Case Study: Arc Systems Data Centre Upgrade
Data Centre Consultancy, Air Conditioning, UPS, Power Infrastructure and DCIM Upgrade
Introduction
Arc Systems is an award winning UK managed IT services provider, delivering IT support, cloud solutions, cyber security and consultancy to businesses nationwide. At the start of 2025, Arc Systems approached Infiniti IT to assess and upgrade its critical data centre infrastructure. Following a detailed review of the existing environment and its future requirements, Infiniti IT was appointed to deliver the required upgrade works.
The Challenge
The data centre was approaching capacity, with several mission critical systems nearing end of life. Legacy cooling could support approximately 35kW to 40kW of IT load in an N+1 configuration, while the existing UPS and electrical distribution environment restricted future expansion. The overall challenge was to upgrade this critical infrastructure around live customer workloads, with zero unplanned downtime. Arc Systems therefore required a data centre specialist to design, manage and deliver a resilient upgrade programme, increasing capacity and operational efficiency while protecting live customer services throughout the works.
Key items included:
- Replacing the legacy UPS and electrical distribution environment with a resilient modular N+1 system.
- Increasing cooling capacity and improving efficiency while protecting live IT operations throughout the transition (no downtime).
- Providing upgraded A and B cabinet distribution to support higher cabinet density and future IT expansion.
- Implementing a modern DCIM platform and BMS controls for improved mission critical systems, power visibility and environmental monitoring.
- Delivering a controlled, auditable programme with detailed risk management, testing, commissioning and handover.
❝ The most pleasing aspect of the project was that we achieved exactly what we set out to do. The platform now gives us the headroom, resilience and operational visibility we need for the next phase of growth. Huge credit must go to the Arc, Infiniti and third-party teams involved in planning, delivering and executing such a complex project. The level of collaboration, preparation and professionalism shown throughout was exceptional.❞
Matthew Clayden, Arc Systems
The Solution
The solution was shaped through an initial planning phase lasting a several months prior to site mobilisation. At its core, this was a structured risk mitigation exercise. Rather than committing to a single delivery approach, Infiniti IT and Arc Systems developed several high level plans and tested each in detail, challenging assumptions, identifying dependencies and mapping potential failure scenarios before selecting the approach ultimately delivered. The chosen plan was selected for one clear reason: it was the only option capable of delivering zero unplanned downtime while providing the strongest protection for Arc Systems and its customers.
The resulting delivery framework incorporated various detailed checkpoints, detailed micro plan runbooks with defined sequencing and rollback criteria, temporary generators and cooling systems to maintain resilience throughout with centralised command and control across all contractors and engineering teams.
Cooling Infrastructure Upgrade
The legacy cooling systems were replaced with new Fläkt hybrid free air cooling units, increasing total cooling capacity from approximately 40 kW N+1 to 64 kW N+1. Each unit combines a glycol based circuit, using an external dry air cooler, with a direct-expansion (DX) compressor circuit as a secondary stage. This approach significantly reduces compressor usage when conditions allow, improving both energy efficiency, cooling resilience and savings on operational costs.
BMS & DCIM Upgrade
Alongside the power and cooling works, Infiniti IT began replacing the legacy building management system (BMS) environment with a modern DCIM platform, delivering significantly enhanced power visibility and operational monitoring across the data centre. The upgrade was designed to bring critical infrastructure into a single, more accessible monitoring environment. This includes the new UPS and cooling systems, intelligent PDUs, environmental sensors and selected alarm points across the wider critical estate. By consolidating these data points, Arc Systems can monitor the performance and condition of key assets in real time, while also retaining historical trend data to support proactive decision making.
The proposed DCIM solution provides operational dashboards, alarm workflows and trend analysis, helping the team identify unusual conditions, manage capacity and assess power consumption with greater accuracy. Intelligent PDU monitoring also enables more visibility of cabinet level loading and energy use, supporting effective load balancing, capacity planning and internal cost analysis where required.
To support this improved connectivity, the legacy BMS controller was replaced with a modern, open protocol controller capable of integrating hardwired equipment and communicating with the DCIM platform. The new architecture supports protocols including BACnet, Modbus and SNMP, creating a flexible foundation for future expansion and integration. The result is a more connected, transparent and proactive operational environment. With improved monitoring of power, cooling and environmental conditions, Arc Systems is better positioned to optimise efficiency, respond quickly to potential issues and manage long term infrastructure growth with confidence.
Overall Summary of our Solution:
- Fully phased design & build package provided in the capacity of design and build contractor including project management and site supervision to CDM requirements.
- Supply and installation of three hybrid free cooling and direct expansion units, increasing cooling capacity from approximately 40 kW N+1 to 64 kW N+1, including dry air coolers, pipework, electrical supplies, testing and commissioning.
- Provision of temporary cooling systems during the phased replacement of the legacy cooling infrastructure, maintaining resilient cooling to the live data-centre environment throughout the works.
- Supply and installation of a Riello 75 kW modular N+1 UPS system, including battery autonomy, switchgear modifications, bypass arrangements and full commissioning.
- Temporary generator power and controlled A and B changeover sequencing to support the live migration of critical IT loads while the legacy UPS and electrical infrastructure were replaced.
- Design and installation of new electrical distribution infrastructure, including upgraded A and B CPDU boards, MCCB modifications, supplementary earthing, high-level containment and associated cabling.
- Supply and installation of intelligent PDUs and dual 32 A overhead cabinet feeds, replacing the existing dual 16 A feeds and increasing cabinet density capability from approximately 3 kW to up to 7 kW per cabinet.
- Replacement of the legacy BMS environment with a modern DCIM and environmental monitoring solution, delivering improved visibility of power, cooling, environmental conditions, alarms and PDU energy usage.
- Supply and installation of a new water leak detection system to support the revised cooling arrangement.
- Integrated testing, client witness testing, completion documentation, training and formal handover for Arc Systems’ IT support and data centre operations teams.
Efficiency and Environmental Impact
Each cooling system uses two complementary cooling circuits to improve efficiency and resilience. A glycol circuit rejects heat through an external dry air cooler, using ambient air to meet the cooling demand wherever possible. A direct expansion (DX) compressor circuit provides additional support only when higher ambient temperatures require it.
Under typical UK conditions, the glycol circuit can deliver cooling with little or no compressor operation. The DX circuit only engages as temperatures rise above approximately 22°C, reducing compressor running hours compared with the previous DX only cooling system. This delivers a measurable reduction in energy consumption and operating costs, while maintaining the resilience required for a live data centre environment.
The improved efficiency is reflected in the facility’s Power Usage Effectiveness (PUE), which has improved from 1.32 to 1.08. This means a greater proportion of incoming power is now available to support the IT load, rather than being consumed by supporting infrastructure. Combined with Arc Systems’ Zero Carbon Electricity tariff, the upgraded cooling platform supports a more efficient and environmentally responsible data centre operation.
Results
The upgrade was delivered without unplanned downtime during either major migration event. Careful sequencing, temporary generator support and resilient temporary cooling enabled the live data centre environment to remain available while critical infrastructure was replaced and commissioned. The project delivered clear improvements across the facility:
- N+1 cooling capacity increased from approximately 40 kW to 64 kW.
- The legacy 40 kW UPS system was replaced with a 75 kW modular N+1 system.
- Available power per cabinet increased from around 3 kW to up to 7 kW. Estimated PUE reduced from 1.32 to 1.08, supporting a more efficient operating model.
- New power and cooling infrastructure created meaningful capacity for future expansion.
- Intelligent monitoring improved visibility of energy use, load distribution and environmental conditions.
- Reduced reliance on compressor led cooling lowered energy consumption and operating costs.
Arc Systems now benefits from a stronger, more scalable and more efficient data centre platform, with the resilience and operational insight needed to support ongoing customer demand.
Planning a data centre upgrade? Choose a partner built for critical environments
Modernising live data centre infrastructure demands more than new equipment. It requires careful planning, proven engineering expertise and a delivery partner able to manage risk without compromising service continuity. Whether you are upgrading power and cooling systems, increasing cabinet density, improving monitoring or preparing for future growth, Infiniti IT delivers fully managed data centre design and build services.
From initial consultation and detailed infrastructure planning through to installation, commissioning and ongoing maintenance, we help organisations create resilient, scalable and energy efficient critical environments. Our approach brings power, cooling, monitoring and operational teams together under one controlled delivery programme, helping to reduce risk, protect uptime and maximise the long term value of your investment.
Planning an infrastructure upgrade or new data centre environment? Speak to our specialist team to discuss the right solution for your business.
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Our services have consistently received numerous awards for their innovative design, reliability, and effectiveness throughout the years. We have extensive experience in delivering fast installation solutions for both new construction projects and refurbishments in various industries.
If you are looking for a comprehensive service that covers the design and construction of data centres, carried out with maximum efficiency and strict adherence to your timelines, we are a reputable and well established organisation that you can rely on.
