temperature reliably, they only provide a tiny portion of the whole picture. Unless the point of measurement happens to coincide with a hot spot, these inspections risk missing critical problems.
This thermal image shows an overhead bus duct from a power generator. Data centers need backup generators to ensure the continued flow of electricity in the event of a utility power outage.
Thermal imaging cameras—whether handheld or mounted throughout the data center—offer a comprehensive view of equipment temperatures. Technicians can use thermal cameras to detect problems in electrical switchgear, motors, uninterruptible power supplies (UPS), power distribution units (PDU), and generators as well as all the electrical devices feeding server systems.
For companies like Aston Martin Red Bull Racing, the key to catching potential failures in their headquarters' data center was regular inspections using a thermal imaging camera.
For example, they used a FLIR ONE® thermal camera to verify the effectiveness of water-cooled rear doors in their data center racks. The camera also helped identify high-load electrical boards and poor connections during spot checks.
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While there is a wide range of handheld thermal cameras on the market, professional models offer distinct advantages for predictive maintenance in data centers.
For example, FLIR T-Series cameras offer dual field-of-view and wide-angle lenses, enabling users to scan large areas or multiple components simultaneously. These cameras now integrate seamlessly with FLIR IgniteTM reporting and analysis software for automatic uploads, historical comparisons, and trend analysis.
Some thermal analysis software, such as FLIR Thermal Studio Pro, interacts with the camera itself to provide guided inspection routes and on-camera reference images, ensuring consistent, repeatable inspections of assets by any technician.
As for fixed cameras, the most recent models incorporate on-the-edge analytics and wireless capability, making them easy to integrate with existing monitoring systems. Many communicate through common modern industrial protocols such as REST and MQTT, simplifying the integration of data from multiple sensor types into a single asset health dashboard.
FLIR T-Series Professional Thermal Cameras and FLIR A50/A70 Fixed-Mount Thermal Cameras
Regular inspections with thermal cameras can help maintenance teams:
• Find and fix hidden problems before they cause unplanned downtime • Detect overloaded circuits or loose connections • Prevent equipment breakdowns • Optimize energy management and space allocation
See a thermal imaging camera from our FLIR Ex Pro-Series hard at work in a data center.
HVAC and Cooling Systems
Data centers need perfectly air-cooled conditions to run efficiently, so most use the hot aisle/cold aisle layout principle to ensure temperature consistency. This configuration sets server racks facing each other above Computer Room Air-Conditioning (CRAC) vents. The CRAC cools the servers from below while hot air vents out the back and away from the equipment.
Thermal imaging has become increasingly important for verifying the proper hot aisle/cold aisle operation, especially because data centers today are condensing more servers into their racks. These cameras enable users to see problems such as misaligned ductwork and electrical faults, and then make decisions about corrective actions.
Temperature is also an important indicator of energy consumption and equipment operation, which is why periodic predictive maintenance inspections with thermal imaging cameras are ideal for verifying power consumption and equipment health across the facility. Thermal imaging can give maintenance crews important information on how to optimize energy and space requirements without causing overheating.
HVAC inspection with a thermal imaging camera can help to:
• Monitor server rack temperature distribution
• Locate leaking or misrouted ducts
• Confirm energy loss sources
• Detect missing insulation and AC condensate leaks
• Identify inoperable internal server fans
Energy Efficiency is Key
Compressed air systems are another major source of energy loss. On average, industrial facilities lose 20–30% of their energy to air leaks, which makes detecting and dealing with them of the utmost importance to energy-intensive industries already under strain.
Acoustic imaging cameras offer a simple solution for data center maintenance. These cameras visualize air leaks, enabling repair crews to easily pinpoint the source of previously undetectable air leaks in real-time and in measurable terms.
Facilities can reduce inspection time by up to 90%, allowing for more frequent and efficient leak checks.
Over the lifetime of an air compressor, even the most minute air leak can decrease its energy efficiency, causing it to consume more power to perform core operations. When left unchecked, these leaks can lead to component failure and costly downtime.
FLIR Si2-Pro Industrial Acoustic Imaging Camera
The FLIR Si2-Series acoustic imaging cameras feature 124 microphones that can pick up very quiet noises from a long distance. These cameras use onboard AI to distinguish the other characteristics of the sound pattern created by leaks or mechanical faults from regular background noise.
With a bandwidth range of 2 kHz to 130 kHz and the ability to detect a leak from up to 200 m (656 ft) away, the FLIR Si2-Pro yields unmatched detection accuracy and identification down to even the smallest breach.
Calculate the energy savings from compressed air leaks here.
Another advantage of acoustic imaging is many cameras, including the Si2-Pro, can also detect partial discharge (PD). This allows dual use for the camera—not only to check for air leaks inside, but also to inspect on-site power substations and other electrical systems critical to data centers.
Fire protection
Though rare, data center fires can be catastrophic. And while companies equip these facilities with fire alarms and firefighting systems, once a fire starts, asset damage is almost certain.
Many companies protect their assets by installing fixed-mount thermal imaging cameras throughout their facilities. These cameras provide 24/7 monitoring of electrical systems, motors, and flammable materials—catching any temperature increase before the target combusts, endangering workers and assets.
Because they rely on infrared rather than visible light, thermal imagers work in all lighting conditions, offering continuous protection.
Conclusion
As data centers grow in complexity and energy demand, imaging technologies like thermal and acoustic cameras are becoming indispensable. Thermal and acoustic technology can equip maintenance teams with the tools they need to detect issues early, reduce energy waste, and prevent costly downtime. By integrating these technologies into regular maintenance routines, data centers can ensure operational efficiency, protect critical infrastructure, and support the high-performance demands of modern computing.
