SENS
How a data center's power deployment timeline decreased
- Hyperscale Data Center operator faced long unpredictable timelines, complex on-site integration amplified by labor shortages, and space limitations…all contributing to project risk.
- The SENS PowerCab®2, a skid-delivered switchgear DC power system, moved all integration complexity off-site and into the factory. Ordered as a single part number and delivered plug-and-play, it ensured asset-level redundancy.
- The hyperscale data center operator standardized on a globally deployable system, drastically reducing onsite labor time and costs, and reducing footprint.
- The result was a more compact, more reliable, safer data center power architecture. The time from concept to scaled product deployment was three quarters.
A new blueprint for hyperscaler power
In late 2023, one of SENS hyperscale data center customers was conducting a factory witness test at SENS’ Longmont, Colorado production facility and corporate headquarters.
The system under test was a traditional loose-piece switchgear power system. While the test was successful, the customer observed the challenge of configuring and testing the loose-piece system, including maneuvering multiple 300lb salt batteries. The SENS team took the opportunity to show the client a factory integrated switchgear power system that was in production for another customer. The hyperscale client immediately saw the enormous potential for eliminating several of their biggest on-site headaches: "Yeah, I like that. I really like that... I want all my systems to look like this."
The companies’ engineering teams set about collaborating to design a system to meet the hyperscaler’s precise needs. The goal became clear: create a system that could be purchased under one part number that would work in all of their data centers worldwide.
From loose pieces to a packaged power block
Within days, collaboration began. The data center drove the high-level requirements and allowed our team of experts to weigh in on solutions. When requirements changed, such as requests for an additional genset connection and for direct IP-based battery communication, together we engineered solutions to meet the dynamic project requirements.
The ultimate goal was a global "standard building block" robust for all climates and environments. The final solution involved incorporating additional AC controls and distribution in an integrated NEMA 3R enclosure that would allow the switchgear power systems to be moved entirely outdoors. The result would be the largest, most innovative PowerCab2 ever built.
Winning the race to the energization
Three quarters later, when the system was commissioned in September 2025, the value of the new system was confirmed. There was zero complex field integration work, zero lifting and transport of batteries, and no need to work with high-voltage circuits or verify system operation on-site. This had all been completed weeks prior in SENS’ controlled factory environment. While a loose-piece system would just have been entering its greatest risk phase of the project, the PowerCab2 was already up and running.
The result is now a highly specific and application tailored solution that will be deployed across this operator’s global fleet.
Why traditional integration fails
The traditional loose-piece system architecture has significant risks:
Timeline Risk: multiple vendors, delivery logistics, and complex project management required.
Safety Risk: field integration of high energy systems exposes dangerous and costly arc flash.
Reliability: complex onsite assembly, wiring, and test.
A template for hyperscaler infrastructure
In today’s speed-driven environment, the better fit to deliver fast, safe, reliable switchgear power systems is a prefabricated, preconfigured, skid-delivered system.
SENS’ factory integrated PowerCab2 eliminated project risk and unpredictability by moving the most difficult aspects of system integration to our controlled factory.
“This collaboration clearly demonstrated that packaged power systems not only speed up the deployment of individual data centers but also enable true plug-and-play capabilities providing point of asset redundancy. Engineered, scalable, packaged power systems ensure hyperscalers can scale their power infrastructure, significantly accelerating all future deployments.”
- Sam Coleman
SENS, Chief Technology Officer
The result is an engineered, integrated, compact, and nimble solution providing reliable non-stop power for today’s modern data centers.
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