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hey dude your problem is so simple..below are my solutions.
if you already secured the fans for the replacement then its easy for you to do it, try to totally shut down your UPS removing the input and battery supply. avoid replacing the fans with power, its to dangerous. it consist of almost 400VDC inside in it.
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The charger in powerware 9 series 9120 6000i ,the fan is of a quality that it fails and the heat sink does not get sufficient cooling ,it runs on 12 volt ,i replaced it with a cpu fan from a mainboard on a pc and it works perfectly now. make sure that the fan is running else the charger might go in protection or can fail due to the transistor on heat sink fails.
The fan replacement is not hard, but it is fiddly.
You need to pull out the battery case to remove DC power. To do this - front display cover off by pushing up the plastic tabs inside the bottom front of the and tapping the top of the cover to release the top tabs. Take off the metal case cover using a Torx screwdriver. Undo the 4 screws on the back holding the steel fan cover. Using needlenose pliers or a very small screwdriver, carefully remove the fan connector from the the back PCB board. This connector is fragile and tends to break easily. Pull out the fan. Note the locaton of the 2 screws on the inside fan cover. I use a NMB-MAT Model 3610KL-04W-B50 12 volt DC replacement fan that I order in specially from any wholesale electronics shop as you want the maximum CFM out of the fan. You need to cut the existing fan leads and solder the existing connector leads to the new fan lead, using heat shrink tubing. The connector goes back in only one way- note the dimple on the side. The leads can be a little longer on your completed fan assembly. The fan maufacturer's label should face the back of the UPS.
You're absolutely right, overtemp on batteries can greatly escalate the failure of batteries, particularly older or heavily loaded ones. The fans are a fairly easy replace, if we can assist in any way, please do not hesistate to contact us.
in the 9120 series the fan is allways working, but as 2 speeds. the higher goes of when the load goes around 80% or the temperature inside is higher. just make sure the the fans are clean, and check the ups temperature.
but is normal.
good luck
sounds like inverter is unhappy(causing the input fuse to blow. maybe, just maybe, this Powerware 9120 has given up the ghost? The inverter can short for a variety of reasons. Try to take out the battery completely, and run it as just a power conditioner. If that works, then you have an unhappy inverter in there.
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