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How to Avoid Battery Monitoring Equipment Failures

By Andrew Erickson

September 5, 2025

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What happens when the very tools you rely on to monitor your backup power begin to show their age?

Every mission-critical telecom or utility site is important to someone (and probably quite a few people). Whether you're operating a handful of huts or hundreds of remote cabinets, you have to protect them.

One client recently brought us onto a project that highlights this exact issue. Their monitoring units, installed in 2017, had been stable and dependable for years. But now, they are approaching the edge of what we call "the reliability cliff" - the point where once-solid hardware starts inching toward higher failure risk.

Let's walk through what they learned, and what you need to be doing now to avoid being blindsided by an equipment failure later that could knock out your visibility at a critical site.

Battery Monitoring

Old Hardware Will Eventually Fail

Like most things, electronics follow a life cycle.

There's an initial stabilization period, then a long window of high reliability, followed by a "knee in the curve" where failure rates rise exponentially. That's the point where even solid, well-built devices face the realities of component aging, oxidation, temperature cycling, and physical wear.

In the client conversation, our team reviewed some SLIM units that had been in service since 2017. That's about 7-8 years of runtime. And while we've seen T/Mon units last well over a decade in the field and support units for nearly forever, every piece of hardware eventually fails.

We also reviewed their RTUs - and their new interest in our newer battery monitoring sensors.

By holding onto any aging monitoring hardware from any manufacturer, you risk:

  • Sudden failures that leave you blind to battery health.
  • Lack of spare parts when something finally does break.
  • Limited compatibility with expanding battery strings or new sensors.
  • Increased service truck rolls due to undetected conditions.

Saving money by not upgrading might cost you big when a site goes dark and you never saw it coming.

Traditional Approaches to Monitoring Fall Short Over Time

It's tempting to rely on simple or integrated monitoring setups. They may have come bundled with the battery plant or the radios or as part of a general site package. At the time, it felt like an easy win.

But time reveals flaws in these approaches:

  • Integrated monitoring lacks flexibility. If you need to monitor multiple battery strings, separate temperature zones, or new conditions, you may find yourself locked into a system that can't scale.
  • Ports get full - and newer port types are introduced. In the client's case, they wanted to monitor two battery strings and add D-Wire Temperature Sensors. Their old unit didn't have the hardware ports to handle it.
  • Vendor lock-in limits options. Some systems only support their own proprietary language. Many times, sending SNMP traps to a central manager isn't supported.
  • Age creates support gaps. What happens when your old unit fails and the manufacturer no longer makes that model?

The original investment was valid, but now the tools are aging out of relevance - and reliability. As your network grows and modernizes, your monitoring must evolve as well.

Use a Custom Monitoring Strategy Built for Growth

Your battery monitoring system can actually make your job easier, not harder.

That involves:

  • Refreshed hardware with full lifecycle support and available spares.
  • Port flexibility to support 1, 2, or even more battery strings.
  • Room for sensor expansion, including temperature, door contacts, humidity, and more.
  • Standard protocol support, like SNMPv3 or DNP3, to fit within your existing NOC tools.
  • Budget certainty so you can get firm quotes - before an emergency forces a panic buy.

That's exactly what we delivered for this client. And it's something you can do too - with a little planning and the right tools.

The DPS G6 Platform Is the Smart Upgrade Path

We recommended that the client refresh their monitoring solution using our G6-based platform. This gives them everything their existing RTUs couldn't anymore - and positions them for scalable success.

The G6 makes sense because it provides:

1. Customizable Port Mapping

When you're monitoring two or more battery strings, you should be able to organize each battery within its string. The G6 allows sensors to label battery strings - and when used with a T/Mon master, you can map these strings as well.

That means no more sensor "clutter" or overload.

2. Dedicated Spare Planning

We don't just sell one box. We help you map out a spares strategy that matches your fleet size.

  • If you want a 10% ("1:10") spare ratio, that's easy.
  • If you need quick-ship replacements for remote regions, we can help.
  • If you want to standardize on one monitoring box across all sites, we'll help you find the right DPS "SKU".

3. Full System Visibility

Aging equipment can hide real problems. The G6 platform gives you real-time data on:

  • Battery voltages
  • Temperature inside enclosures
  • Door status (open/closed)
  • Humidity levels
  • Power input/output states

Combined with T/Mon or any SNMP manager, you get total visibility over 1-100+ sites.

4. A Clean Upgrade Path

If your SLIM (or other manager) is nearing end-of-life, you don't want to rip and replace everything.

The G6 is form-factor compatible with many legacy systems and supports flexible mounting. You can drop it in with minimal wiring changes.

Receive Budgetary Quotes & Build-To-Order Flexibility

During the call, the client also asked for budgetary quotes for expansion. These include monitoring equipment for a smaller site currently running 12V cells, with plans to add another two battery strings.

We didn't just nod and promise to "get back to you." Instead, we committed to building a full package quote including:

  • New G6 NetGuardian RTU
  • Battery Voltage Monitors (BVMs)
  • Optional spares quote
  • Budgetary option for future NetGuardian + BVM combo site

This kind of proactive quoting allows teams like yours to:

  • Secure budget approval
  • Scope pilot deployments
  • Compare internal specs vs field results

That's part of the DPS difference: We don't just ship boxes. We help you build the plan.

You Can Learn From This Example Client

Here's a quick recap of how the client handled this situation, so you can follow a similar path:

They Noticed Equipment Age

They didn't wait until a failure. Around Year 7, they asked, "Should we upgrade?" That's exactly the time to review your fleet.

They Reached Out to DPS

They contacted our team with clear goals:

  • Refresh old units
  • Expand battery monitoring
  • Get new quotes

They Asked the Right Questions

  • "Can we support 2 battery strings with this box?"
  • "How many ports do we need for temperature?"
  • "Can we monitor the NetGuardians as well?"

These are the conversations we love to have.

They Requested Budgetary and Spare Quotes

This allowed them to evaluate the total cost of ownership - before things failed.

What's at Stake If You Don't Plan Ahead

If you don't assess your battery monitoring fleet and deploy a quality monitoring system, you might:

  • Lose visibility into a key battery site.
  • Have the battery fail, while backup power is compromised.
  • Go offline at central sites.
  • Have to dispatch a team without knowing what they'll find.

The root cause of all these issues is a failed monitoring unit that should have been replaced years ago. It's avoidable - and preventable - with a small investment of time and planning.

Let's Build Your Monitoring Refresh Plan Together

If your battery monitoring units were installed between 2015-2018, it's time to review them. You may not need to replace everything right now, but you definitely need:

  • A site audit of what you have
  • A lifecycle status for each unit
  • A roadmap for upgrades, spares, and expansion

We've helped hundreds of clients build these plans, and we'd love to help you too.

Here's how to get started:

  1. Call us now at (559) 454-1600
    You'll speak directly with a monitoring expert who knows the ins and outs of remote battery management.
  2. Email us: sales@dpstele.com
    Send us your equipment list, site photos, or a simple request like "Can you review our 2017 install and tell us what we can improve?"
  3. Ask for a free quote
    We'll prepare a line-item proposal for replacement gear, spares, or new monitoring for additional strings or voltage types.

Don't Wait for Downtime to Start Planning

Your battery monitoring gear has a lifecycle. Don't let a silent failure be your wake-up call.

With the G6 platform and DPS engineering support, you can upgrade confidently - with better visibility, flexible port design, and full support for multi-string sites.

Let's work together to build a monitoring strategy that keeps you ahead of failure - and puts your budget and field teams in control.

Get started today. Call DPS at (559) 454-1600 or email sales@dpstele.com.

We'll help you modernize your battery monitoring - before it's too late.

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Andrew Erickson

Andrew Erickson

Andrew Erickson is an Application Engineer at DPS Telecom, a manufacturer of semi-custom remote alarm monitoring systems based in Fresno, California. Andrew brings more than 18 years of experience building site monitoring solutions, developing intuitive user interfaces and documentation, and opt...