Powerware 9120 6kva. The message: disconnect battery. Pulled out all four packs of batteries at all 25V voltage and should be 60V

Sounds like it is not regulating the voltage and current charging the batteries.
Consult a service manual to look for a repair method.

I would takes 20 batteries to make one string:

1. GPS- 58EGPS-12-26-I
or
2. Yuasa - NPX-150R
or
3. Data Safe 12HX150-FR

Check the connections on the batteries. One or more may be loose or corroded. Also check the fuse for the batteries. It may have blown.

It's probably a failed battery going open circuit or DC voltage is below limit on a cell

The charger board has failure. Model already obsolete. Propose to buy a new unit

open the screws and disconnect the battery look the voltage written on it and AH (ampere/hour) e.g.12v & 7ah and purchase same value battery and connect look carefully the +ve &-ve polarity of battery and connect in proper way

The Batts can be charged externally, then refitted, usually I extend the DC cables so I can work with the batt outside the unit. This is ONLY to be done if you understand the risk and what may happen if you get it wrong.

Batts are always live and can cause fire/explosion/severe burns if shorted!
IF YOU ARE NOT SURE THEN GET SOME EXPERIENCED HELP!

OK so the UPS will not normally recognise a very low batt pack, that is the reason you can not start the test, this test will back of the rectifier so the batt pack takes the load for a short period.

If the batt pack is out of range then this will make the load go off, so the UPS is designed not to allow the test,unless the batt is at the right level.

If you can get the batt pack up close to normal then the unit will recharge it to full.,Wait until it is fully charged before testing.
If this is sucessful the cyle the batt a few times allowing it to reach around low batt warning before recharging. This will assist the batt in recovery. During this process if possible monitor with a test intrument(fluke 123 or 43B will do) the batt pack discharge curve , once the batt pack has dropped to its charge level from float, it should be a smooth decay.
depending on the state of the batts you may be ok, if there are weak ones in the string then you may have to replace all of them depending on the age of the batt pack.

MAKE SURE YOU ARE VERY CAREFUL WITH BATTERIES, THEY ARE VERY DANGEROUS, AND ALWAYS LIVE!

Check you manual for safety procedures, BEFORE working on Batteries.


hope this helps

thanks for using Fixya

Replace the batteries with new one then power the UPS without load for three hours or more so that the batteries can be charged. Then disconnect or switch off power to the UPS and observe if it will till be on using the batteries. If it will be ON then your problem is solved but if it goes off then your UPS is on BYPASS

Hi,

After you replaced the batteries did you perform a manual battery test?

If not do so.

Regards
Alan Hood
ami-man
UK

sometimes the battery tester is not enough to check the battery. battery also prone to tear and wear.because of charging ang discharging. replace the battery