Unlock Predictive Reliability Through CWC and ESA

One of the most pressing challenges for data centers is heat management. Servers and high-performance computing equipment generate a substantial amount of heat, and without effective cooling systems, overheating can cause equipment failures, reduce performance, and shorten the lifespan of critical assets. As data centers grow and equipment density increases, maintaining optimal temperatures becomes even more critical.

Unexpected electrical failures can disrupt operations, damage equipment, and lead to costly downtime. Understanding how to detect issues before they escalate is crucial in managing electrical infrastructure effectively. Two key techniques—Continuous Waveform Capture (CWC) and Electrical Signature Analysis (ESA)—provide valuable insights that help engineers identify problems early and maintain reliable systems.

What is Continuous Waveform Capture?

Continuous Waveform Capture involves monitoring electrical signals, specifically voltage and current, at a very high sampling rate—often around 20 kHz or more. Unlike traditional monitoring systems that take periodic samples or rely on averaged data (like RMS voltage or current), CWC records the complete waveform continuously.

This level of detail allows for the detection of transient events and power quality issues that occur over milliseconds or a few cycles. For example, short voltage dips or spikes might cause sensitive equipment such as servers or motors to reset or malfunction, but they are often missed by conventional monitoring systems.

In one documented case, slight voltage variations early in the day revealed a failing contactor. Over time, the issue progressed to single-phasing of a motor, a condition that can cause severe damage if not addressed promptly. Capturing these subtle waveform changes enabled early intervention, preventing expensive equipment failure.

Understanding Electrical Signature Analysis

Electrical Signature Analysis is a diagnostic technique that interprets patterns in voltage and current waveforms to assess the condition of electromechanical equipment, such as motors, fans, and gearboxes. The basic premise is that voltage is a consequence of the power source, while variations in current indicate changes in the load or equipment condition.

By performing a harmonic analysis on the current waveform over time, it is possible to detect mechanical degradation. For example, a loosening fan belt changes the harmonic content of the current draw, creating a trend that can be monitored. Identifying these trends early supports maintenance decisions before failure occurs.

ESA is particularly useful because it doesn’t require direct access to the equipment. Measurements taken at a motor controller or disconnect can reveal the health of equipment located in hard-to-reach or hazardous areas.

Why High-Resolution Data Matters

Many facilities rely on systems like DCIM (Data Center Infrastructure Management), EPMS (Electrical Power Monitoring Systems), or BMS (Building Management Systems) for electrical monitoring. These systems typically provide averaged or snapshot data, such as RMS voltage and current values, which offer limited insight into transient or subtle issues.

High-resolution continuous waveform data, on the other hand, captures all electrical activity in detail. This enables the identification of “ghost” electrical problems—small, brief events that cumulatively lead to equipment faults or downtime.

For example, a facility once struggled with a motor that worked well on utility power but repeatedly tripped when running on a backup generator. Conventional analysis suggested expensive hardware solutions, but detailed waveform capture revealed harmonic oscillations caused by voltage regulator fluctuations on the generator. A relatively inexpensive targeted filter resolved the problem once the true cause was identified.

Moving from Data to Diagnosis

Collecting waveform data is only useful if it can be interpreted effectively. One challenge faced by many facilities is having vast amounts of data without clear guidance on what it means or how to act.

In electrical reliability, data must be translated into actionable insights. This involves analyzing trends, identifying fault signatures, and providing early warnings about equipment degradation. For example, detecting a welded contactor before it causes a motor to run improperly can save thousands of dollars and prevent extended downtime.

Developing a fault library—an archive of known electrical signatures linked to specific failures—supports this diagnostic process, allowing technicians and engineers to quickly understand what an anomaly signifies.

Extending Equipment Lifespan and Reducing Downtime

Predictive maintenance relies on detecting small anomalies before they become major failures. By monitoring electrical signatures continuously, facility managers can plan repairs or replacements in advance, reducing emergency downtime and avoiding costly equipment damage.

For instance, replacing a failing $200 contactor is a simple task compared to the time and expense of repairing or replacing a $20,000 motor damaged by single-phasing. Early detection also allows for maintenance scheduling during planned downtime rather than emergency intervention.

The Role of AI and Remote Monitoring

As the complexity of electrical systems grows and experienced technicians retire, software-driven monitoring and analysis become increasingly important. AI algorithms trained on historical waveform data can automate fault detection and suggest corrective actions, helping facilities that lack on-site expertise.

Remote monitoring is particularly valuable for equipment in hard-to-access locations. By measuring electrical signatures at accessible points, operators can infer the condition of remote assets without physically inspecting each piece of equipment. This reduces risk and improves maintenance efficiency.

How Volta Insite Can Help with Predictive Reliability

Volta Insite specializes in providing high-resolution electrical monitoring and predictive diagnostics using Continuous Waveform Capture and Electrical Signature Analysis. Their platform delivers 24/7 remote visibility into the condition of your electrical assets—without disrupting operations or requiring invasive inspections. With advanced analytics, a growing fault signature library, and expert guidance, Volta Insite helps facilities detect problems early, plan maintenance intelligently, and avoid costly downtime. Whether you're managing a manufacturing plant, data center, or commercial facility, Volta Insite gives you the tools to operate with greater reliability and confidence.

You can watch the full video of Denis’ talk from DCD>Connect here: https://youtu.be/Q0qJakP9hQU