| Product name | ZAPI AC0 Controller |
| DDP# | DDPTMCFBJZL92E15 |
| Brand | ZAPI |
| PN | 23335100010000 |
| Voltage | 24V/36V/48V |
| Current | 320A/400A |
| Size | Standard size |
| Color | Black |
| Function | Control vehicle forward and backward ，steering, etc. |
| Used for | Electric stacker Electric pallet truck |
| Product name | ZAPI AC0 Controller |
| DDP# | DDPTMCFBJZL92E15 |
| Brand | ZAPI |
| PN | 23335100010000 |
| Voltage | 24V/36V/48V |
| Current | 320A/400A |
| Size | Standard size |
| Color | Black |
| Function | Control vehicle forward and backward ，steering, etc. |
| Used for | Electric stacker Electric pallet truck |
ACQUIRE ABORT (MDI/LED code = 2)
Cause:
The acquiring procedure relative to the absolute feedback sensor aborted.
ACQUIRING A.S. (MDI/LED code = 2)
Cause:
Controller is acquiring data from the absolute feedback sensor.
Troubleshooting:
The alarm ends when the acquisition is done.
ACQUIRE END (MDI/LED code = 2)
Cause:
Absolute feedback sensor acquired.
ANALOG INPUT (MDI/LED code = 96)
Cause
This alarm occurs when the A/D conversion of the analog inputs returns
frozen values, on all the converted signals, for more than 400 ms. The goal of
this diagnosis is to detect a failure in the A/D converter or a problem in the
code flow that skips the refresh of the analog signal conversion.
Troubleshooting
If the problem occurs permanently it is necessary to replace the logic board.
AUX BATT. SHORT. (MDI/LED code = 27)
Cause:
The voltage on PEB output (pin A2) is at high value even if it should not.
For the versions where the smart driver is not installed (36/48V and 80V), it is
possible to decide where the positive supply for pin A2 comes from by
choosing a dedicated hardware configuration. The parameter POSITIVE E.B.
has to be set in accordance with the hardware configuration (see paragraph
8.2.5), because the software makes a proper diagnosis depending on the
parameter; a wrong setting could generate a false fault. The available
choices are:
– 0 = PEB is managed by the smart driver (available for 24V version
only).
– 1 = PEB comes from the TILLER input (A1).
– 2 = PEB comes from PEV (A3). PEV must be connected to terminal
+B of the controller. This is the default configuration for 36/48V and
80V version.
This alarm can only appear if POSITIVE E.B. is set as 1 TILLER/SEAT.
Troubleshooting:
– Verify that the parameter POSITIVE E.B. is set in accordance with the
actual coil positive supply (see paragraph 8.2.5).
– In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.
BATTERY LOW (MDI/LED code = 0)
Cause:
Parameter BATTERY CHECK is other than 0 (SET OPTION list, paragraph
8.2.2) and battery charge is evaluated to be lower than BATT.LOW
TRESHLD (ADJUSTMENTS list, paragraph 8.2.3).
Troubleshooting:
– Check the battery charge and charge it if necessary.
– If the battery is actually charged, measure the battery voltage through a
voltmeter and compare it with the BATTERY VOLTAGE reading in the
TESTER function. If they are different, adjust the ADJUST BATTERY
parameter (ADJUSTMENTS list, paragraph 8.2.3) with the value
measured through the voltmeter.
– If the problem is not solved, replace the logic board.
BRAKE RUN OUT (MDI/LED code = 63)
Cause:
The CPOT BRAKE input read by the microcontroller is out of the range
defined by parameters SET PBRK. MIN and SET PBRK. MAX
(ADJUSTMENTS list, paragraph 8.2.3).
Troubleshooting:
– Check the mechanical calibration and the functionality of the brake potentiometer.
– Acquire the minimum and maximum potentiometer values.
– If the alarm is still present, replace the logic board.
BUMPER STOP (MDI/LED code = 0)
Cause
The two digital inputs dedicated to the bumper functionality are high at the
same time. The alarm can occur only if parameter BUMPER STOP = ON and
only if the controller is in CAN OPEN configuration (see parameter
CONTROLLER TYPE in SPECIAL ADJUST. list, paragraph 8.2.4).
Troubleshooting
– Turn off one or both inputs dedicated to the bumper functionality.
– If the alarm occurs even if the inputs are in the rest position, check if the
microswitches are stuck.
– In case the problem is not solved, replace the logic board.
CAPACITOR CHARGE (MDI/LED code = 60)
Cause
It is related to the capacitor-charging system:
When the key is switched on, the inverter tries to charge the power
capacitors through the series of a PTC and a power resistance, checking if
the capacitors are charged within a certain timeout. If the capacitor voltage
results less than a certain percentage of the nominal battery voltage, the
alarm is raised and the main contactor is not closed.
Troubleshooting
– Check if an external load in parallel to the capacitor bank, which sinks
current from the capacitors-charging circuit, thus preventing the caps
from charging well. Check if a lamp or a dc/dc converter or an auxiliary
load is placed in parallel to the capacitor bank.
– The charging resistance or PTC may be broken. Insert a power
resistance across line-contactor power terminals; if the alarm disappears,
it means that the charging resistance is damaged.
– The charging circuit has a failure or there is a problem in the power
section. Replace the controller.
CHECK UP NEEDED (MDI/LED code = 0)
Cause:
This is a warning to point out that it is time for the programmed maintenance.
Troubleshooting:
Turn on the CHECK UP DONE option after that the maintenance service.
COIL SHOR. EB (MDI/LED code = 76)
Cause
This alarm occurs when an overload of the EB driver (output NEB A4)
occurs.
Troubleshooting
– Check the connections between the controller outputs and the loads.
– Collect information about characteristics of the coil connected to the
driver and ask for assistance to a Zapi technician in order to verify that
the maximum current that can be supplied by the hardware is not
exceeded.
– In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.
COIL SHOR. EVAUX (MDI/LED code = 21)
Cause:
This alarm occurs when an overload of the EV drivers occurs.
Troubleshooting:
– Check the connections between the controller outputs and the loads.
– Collect information about characteristics of the coils connected to the
drivers and ask for assistance to a Zapi technician in order to verify that
the maximum current that can be supplied by the hardware is not
exceeded.
In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.
COIL SHOR. MC (MDI/LED code = 76)
Cause
This alarm occurs when an overload of the MC driver (output NMC A12)
occurs.
Troubleshooting
– Check the connections between the controller outputs and the loads.
– Collect information about characteristics of the coil connected to the
driver and ask for assistance to a Zapi technician in order to verify that
the maximum current that can be supplied by the hardware is not
exceeded
– In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.
CONT. DRV. EV 02 (MDI/LED code = 21)
Cause:
AUX valve driver is not able to drive the load.
Troubleshooting:
The device or its driving circuit is damaged. Replace the controller.
CONTACTOR CLOSED (MDI/LED code = 37)
Cause
Before driving the LC coil, the controller checks if the contactor is stuck. The
controller drives the power bridge for several dozens of milliseconds, trying to
discharge the capacitors bank. If the capacitor voltage does not decrease by
more than a certain percentage of the key voltage, the alarm is raised.
Troubleshooting
It is suggested to verify the power contacts of LC; if they are stuck, is
necessary to replace the LC.
CONTACTOR DRIVER (MDI/LED code = 75)
Cause
The LC coil driver is not able to drive the load. The device itself or its driver
circuit is damaged.
Troubleshooting
This type of fault is not related to external components; replace the logic
board.
CONTACTOR OPEN (MDI/LED code = 38)
Cause
The LC coil is driven by the controller, but it seems that the power contacts
do not close. In order to detect this condition the controller injects a DC
current into the motor and checks the voltage on power capacitor. If the
power capacitors get discharged it means that the main contactor is open.
Troubleshooting
– LC contacts are not working. Replace the LC.
– If LC contacts are working correctly, contact a Zapi technician.
CONTROLLER MISM. (MDI/LED code = 12)
Cause
The software is not compatible with the hardware. Each controller produced
is “signed” at the end of line test with a specific code mark saved in EEPROM
according to the customized Part Number.
According with this “sign”, only the customized firmware can be uploaded.
Troubleshooting
– Upload the correct firmware.
– Ask for assistance to a Zapi technician in order to verify that the firmware
is correct.
CURRENT GAIN (MDI/LED code = 92)
Cause:
The maximum current gain parameters are at the default values, which
means that the maximum current adjustment procedure has not been carried
out yet.
Troubleshooting:
Ask for assistance to a Zapi technician in order to do the adjustment
procedure of the current gain parameters.
DATA ACQUISITION (MDI/LED code = 0)
Cause:
Controller in calibration state.
Troubleshooting:
The alarm ends when the acquisition is done.
DRIVER SHORTED (MDI/LED code = 74)
Cause
The driver of the LC coil is shorted.
Troubleshooting
– Check if there is a short or a low impedance pull-down between NMC
(A12) and -B.
– The driver circuit is damaged; replace the logic board.
DRV. SHOR. EV 02 (MDI/LED code = 21)
Cause:
AUX valve driver is shorted.
Troubleshooting:
– Check if there is a short circuit or a low impedance path between the
negative terminal of the coils and -B.
– If the problem is not solved, replace the logic board.
Cause:
This fault appears when no load is connected between the NEB output (A4)
and the EB positive terminal PEB (A2).
Troubleshooting:
– Check the EB coil.
– Check the wiring.
– If the problem is not solved, replace the logic board.
Cause:
The EB coil driver is not able to drive the load. The device itself or its driving
circuit is damaged.
Troubleshooting:
This type of fault is not related to external components. Replace the logic
board.
the feedback at the EB output.
Troubleshooting:
– Check if there is a short or a low impedance path between the negative
coil terminal and -B.
– Check if the voltage applied is in accordance with the parameters
settings (see paragraph 8.2.5).
– If the problem is not solved, replace the controller.
ED SPLIP MISMATCH (MDI/LED code = 7)
Cause
The control detects a mismatch between the expected slip and the evaluated
one. This diagnostic occurs only if ED COMPENSATION = TRUE.
EEPROM KO (MDI/LED code = 13)
Cause:
A HW or SW defect of the non-volatile embedded memory storing the
controller parameters. This alarm does not inhibit the machine operations,
but it makes the truck to work with the default values.
Troubleshooting:
Execute a CLEAR EEPROM procedure (refer to the Console manual). Switch
the key off and on to check the result. If the alarm occurs permanently, it is
necessary to replace the controller. If the alarm disappears, the previously
stored parameters will be replaced by the default parameters.
ENCODER D.ERR XX (MDI/LED code = 3)
Cause:
This alarm occurs only when the controller is configured as PMSM and the
feedback sensor selected is the encoder. The A and B pulse sequence is not
correct. The hexadecimal value “XX” facilitates Zapi technicians debugging
the problem.
Troubleshooting:
– Check the wirings.
– If the motor direction is correct, swap A and B signals.
– If the motor direction is not correct, swap two of the motor cables.
– If the problem is not solved, contact a Zapi technician.
ENCODER ERROR (MDI/LED code = 82)
Cause
This fault occurs when the frequency supplied to the motor is higher than 30
Hz and the signal feedback from the encoder has a too high jump in few tens
of milliseconds. This condition is related to an encoder failure.
Troubleshooting
– Check the electrical and the mechanical functionality of the encoder and
the wires crimping.
– Check the mechanical installation of the encoder, if the encoder slips
inside its housing it will raise this alarm.
– Also the electromagnetic noise on the sensor can be the cause for the
alarm. In these cases try to replace the encoder.
– If the problem is still present after replacing the encoder, the failure is in
the controller.
EPS RELAY OPEN (MDI/LED code = 70)
Cause:
The controller receives from EPS information about the safety contacts being
open.
Troubleshooting:
Verify the EPS functionality.
EVP COIL OPEN (MDI/LED code = 9)
Cause:
No load is connected between the EVP output (A24) and the electrovalve
positive terminal.
Troubleshooting:
– Check the EVP condition.
– Check the EVP wiring.
– If the problem is not solved, replace the logic board.
–
EVP DRIVER OPEN (MDI/LED code = 9)
Cause:
The EVP driver is not able to drive the EVP coil. The device itself or its
driving circuit is damaged.
Troubleshooting:
This fault is not related to external components. Replace the logic board.
EVP DRIV. SHORT. (MDI/LED code = 9)
Cause
– The EVP driver (output A24) is shorted.
– The microcontroller detects a mismatch between the valve set-point and
the feedback of the EVP output.
Troubleshooting
– Check if there is a short circuit or a low-impedance conduction path
between the negative of the coil and -B.
– Collect information about:
o the voltage applied across the EVP coil,
o the current in the coil,
o features of the coil.
Ask for assistance to Zapi in order to verify that the software diagnoses are
in accordance with the type of coil employed.
If the problem is not solved, it could be necessary to replace the controller.
EVP2 COIL OPEN (MDI/LED code = 10)
Cause:
No load is connected between the EVP2 output (A23) and the electrovalve
positive terminal.
Troubleshooting:
– Check the EVP2 condition.
– Check the EVP2 wiring.
The EVP2 driver is not able to drive the EVP2 coil. The device itself or its
driving circuit is damaged.
Troubleshooting:
This fault is not related to external components. Replace the logic board.
EVP2 DRIV. SHORT. (MDI/LED code = 10)
Cause
– The EVP2 driver (output A23) is shorted.
– The microcontroller detects a mismatch between the valve set-point and
the feedback of the EVP2 output.
Troubleshooting
– Check if there is a short circuit or a low-impedance conduction path
between the negative of the coil and -B.
– Collect information about:
o the voltage applied across the EVP2 coil,
o the current in the coil,
o features of the coil.
Ask for assistance to Zapi in order to verify that the software diagnoses are
in accordance with the type of coil employed.
– If the problem is not solved, it could be necessary to replace the
controller.
FIELD ORIENT. KO (MDI/LED code = 36)
Cause
The error between the Id (d-axis current) setpoint and the estimated Id is out
of range.
Troubleshooting
Ask for assistance to a Zapi technician in order to do the correct adjustment
of the motor parameters.
FORW + BACK (MDI/LED code = 80)
Cause:
This alarm occurs when both the travel requests (FW and BW) are active at
the same time.
Troubleshooting:
– Check that travel requests are not active at the same time.
– Check the FW and BW input states through the TESTER function.
– Check the wirings relative to the FW and BW inputs.
– Check if there are failures in the microswitches.
– If the problem is not solved, replace the logic board.
HANDBRAKE (MDI/LED code = 46)
Cause:
Handbrake input is active.
Troubleshooting:
– Check that handbrake is not active by mistake.
– If the problem is not solved, replace the logic board.
HOME SENS.ERR XX (MDI/LED code = 3)
Cause
The controller detected a difference between the estimated absolute
orientation of the rotor and the position of the index signal (ABI encoder).
It is caused by a wrong acquisition of the angle offset between the orientation
of the rotor and the index signal. The hexadecimal value “XX” facilitates Zapi
technicians debugging the problem.
Troubleshooting
Repeat the auto-teaching procedure.
HW FAULT EB. XX (MDI/LED code = 34)
Cause:
At start-up, the hardware circuit dedicated to enable and disable the EB
driver (output A4) is found to be faulty. The hexadecimal value “XX” facilitates
Zapi technicians debugging the problem.
Troubleshooting:
This type of fault is not related to external components. Replace the logic
board.
HW FAULT EV. XX (MDI/LED code = 16)
Cause:
At start-up, the hardware circuit dedicated to enable and disable the EV
drivers is found to be faulty. The hexadecimal value “XX” facilitates Zapi
technicians debugging the problem.
Troubleshooting:
This type of fault is not related to external components. Replace the logic
board.
HW FAULT XX (MDI/LED code = 32)
Cause
At start-up, some hardware circuit intended to enable and disable the power
bridge or the LC driver (output A12) is found to be faulty. The hexadecimal
value “XX” facilitates Zapi technicians debugging the problem.
Troubleshooting
This type of fault is related to internal components. Replace the logic board.
INCORRECT START (MDI/LED code = 79)
Cause:
Incorrect starting sequence. Possible reasons for this alarm are:
– A travel demand active at key-on.
– Man-presence sensor active at key on.
Troubleshooting:
– Check wirings.
– Check microswitches for failures.
– Through the TESTER function, check the states of the inputs are
coherent with microswitches states.
– If the problem is not solved, replace the logic board.
INIT VMN HIGH XX (MDI/LED code = 31)
Cause
Before closing the LC, the software checks the power-bridge voltage without
driving it. The software expects the voltage to be in a “steady state” value.
If it is too high, this alarm occurs. The hexadecimal value “XX” identifies the
faulty phase:
81: phase U
82: phase V
83: phase W
Troubleshooting
– Check the motor power cables.
– Check the impedance between U, V and W terminals and -B terminal of
the controller.
– Check the motor leakage to truck frame.
– If the motor connections are OK and there are no external low
impedance paths, the problem is inside the controller. Replace it.
INIT VMN LOW XX (MDI/LED code = 30)
Cause
Before closing the LC, the software checks the power-bridge voltage without
driving it. The software expects the voltage to be in a “steady state” value. If
it is too low, this alarm occurs. The hexadecimal value “XX” identifies the
faulty phase:
01: phase U
02: phase V
03: phase W
Troubleshooting
– Check the motor power cables.
– Check the impedance between U, V and W terminals and -B terminal of
the controller.
– Check the motor leakage to truck frame.
– If the motor connections are OK and there are no external low
impedance paths, the problem is inside the controller. Replace it.
IQ MISMATCHED (MDI/LED code = 24)
Cause
The error between the Iq (q-axis current) setpoint and the estimated Iq is out
of range.
Troubleshooting
Ask for assistance to a Zapi technician in order to do the correct adjustment
of the motor parameters.
LC COIL OPEN (MDI/LED code = 22)
Cause
This fault appears when no load is connected between the NMC output A12
and the positive voltage (for example the KEY voltage).
– If the alarm is still present, than the problem is inside the logic board;
replace it.
LIFT+LOWER (MDI/LED code = 49)
Cause:
Both the pump requests (LIFT and LOWER) are active at the same time.
Troubleshooting:
– Check that LIFT and LOWER requests are not active at the same time.
– Check the LIFT and LOWER input states through the TESTER function.
– Check the wirings.
– Check if there are failures in the microswitches.
– If the problem is not solved, replace the logic board.
LOGIC FAILURE #1 (MDI/LED code = 19)
Cause
This fault is displayed when the controller detects an undervoltage condition
at the KEY input (A10). Undervoltage threshold depends on the nominal
voltage of the controller.
Nominal voltage 24V 36/48V 72/80V 96V
Undervoltage threshold 10V 10V 30V 30V
Troubleshooting (fault at startup or in standby)
– Fault can be caused by a key input signal characterized by pulses below
the undervoltage threshold, possibly due to external loads like DC/DC
converters starting-up, relays or contactors during switching periods,
solenoids energizing or de-energizing. Consider to remove such loads.
– If no voltage transient is detected on the supply line and the alarm is
present every time the key switches on, the failure probably lies in the
controller hardware. Replace the logic board.
Troubleshooting (fault displayed during motor driving)
– If the alarm occurs during motor acceleration or when there is a
hydraulic-related request, check the battery charge, the battery health
and power-cable connections.
LOGIC FAILURE #2 (MDI/LED code = 18)
Cause
Fault in the hardware section of the logic board which deals with voltage
feedbacks of motor phases.
Troubleshooting
The failure lies in the controller hardware. Replace the controller.
LOGIC FAILURE #3 (MDI/LED code = 17)
Cause
A hardware problem in the logic board due to high currents (overload). An
overcurrent condition is triggered even if the power bridge is not driven.
Troubleshooting
The failure lies in the controller hardware. Replace the controller.
master and the supervisor microcontrollers.
Troubleshooting:
Restore and save again the parameters list.
MOT.PHASE SH. XX (MDI/LED code = 47)
Cause
Short circuit between two motor phases. The hexadecimal value “XX”
identifies the shorted phases:
36: U – V short circuit
37: U – W short circuit
38: V – W short circuit
Troubleshooting
– Verify the motor phases connection on the motor side.
– Verify the motor phases connection on the inverter side.
– Check the motor power cables.
– Replace the controller.
– If the alarm does not disappear, the problem is in the motor. Replace it.
MOTOR TEMP. STOP (MDI/LED code = 65)
Cause:
The temperature sensor has overtaken the threshold defined by STOP
MOTOR TEMP. (if analog, see paragraph 8.2.3).
Troubleshooting:
– Check the temperature read by the thermal sensor inside the motor
through the MOTOR TEMPERATURE reading in the TESTER function.
– Check the sensor ohmic value and the sensor wiring.
– If the sensor is OK, improve the cooling of the motor.
– If the warning is present when the motor is cool, replace the controller.
MOTOR TEMPERAT. (MDI/LED code = 65)
Cause:
This warning occurs when the temperature sensor is open (if digital) or if it
has overtaken the MAX. MOTOR TEMP. threshold (if analog) (see paragraph
8.2.3).
Troubleshooting:
– Check the temperature read by the thermal sensor inside the motor
through the MOTOR TEMPERATURE reading in the TESTER function.
– Check the sensor ohmic value and the sensor wiring.
– If the sensor is OK, improve the cooling of the motor.
– If the warning is present when the motor is cool, replace the controller.
NO CAN MSG. XX (MDI/LED code = 67)
Cause
CANbus communication does not work properly. The hexadecimal value “XX”
identifies the faulty node.
Troubleshooting
Cause:
It is necessary to acquire the offset angle between the stator and the speed
sensor, i.e. they mutual angular misalignment. An automatic function is
dedicated to this procedure.
Troubleshooting:
Perform the teaching procedure: in OPTIONS, select ABS SENS. ACQUIRE.
See paragraph 7.3.1 for more details.
OPEN COIL EV. (MDI/LED code = 21)
Cause:
This fault appears when no load is connected between one or more EV
outputs and the positive terminal PEV (pin A3). For the meaning of code
“XX”, refer to paragraph 10.510.5.
Troubleshooting:
– Check the coils.
– Check the wiring.
– If the problem is not solved, replace the logic board.
OVERLOAD (MDI/LED code = 57)
Cause
The motor current has overcome the limit fixed by hardware.
Troubleshooting
If the alarm condition occurs again, ask for assistance to a Zapi technician.
The fault condition could be affected by wrong adjustments of motor
parameters.
PARAM RESTORE (MDI/LED code = 14)
Cause:
The controller has restored the default settings. If a CLEAR EEPROM has
been made before the last key re-cycle, this warning informs you that
EEPROM was correctly cleared.
Troubleshooting:
– A travel demand or a pump request does cancel the alarm.
– If the alarm appears at key-on without any CLEAR EEPROM performed,
replace the controller.
PARAM TRANSFER (MDI/LED code = 93)
Cause:
Master uC is transferring parameters to the supervisor.
Troubleshooting:
Wait until the end of the procedure. If the alarm remains longer, re-cycle the
key.
from that defined by parameter SET POSITIVE PEB (see the
ADJUSTMENTS list, paragraph 8.2.3).
This alarm can occur if output NAUX1 is present (and the related setting is
active) or the AUX OUT function is active.
Troubleshooting:
– Check PCOM terminal: it must be connected to the battery voltage (after
the main contactor).
– Set the nominal PCOM voltage in parameter SET POSITIVE PEB in
ADJUSTMENTS list (see paragraph 8.2.3).
POS. EB. SHORTED (MDI/LED code = 84)
Cause:
The voltage on pin A2 is high even if the smart driver is turned OFF.
Troubleshooting:
– Verify that the parameter POSITIVE E.B. is set in accordance with the
actual coil positive supply (see paragraph 8.2.5).
– Check if there is a short or a low impedance path between pin A2 and of
the +B. In case no failures/problems have been found, the problem is in
the controller, which has to be replaced.
POSITIVE LC OPEN (MDI/LED code = 35)
Cause
The positive voltage of LC is different from expected.
Troubleshooting
– Verify LC coil is properly connected.
– Verify CONF. POSITIVE LC parameter is set in accordance with the
actual coil positive supply (see paragraph 8.2.5). Software, depending on
the parameter value, makes a proper diagnosis; a mismatch between the
hardware and the parameter configuration could generate a false fault.
– In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.
POWER MISMATCH (MDI/LED code = 39)
Cause
The error between the power setpoint and the estimated power is out of
range.
Troubleshooting
Ask for assistance to a Zapi technician about the correct adjustment of the
motor parameters.
POWERMOS SHORTED (MDI/LED code = 89)
Cause
The DC-link voltage drops to zero when a high-side or low-side MOSFET is
turned on.
Troubleshooting
– Check that motor phases are correctly connected.
– Check that there is no dispersion to ground for every motor phases.
The minimum voltage of the lift potentiometer is not correctly set.
Troubleshooting:
It is suggested to repeat the acquiring procedure of MIN LIFT and MAX LIFT
(see paragraph 9.2).
PUMP VMN LOW (MDI/LED code = 28)
Cause:
The pump motor output is lower than expected, considering the PWM duty cycle
applied.
Troubleshooting:
– Motor internal connections;
– Motor power cables connections;
– If the motor connection are OK, the problem is inside the controller.
again), check:
– Motor internal connections;
– If motor windings/cables have leakages towards truck frame;
– If no problem are found on the motors, the problem is inside the
controller.
– Motor internal connections;
– If motor windings/cables have leakages towards truck frame;
– That the LC power contact closer properly, with a good contact;
– If no problem are found on the motors, the problem is inside the
controller, it is necessary to replace the logic board.
PUMP VMN HIGH (MDI/LED code = 29)
Cause:
This test is carried out when the pump motor is turning (PWM applied). The
pump motor output is higher than expected, considering the PWM applied.
Troubleshooting:
– Motor internal connections
– If motor windings/cables have leakages towards truck frame
– If no problem are found on the motors, the problem is inside the
controller, it is necessary to replace the logic board.
PUMP VMN NOT OK (MDI/LED code = 33)
Cause:
Switching the LC on, the software checks the output voltage on -P connector, and
expects that it is at a “steady state” value (if DC PUMP option is set to ON, see
paragraph 8.2.1 – HYDRO SETTINGS).
If the voltage is too low, this alarm occurs.
Troubleshooting:
Please check:
– Motor internal connections
– Motor power cables connections
– Motor leakage to truck frame
– If the motor connections are ok, the problem is inside the controller it is
necessary to replace the logic board.
PUMP I NO ZERO (MDI/LED code = 56)
Cause:
In standby condition (pump motor not driven), the feedback coming from the
current sensor in the pump chopper gives a value out of a permitted range,
because the pump current is not zero.
Troubleshooting:
This type of fault is not related to external components; replace the
controller.
PUMP I=0 EVER (MDI/LED code = 52)
Cause:
While the pump motor is running, the current feedback is constantly stuck to
zero.
Troubleshooting:
Check the motor connection, that there is continuity. If the motor
connection is opened, the current cannot flow, so the test fails and the
error code is displayed;
If everything is ok for what it concerns the motor, the problem could be in
the current sensor or in the related circuit.
PUMP INC START (MDI/LED code = 79)
Cause:
Man-presence switch is not enabled at pump request.
Troubleshooting:
– Check wirings.
– Check microswitches for failures.
– Through the TESTER function, check the states of the inputs are
coherent with microswitches states.
– If the problem is not solved, replace the logic board.
PWM ACQ. ERROR (MDI/LED code = 6)
Cause
This alarm occurs only when the controller is configured to drive a PMSM
and the feedback sensor selected in the HARDWARE SETTINGS list is
ENCODER ABI + PWM.
The controller does not detect correct information on PWM input at start-up.
Troubleshooting
– Re-cycle the key.
– Check the sensor in order to verify that it works properly.
– Check the wiring.
– If the problem occurs permanently it is necessary to substitute logic
board.
threshold speed.
SEAT MISMATCH (MDI/LED code = 15)
Cause
This alarm can appear only in a Traction + Pump configuration or in a multi
motor one.
There is an input mismatch between the traction controller and the pump
controller relatively to the TILLER/SEAT input (A1): the two values recorded
by the two controllers are different.
Troubleshooting
– Check if there are wrong connections in the external wiring.
– Using the TESTER function, verify that the seat inputs are in accordance
with the actual state of the external switch.
– In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.
SENS MOT TEMP KO (MDI/LED code = 68)
Cause:
The output of the motor thermal sensor is out of range.
Troubleshooting:
– Check if the resistance of the sensor is what expected measuring its
resistance.
– Check the wiring.
– If the problem is not solved, replace the logic board.
SIN/COS D.ERR XX (MDI/LED code = 3)
Cause:
This alarm occurs only when the controller is configured as PMSM and the
feedback sensor selected is sin/cos. The signal coming from sin/cos sensor
has a wrong direction. The hexadecimal value “XX” facilitates Zapi
technicians debugging the problem.
Troubleshooting:
– Check the wirings.
– If the motor direction is correct, swap the sin and cos signals.
– If the motor direction is not correct, swap two of the motor cables.
– If the problem is not solved, contact a Zapi technician.
SPEED FB. ERROR (MDI/LED code = 81)
Cause
This alarm occurs if the absolute position sensor is used also for speed
estimation. If signaled, it means that the controller measured that the engine
was moving too quick.
Troubleshooting
– Check that the sensor used is compatible with the software release.
– Check the sensor mechanical installation and if it works properly.
– Also the electromagnetic noise on the sensor can be a cause for the
alarm.
Cause:
There is a hardware problem in the smart driver circuit (high-side driver on
pin A2). The driver is set to be ON but the output voltage does not increase.
Troubleshooting:
– Verify that the EB coil is connected correctly between pin A2 and pin A4.
– Verify that the parameter POSITIVE E.B.is set in accordance with the
actual configuration (see paragraph 8.2.5). The software, in fact,
depending on specific parameter value, makes a proper diagnosis; a
wrong configuration of this parameter could generate a false fault.
– In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.
STALL ROTOR (MDI/LED code = 11)
Cause:
The traction rotor is stuck or the encoder signal is not correctly received by
the controller.
Troubleshooting:
– Check the encoder condition.
– Check the wiring.
– Through the TESTER function, check if the sign of FREQUENCY and
ENCODER are the same and if they are different from zero during a
traction request.
– If the problem is not solved, replace the logic board.
STBY I HIGH (MDI/LED code = 53)
Cause
In standby, the sensor detects a current value different from zero.
Troubleshooting
The current sensor or the current feedback circuit is damaged. Replace the
controller.
STEER SENSOR KO (MDI/LED code = 95)
Cause:
The voltage read by the microcontroller at the steering-sensor input is not
within the STEER RIGHT VOLT ÷ STEER LEFT VOLT range, programmed
through the STEER ACQUIRING function (see paragraph 9.3).
Troubleshooting:
– Acquire the maximum and minimum values coming from the steering
potentiometer through the STEER ACQUIRING function. If the alarm is
still present, check the mechanical calibration and the functionality of the
potentiometer.
– If the problem is not solved, replace the logic board.
Cause:
The temperature of the controller base plate is above 85 °C.
The maximum current is proportionally decreased with the temperature
excess from 85 °C up to 105 °C. At 105 °C the current is limited to 0 A.
cooling-air temperature. If the thermal dissipation is realized by applying the
controller base plate onto the truck frame, the important factors are the
thickness of the frame and the planarity and roughness of its surface.
If the alarm occurs when the controller is cold, the possible reasons are a
thermal-sensor failure or a failure in the logic board. In the last case, it is
necessary to replace the controller.
THERMIC SENS. KO (MDI/LED code = 61)
Cause:
The output of the controller thermal sensor is out of range.
Troubleshooting:
This kind of fault is not related to external components. Replace the
controller.
THROTTLE PROG. (MDI/LED code = 48)
Cause:
A wrong profile has been set in the throttle profile.
Troubleshooting:
Set properly the throttle-related parameters (see paragraph 9.8).
TILLER ERROR (MDI/LED code = 64)
Cause:
Input mismatch between the Hard&Soft input (A6) and the TILLER/SEAT input
(A1): the two inputs are activated at the same time.
Troubleshooting:
– Check if there are wrong connections in the external wiring.
– Using the TESTER menu of the controller verify that what the controller
sees in input is in accordance with the actual state of the external switch
inputs.
– Check if there is a short circuit between A6 and A1.
– In case no failures/problems have been found, the problem is in the
controller, which has to be replaced.
TILLER OPEN (MDI/LED code = 51)
Cause:
Tiller/seat input has been inactive for more than 120 seconds.
Troubleshooting:
– Activate the tiller/seat input.
– Check the tiller/seat input state through the TESTER function.
– Check the wirings.
– Check if there are failures in the microswitches.
– If the problem is not solved, replace the logic board.
TORQUE PROFILE (MDI/LED code = 98)
Cause:
There is an error in the choice of the torque profile parameters.
Cause:
At key-on and immediately after that, the travel demands have been turned
off. This alarm occurs if the ACCELERATOR reading (in TESTER function) is
above the minimum value acquired during the PROGRAM VACC procedure.
Troubleshooting:
– Check the wirings.
– Check the mechanical calibration and the functionality of the accelerator
potentiometer.
– Acquire the maximum and minimum potentiometer value through the
PROGRAM VACC function.
– If the problem is not solved, replace the logic board.
VACC OUT RANGE (MDI/LED code = 85)
Cause:
– The CPOT input read by the microcontroller is not within the MIN VACC
÷ MAX VACC range, programmed through the PROGRAMM VACC
function (see paragraph 9.1).
– The acquired values MIN VACC and MAX VACC are inconsistent.
Troubleshooting:
– Acquire the maximum and minimum potentiometer values through the
PROGRAM VACC function. If the alarm is still present, check the
mechanical calibration and the functionality of the accelerator
potentiometer.
– If the problem is not solved, replace the logic board.
VDC LINK OVERV. (MDI/LED code = 77)
Cause
This fault is displayed when the controller detects an overvoltage condition.
Overvoltage threshold depends on the nominal voltage of the controller.
Nominal voltage 24V 36/48V 72/80V 96V
Overvoltage threshold 35V 65V 115V 130V
As soon as the fault occurs, power bridge and MC are opened. The condition
is triggered using the same HW interrupt used for undervoltage detection, uC
discerns between the two evaluating the voltage present across DC-link
capacitors:
– High voltage Overvoltage condition
– Low/normal voltage Undervoltage condition
Troubleshooting
If the alarm happens during the brake release, check the line contactor
contact and the battery power-cable connection.
VDC OFF SHORTED (MDI/LED code = 88)
Cause
The logic board measures a voltage value across the DC-link that is
constantly out of range, above the maximum allowed value.
– If the battery voltage is ok, replace the logic board.
VKEY OFF SHORTED (MDI/LED code = 20)
Cause
At key-on, the logic board measures a voltage value of the KEY input that is
constantly out of range, below the minimum allowed value.
Troubleshooting
– Check that the battery has the same nominal voltage of the inverter.
– Check the battery voltage, if it is out of range replace the battery.
– If the battery voltage is ok, replace the logic board.
VMN HIGH (MDI/LED code = 31)
Cause 1
Before switching the LC on, the software checks the power bridge: it turns on
alternatively the low-side power MOSFETs and expects the phase voltages
decrease down to -B. If the phase voltages are higher than a certain
percentage of the nominal battery voltage, this alarm occurs.
Cause 2
This alarm may also occur when the start-up diagnosis has succeeded and
so the LC has been closed. In this condition, the phase voltages are
expected to be lower than half the battery voltage. If one of them is higher
than that value, this alarm occurs.
Troubleshooting
– If the problem occurs at start-up (the LC does not close), check:
– motor internal connections (ohmic continuity);
– motor power cables connections;
– if the motor connections are OK, the problem is inside the controller.
Replace it.
– If the alarm occurs while the motor is running, check:
– motor connections;
– that the LC power contact closes properly, with a good contact;
– if no problem is found, the problem is inside the controller. Replace it.
VMN LOW (MDI/LED code = 30)
Cause 1
Start-up test. Before switching the LC on, the software checks the power
bridge: it turns on alternatively the high-side power MOSFETs and expects
the phase voltages increase toward the positive rail value. If one phase
voltage is lower than a certain percentage of the rail voltage, this alarm
occurs.
Cause 2
Motor running test. When the motor is running, the power bridge is on and
the motor voltage feedback tested; if it is lower than expected value (a range
of values is considered), the controller enters in fault state.
Troubleshooting
– If the problem occurs at start up (the LC does not close at all), check:
– motor internal connections (ohmic continuity);
– motor power-cables connections;
