Revolutionising UPS Performance with Modular Systems

Socomec has reimagined big data centre technology to redefine modular UPS – making it possible to stay on course, effortlessly.

The Customer

When recently attending a reported fault, Socomec Field Engineer, Ciprian Hancer, noticed that one unit of a modular system – the Modulys XL - was offline and had triggered a number of alarms.

“With up to 6 modules in parallel, modules can be disconnected from the system and alarms can be triggered but the system will still run online and support the load.”? Ciprian explains.

“In some cases, disconnecting and resetting the module can be enough to resolve the issue that’s triggered the alarms. The modules are easy to remove as they sit on their own wheels, and the system remains online even when the module is disconnected.? A simple visual inspection can sometimes determine whether there are any obvious faults.”

In other cases, however, the fault itself is not as straightforward as this – but with a spare module, the solution can be just as simple.

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The Project

Providing the right kind of modularity is essential. Not all modular systems are created equal: many UPS’s available today claim to be “modular” if they comprise multiple power bricks but they don’t actually provide the features and benefits necessary to be truly modular. By working closely with individual customers to understand their specific needs and concerns, Socomec has been able to adapt their latest system for the particular requirements of the high power UPS market - creating a solution that provides the benefits associated with genuine modularity.

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The Requirements

Safe and easy deployment is a key priority – whether for a focused and compact installation or seriously super-scaled infrastructure.? True modular flexibility that de-risks late-stage specification changes or last-minute on-site adaptations is vital, particularly in terms of enabling quick and easy customisation.

The customer was keen to eliminate cabling challenges and keep things simple so that just one member of their team could manage straightforward hot-swaps and maintenance activities.

In parallel, ensuring that the system is fit for the future was an important consideration – with guaranteed hardware and firmware compatibility within a dynamic infrastructure.

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The Solution

What is MODULYS XL?

MODULYS XL is a modular UPS based on 200 kW bricks for deployment within UPS units from 200 to 1200 kW - that can also be installed in parallel up to 4 units. The system has simplified connections – with power converters based on the DELPHYS GP UPS technology, combined with MODULYS GP 2.0 electronic and firmware platforms – to deliver a higher power MODULYS. This development delivers the best possible user experience – while eliminating the uncertainties associated with new technologies.

What sets the MODULYS XL apart?

Achieving the right granularity requires balance between system MTBF and intrinsic redundancy – with limited losses in available power due to missing modules, or inflated maintenance costs due to excessive numbers of modules. Taking this into account, MODULYS XL has been designed with power modules of the right size for large UPS systems, while remaining as easy to handle as a smaller module.

In-situ maintenance, servicing and repairs are crucial moments when it comes to the protection of highly critical loads. By fully isolating a power module, the MODULYS XL allows concurrent maintenance of each subset, safely and simply. A module can be extracted out of the system to avoid any risk to the ongoing operation and the user can have complete confidence in these pre-tested units.

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The Benefits

The 5-minute, zero risk hot-scale

Module plug-in based on a patented connection system means that a 200kW module can be added or removed - in less than 5 minutes, by just one person - while the load is fully protected, working in inverter mode, and with zero risk of human error.? The scalability is fast and fool-proof – no specific software tools or complex procedures.? The simple plug-in process means that there are no requirements to place “hands inside” – nor are there any complicated cabling reconfigurations to grapple with, therefore eliminating potential mistakes or hazards. Additional modules self-test and auto-configure, and the hassle-free automatic connection / disconnection ensures operator safety at all times.

Ciprian comments; “The plug-in takes just a few minutes, with simple instructions for power or redundancy level changes shown on the display screen.? Modules are completely interchangeable and the load is fully protected in online double-conversion mode.? This means that system extensions, module maintenance or swaps are incredibly straightforward.? Adding a new module into an empty bay is fast and simple – which means that managing future power evolutions within a dynamic electrical architecture is easier than ever before.”

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Risk-free maintenance

Modular solutions deliver much faster risk-free maintenance at critical and sensitive stages – all while protecting the load in online mode during operation, maintenance and upgrade.?

The MODULYS XL has been created with a disruptive approach to safety and maintenance and eliminates the risks associated with life cycle management.?

Concurrent maintenance means that you can maintain all components while the rest of the UPS system supports the load in online mode.?

Self-diagnostics provide immediate fault detection – and isolation, when required. Single modules can be maintained – without risk – outside the system.? This avoids the need for in-situ maintenance, service or repair which could otherwise put the operating system at risk.

Local spare modules make for an easy-swap. ?Full module and subassembly extraction – with 360 degree access to all components - means that maintenance can take place outside the critical system for a low MTTR.

Operation and testing are failsafe thanks to the ability to perform a functional and full-power heat-run test – without the need for a dummy load – as well as post-transportation or post-maintenance functional testing.

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The results

Ciprian explains; “In this instance, we were really fortunate because we were able to swap the module in question with a spare.? The modules are incredibly quick and easy to wheel out – no heavy lifting – and the spare module was connected in no time as it’s a true hot-swap.”? The performance of the overall system is not affected, everything remains online and once the communications have been confirmed as working, the entire system is 100% back online.

“For us – and for the client - it’s so important to be able to work in this way, particularly when it comes to time-sensitive applications where interruptions or the escalation of issues might be costly and disruptive.

“The concept of having a spare module is a bit like having a spare tyre in the car; you hope you’ll never have to use it but you need it to be there as backup.? If you have a puncture – and you have a spare tyre – you can continue on your journey.? With a spare module, you have the assurance that the entire system can be working exactly as it should be because the spare can be hot-swapped at any time.

“With a spare module, there is no need for a situation to escalate – it allows you to remain very much in control and any issues can be dealt with swiftly and efficiently.

“Although there is a cost associated with the spare module, the cost of not having one to hand when needed may far outweigh the price of the unit.? In this particular instance, it was a huge benefit that the spare module was available; there was no need to raise issues further up the chain, the fix was virtually invisible with the spare as a substitute and it meant that the faulty module could be removed, safely, and repaired with time to source the correct parts.”

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Immediate relief in challenging working conditions

Ciprian highlights the fact that in some settings, access might be very restricted in terms of security clearance or physical space or both.? In these instances, where working conditions are far from ideal for carrying out diagnostics and remedial work, the ability to make the quick switch to the spare module is invaluable.

“When you’ve got a spare to hand, the problem created by the faulty module is diminished – instantly.? The spare is dropped into the system and the faulty module becomes a far smaller issue that can be fixed at the next available opportunity.?? On the occasion of this particular fault, it was a Friday night – as is so often the case – and the offices were closed.? It would have been much harder to fix and bring back online if it hadn’t been a modular system – and the spare hadn’t been available.? The reassurance that the spare unit delivers cannot be overstated, especially in applications where downtime is particularly costly. It’s the difference between a quick pit stop versus complete roadside recovery.”

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Maintenance that’s uncomplicated, effortless and straightforward

The concept of a spare module means that you can fully realise the breadth of benefits that a modular system has to offer.? It means that reactions and resolutions are rapid and fuss-free.? So what would have been the case had the spare not been available?

Ciprian explains that there are always alternative solutions – and that changing from 6 to 5 modules could have been an option – but that this would have necessitated escalation and potentially raised additional issues.? “To use the spare tyre analogy once more, our cars run with four wheels – but by having a spare on board, we can be up and running again in no time, rather than waiting for additional assistance. The concept of the spare simplifies the engineer’s job – so the process is more efficient and effective – and it delivers complete peace of mind to the client.”

The concept of a module as a spare makes maintenance uncomplicated, effortless and straightforward – whether it’s used as a temporary stand-in and returned to “spare” status once the original module has been repaired, or whether the original repaired module becomes the new spare.

“Importantly, having a substitute means that further investigations into a faulty module can be carried out in a completely safe working environment.? For example, in this case the tests were carried out the following Monday using the Socomec service hub where the module could be tested fully, as it was not connected to the load.? By not trying to fix the module in situ, it means that there is no opportunity to inadvertently introduce additional faults – because you’re not testing on a live system.? It reduces risk and allows for a more thorough investigation because you’re working in total safety and the “emergency rescue” pressure is removed thanks to the spare.? What could be a tricky in-situ fix becomes a complete non-event and is totally painless.”

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The Outlook

By combining the benefits of gold-standard modular technology and taking a more innovative approach to servicing – eliminating the risk of repairs under challenging conditions - it’s now possible to move to a permanent uptime approach.? This means that UPS availability can be guaranteed with a module hot-swap, leaving the fix to the Socomec experts.

Standard maintenance contract subscriptions include preventive and corrective visits – and the precise nature of the contract can be customised according to need.

Ciprian explains; “Using the power module as an on-site spare means that it’s possible to maintain availability under any circumstances.? The module can be swapped in case of failure in under 5 minutes – or it can be used during preventive maintenance while the maintained module is removed for inspection.

“The Socomec Service Centre remotely and continuously monitors over 150 operating parameters – this means that preventive actions can be prescribed by a Service Engineer in order to anticipate anomalies and quickly trigger remedial action.

“By adopting a more progressive approach to modularity and maintenance, there are immediate benefits in terms of rightsizing through modularity and robust design.? System reliability can be maximised for the best possible overall resilience at the entire modular UPS level.? Designed and engineered with no single point of failure – and zero fault propagation – the power module delivers a certified 1,000,000 MTBF, with appropriate granularity between intrinsic redundancy and MTBF impact at system level giving the required superior resilience.? This delivers benefits in the longer term – truly eliminating some of the risks commonly associated with lifecycle management.”

To learn more about how MODULYS XL can revolutionise your UPS system and ensure uninterrupted power supply for your critical loads, visit Socomec on stand D610 at Data Centre World and schedule a consultation with one of our experts.