There are literally hundreds of potential Electrical hotspots in Data centres, to try and help client identify these areas we have written the following article highlighting the most common electrical hotspots found in data centers. hotspots are one of the biggest hidden threats inside modern data centers. They develop quietly, often without triggering alarms or showing visible signs, yet they can escalate rapidly into equipment failure, fire risk, or full‑hall outages. Because data centres operate continuously under high load, even a small hotspot can compromise redundancy and put uptime at risk.
This is why electrical thermography has become a critical part of preventative maintenance. By detecting abnormal heat patterns in live electrical systems, thermal imaging reveals faults long before they become dangerous. Understanding the most common types of hotspots — and what causes them — is essential for maintaining a reliable, resilient data‑centre environment.
1. Loose or Deteriorating Electrical Connections
This is the number one cause of electrical hotspots in data centres. Over time, vibration, thermal cycling, and mechanical stress can loosen connections in:
- Switchgear
- PDUs
- UPS systems
- Busbars
- Distribution boards
A loose connection increases resistance, and resistance generates heat. Left unchecked, this can lead to arcing, component failure, or even electrical fire.
Thermography benefit:
Loose connections produce clear, localised hotspots that are easy to identify early by thermal imaging, so rapid remeadial action can be undertaken to the electrical system.
2. Electrical Hotspots Via Overloaded Circuits in Data Centers
Data centres often experience load changes as equipment is added, removed, or redistributed. When circuits become overloaded, they heat up rapidly, especially under peak demand.
Common overload points include:
- UPS output phases
- PDU circuits
- Rack‑level power feeds
- Cooling system electrical supplies
Overloading not only creates hotspots but also accelerates component wear.
Thermography benefit:
Thermal imaging highlights load imbalance and overheating before breakers trip.
3. Phase Imbalance in Three‑Phase Systems
Phase imbalance occurs when electrical loads are unevenly distributed across phases. This is common in data centres due to varying rack densities and equipment types.
Imbalance causes:
- Uneven heating
- Reduced efficiency
- Increased neutral current
- Premature component failure
It is one of the most overlooked causes of hotspots.
Thermography benefit:
Infrared imaging cameras clearly shows temperature differences between phases, making imbalance easy to diagnose.
4. Failing UPS Components in Data Centers
UPS systems contain batteries, capacitors, rectifiers, and inverters — all of which degrade over time. As components age, they begin to run hotter.
Typical UPS hotspots include:
- Battery cells entering thermal runaway
- Loose battery terminals
- Overheating capacitors
- Internal component failures
- Cooling blockages
Because UPS systems are mission‑critical, these hotspots pose a significant risk.
Thermography benefit:
Thermal imaging identifies failing components long before alarms activate.
5. Hotspots in HV/LV Switchgear
Switchgear is one of the highest‑risk areas in any data centre. Hotspots often develop at:
- Busbar joints
- Breaker contacts
- Cable terminations
- CT chambers
- Neutral bars
These faults can escalate quickly and may affect entire power trains.
Thermography benefit:
Switchgear hotspots are highly visible on thermal imaging inspections, allowing early intervention.
6. Degraded or Corroded Terminations
Moisture, oxidation, and environmental contaminants can degrade electrical terminations. This increases resistance and creates heat.
Common locations include:
- Generator control panels
- External switchboards
- Cooling system feeds
- Roof‑level electrical enclosures
Thermography benefit:
Thermal imaging detects corrosion‑related heating before it becomes dangerous.
Why Early Detection Matters
Electrical hotspots rarely stay stable. They worsen over time, often accelerating rapidly. Without early detection, they can lead to:
- Breaker trips
- UPS shutdowns
- Fire risk
- Loss of redundancy
- Full‑hall outages
- Expensive emergency repairs
Thermography provides a fast, non‑intrusive way to identify these issues while systems remain live and operational.
Explore our Data Centre Electrical Thermography Services to prevent these common hotspots from causing downtime.
Why you should use APT for your Data Center Thermography Inspection
We follow a structured process for every Thermal Imaging Survey, beginning with a detailed consultation to understand the specific needs of our clients. This allows us to tailor our approach, ensuring we focus on the areas most relevant to each project. We provide the following premium services:
- Supply of an ITC trained Level 3 thermographer
- We us large format FLIR T Series (640×480 resolution) thermal imaging cameras.
- Comprehensive report to include Introduction and fault cover pages, summary problem pages, elevation inventory,
- Detailed fault documentation pages with possible root cause and remedial recommendation (isotherm included if using equations), baseline IR and DC image of every elevation (100% coverage-no isotherm)
- Application of thermal indexing formulas
- Eco Friendly Email Report within 24 hours
# About the Author
Darren Helliwell is a building performance specialist with over 25 years of hands-on experience leveraging thermal imaging, blower door testing, and smoke analysis to optimise air tightness in both new-build and refurbishment projects such as Battersea Power Station, Imperial War Museum and Harrods.
Using advanced infrared thermal imaging cameras alongside state-of-the-art blower door and smoke-testing equipment, Darren’s team delivers detailed thermographic surveys across residential and commercial buildings. These thermal imaging surveys pinpoint invisible air leaks, identify insulation defects, and reveal thermal bridging—empowering architects, contractors, and property owners to make targeted, energy-saving improvements.
Darren’s ongoing mission is to help design teams and contractors harness the power of thermal imaging to achieve truly airtight, energy-efficient building envelopes. By reducing heat loss and driving down energy bills, his thermography expertise supports sustainable, cost-effective construction and refurbishment outcomes.
Connect with Darren Helliwell:
Email] info@aptsoundtesting.co.uk [LinkedIn] https://www.linkedin.com/in/darren-helliwell-78789b26
Contact us now
For more information our Thermal Imaging Service to Data Centers, please contact Darren on 07775623464 and/or email us at info@airpressuretetsing.co.uk