A Data-Driven Approach to Battery Management: Insights from Our Battcon 2025 White Paper
Simon Boivin, CTO at Multitel
In critical facilities such as headends, data centers, and telecom central offices, the reliability of backup power systems depends directly on the performance of their batteries. Yet many organizations continue to rely on age-based replacement strategies that often lead to premature replacements, unnoticed degradation, and unnecessary operational expenses.
To address these challenges, Multitel partnered with Cox Communications to develop a comprehensive, field-tested methodology for modernizing battery management. Presented at Battcon 2025, our new white paper outlines how a data-driven, condition-based approach can significantly improve reliability, reduce OpEx, and extend the useful life of battery assets.
Moving Beyond Age-Based Replacement
Age alone is not an accurate indicator of battery health. Two batteries installed on the same day can age differently depending on temperature, usage patterns, installation quality, and environmental conditions. By replacing batteries solely on a fixed schedule, organizations risk discarding healthy assets and exposing their network to failures caused by overlooked degradation.
A condition-based strategy instead combines multiple sources of data to evaluate actual battery performance. This approach offers a more accurate, cost-effective, and reliable method for making replacement decisions.
Combining Four Key Data Inputs
The white paper presents a holistic model based on four complementary sources of data:
Battery Monitoring System (BMS)
Continuous measurements of ohmic values, voltage, and temperature offer daily insight into battery condition. State of Health (SOH) calculations derived from conductance trends help detect early degradation.Handheld Ohmic Testing
Performed every three years to validate BMS readings and identify discrepancies. Variations beyond ±10 percent trigger deeper investigation.Discharge Testing
Conducted every three to five years or when data indicates declining performance, confirming whether a battery meets duty-cycle requirements.On-Site Visual Inspections
Identifying physical indicators such as swelling, corrosion, or leaking posts that no monitoring system can detect.
Together, these inputs create a complete and accurate view of each battery string’s performance throughout its lifecycle.
Real-World Implementation at Cox Communications
Before standardizing their replacement process, Cox facilities used a variety of approaches—some fully age-based, others relying on handheld testing, and some using periodic discharge tests. This inconsistency created inefficiencies and uneven reliability across sites.
By consolidating monitoring data into a centralized software platform and applying a unified, data-driven strategy, Cox gained global visibility over fleet-wide battery health. This allowed their teams to:
Reduce premature replacements
Identify strings performing well beyond their expected lifespan
Uncover hidden degradation risks
Improve budgeting accuracy and long-term forecasting
In practice, many batteries were still performing reliably after 12 years, far exceeding manufacturer expectations.
The Cost-Benefit Advantage
One of the most compelling components of the white paper is the cost comparison between three typical battery maintenance strategies:
| Approach | Total Lifecycle Cost | Outcome |
|---|---|---|
| Handheld Testing Only | $16,800 | Lower cost but higher operational risk |
| Discharge Testing Primary | $28,800 | High confidence, high cost |
| Battery Monitoring System Primary | $8,800 | Best balance of cost, reliability, and visibility |
A monitoring-based, condition-driven method can reduce lifecycle costs by up to 70 percent while strengthening reliability and reducing unexpected failures.
The Role of Centralized Battery Management Software
Managing thousands of cells across an entire network requires more than raw data. A centralized software platform is essential for correlating, analyzing, and visualizing battery performance over time. By automating thresholds, providing trend analysis, validating datasets, and creating audit-ready reports, a centralized system transforms battery data into actionable insights.
Practical Guidelines for a Modernized Strategy
The white paper outlines a three-step process adopted by Cox Communications:
Daily SOH tracking through real-time BMS data
Periodic handheld validation every three years
Targeted discharge testing every three to five years based on data triggers
This model aligns with IEEE standards while minimizing unnecessary testing and optimizing replacement timing.
Conclusion
Battery systems are essential to ensuring power continuity in critical infrastructure. Through a data-driven, condition-based approach, organizations can significantly improve reliability while reducing operational expenditures. The insights shared in this white paper provide a practical, scalable framework that helps operators confidently manage their battery assets across large, distributed networks.
To explore the full methodology, detailed cost analysis, and real performance results from Cox Communications, download the complete white paper here.
If your organization is considering modernizing its battery management practices, our team would be happy to discuss how these strategies can be adapted to your operational environment.
