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Battery Lifecycle Intelligence

Know the Condition of Every Battery, Every Day

Most battery failures are visible months in advance. They are simply not being watched. Continuous monitoring turns the least visible asset in your critical power chain into the best evidenced one.

The Problem

An Annual Test Tells You About One Day of the Year

A battery bank that passed its test in March can be incapable of carrying the load by August. Between visits, the asset that your entire uptime strategy depends on is unobserved. Meanwhile, calendar-based replacement throws away serviceable batteries at some sites and leaves degraded ones in service at others.

Invisible degradation

Cell impedance rises and capacity falls gradually. Nothing on the UPS front panel shows it until the load transfers and the bank collapses.

Thermal risk

Rising temperature accelerates ageing and, in the worst case, leads to thermal runaway. It is trivial to detect and easy to miss.

Blind capital spend

Without condition data, replacement budgets are guesses. Money goes to the sites that are due, not the sites that are failing.

How It Works

From Sensor to Decision

1. InstrumentMonitoring hardware is installed across the string, with sensing at cell or block level plus current and temperature.
2. ConnectEach site connects over its own secure 4G service, insulated from the customer's IT environment, so there is no dependency on the customer's network team.
3. WatchData is trended continuously. Alarms are triaged by our team, not left sitting in an unattended inbox.
4. Report and actMonthly condition reporting through PowerShield Assure, with replacement recommendations that name the specific strings at risk.
Why separate connectivity matters. Monitoring runs on its own secure 4G service, insulated from the customer's IT environment. There is no dependency on the customer's network team and no change request required to get a site online. That is what makes multi-site rollouts across hundreds of locations practical.
What We Measure

The Parameters That Predict Failure

  • Cell or block voltage, continuously, across the full string
  • Internal impedance trended over time, so the rate of change is visible
  • String current: float, charge and discharge events
  • Ambient and battery temperature
  • Discharge events captured automatically when they occur in service
  • Ripple and charger behaviour where the system supports it

Backed by physical testing

Monitoring does not replace a proper discharge test, it tells you when one is worth doing. We carry out capacity and discharge testing to prove real autonomy, and the result is trended alongside the monitored data.

Chemistries supported

  • Lead-acid, including VRLA, AGM, gel and flooded cells
  • Lithium
  • Nickel-cadmium

Deployment scale

From a single UPS at one site to fleet rollouts across hundreds of remote and unmanned locations, with staged rollout and a consolidated installation standard.

The Outcome

Replace on Condition, Not on the Calendar

Risk where it is

You know which strings are degrading and which are fine, by site, by string, with the data behind it.

Planned spend

Replacements are forecast and budgeted ahead of failure instead of funded as emergencies.

Fewer surprises

Thermal and voltage alarms surface problems while there is still time to act on them.

Evidence on file

Audit-ready condition history for every asset, under your brand, ready for compliance and board reporting.

How onsite work is reported

When Monitoring Predicts Risk

Onsite Support and Lifecycle Services

Monitoring tells you where the risk is. It is not an all-inclusive service, and it does not pretend to be. When it predicts a problem, our onsite support and lifecycle services are available to get things back into shape, engaged as you need them or under a service contract.

Monitoring is available on its own, or with onsite servicing added: a scheduled onsite verification program covering capacity testing, torque verification and calibration checks.

Available when you need it

  • Onsite fault response and repair
  • Discharge and capacity testing
  • String and bank replacement
  • Compliant removal, transport and recycling of end-of-life batteries
  • Onsite verification program under a service contract

Service contract options →

Get Your Battery Fleet Under Observation

Single site or several hundred, monitoring starts with an assessment of what you have and what it is doing now.

Request an Assessment1300 905 247