AORA and EDI for maximum flexibility and real-time monitoring in the data center
It’s an image full of contradictions: in the server room, the LEDs on state-of-the-art blade servers blink, monitored by AI-powered security tools. But one floor below, in the engine room, a technological silence reigns.
The operator in the control room loves data, but his gas engines often leave him in the dark. The old OEM controllers are locked “black boxes.” They run until they stop — and the reason they stopped is often only revealed when the manufacturer’s service technician is on site with the right dongle.
For a data center manager whose currency is uptime, this situation is untenable. Lack of transparency is a risk. You can’t manage what you don’t measure. The solution doesn’t necessarily lie in buying new engines, but in the digital transformation of the inventory.
An upgrade to the gas-engine control system breaks the machines’ silence. It transforms clunky analog hardware into intelligent data providers that restore full control to you.
Challenges arising from analogue technology in digital infrastructures
The discrepancy between the high-tech environment of a data centre and the control systems for its emergency generators — often 15 to 20 years old — couldn’t be greater. Older systems often provide only binary status messages: “Running” or “Fault.” What happens in between — gradual temperature rises, minor misfires, or subtle vibration trends — remains hidden.
The risk of missing data
If you drive by sight, you cannot avoid obstacles. Without depth data, trend analysis is impossible. A cylinder that is slowly overheating is detected only when the threshold is exceeded and the emergency shutdown is triggered.
By that point, redundancy has already been lost. Moreover, proprietary systems force the operator into dependency: even minor parameter adjustments require costly external support. An open gas engine control system ends this hostage situation and often makes retrofitting far more economical than a complete engine replacement.
AORA and EDI: The brain upgrade for your fleet
The hardware of an engine – the block, pistons and crankshaft – can last for decades with proper maintenance. It’s the “brain” that becomes obsolete. AORA and EDI are two powerful retrofit solutions specially developed to bring existing installations, for example from MTU®, MWM®, Jenbacher® and other manufacturers, up to the level of modern smart-grid technology. Our solutions are compatible with these engines, but they are not original parts from the manufacturers mentioned.
AORA: Designed for use in MWM® engines
For operators of MWM® units (e.g., TCG 2016 or 2020) who feel constrained by the rigid structure of the original TEM controller, AORA is the liberating solution. This retrofit solution, developed by PowerUP, is designed to overcome the limitations of proprietary systems:
- Full control over your data: No more dongles or hidden menus. AORA gives you full access to all relevant parameters. You set the permission levels yourself and decide who can view and modify which settings.
- Limitless connectivity: Thanks to state-of-the-art cloud and remote connectivity provided by our Competence Center, you can monitor your system at all times. In addition, the system integrates seamlessly into your control system via open interfaces – without the need for expensive additional hardware.
EDI: The intuitive all-in-one solution
EDI stands for “Total Engine Control” and was implemented in close cooperation with our engineering partner AVAT. It is the solution to complex, fragmented control cabinets where ignition, engine speed regulation, and knock control are handled by separate devices.
- All-in-one: EDI integrates control, monitoring, and ignition in a single robust unit built on proven technology.
- Usability: The user interface is so intuitively designed that operators can immediately assess the machine’s condition even without extensive engineering training.
Security and transparency through continuous monitoring
A modern upgrade to the gas-engine control system brings the engine room to your tablet. Secure Remote Access provides access to your fleet anytime, anywhere. This is crucial for data centers that are often run “lights-out” (without on-site personnel) or with minimal staffing.
If a warning message appears on the dashboard, you don’t have to go down to the basement first. You can see in real time whether it’s a critical fault or just sensor drift.
This data can be fed directly into the data center’s central SCADA system (DCIM) via Modbus or Profibus. That way, energy generation becomes an integral part of overall monitoring, just like server temperature or UPS utilization.
Increasing efficiency through predictive maintenance strategies
The greatest benefit of digitization is its forward-looking perspective. A modern gas engine control system is not merely a switch but a high-precision diagnostic tool. It enables the transition from reactive to predictive maintenance (Predictive Maintenance).
The system no longer simply reports “Cylinder 5 failure.” It reports weeks in advance: “Ignition voltage demand at cylinder 5 is steadily increasing.”
For the technician, this is a clear indication that the spark plug is worn—long before any misfires occur. Maintenance windows can therefore be scheduled based on actual wear data, rather than rigidly by calendar or only after a failure. This saves money, reduces stress, and ensures uptime.
We put control back in your hands – PowerUP
Modernizing control systems is a crucial step to ensure the long-term availability of your equipment. At PowerUP, we understand the importance of transparent data for safe, cost-effective operations.
With the AORA and EDI solutions, we help you remove technical barriers and gain deep insight into your engines’ processes.
Our goal is to provide you with the necessary tools for predictive control and to technologically upgrade your existing systems. Technology is our driving force, and efficiency is our focus.
