Description

ZAPI ACE0 Controller fault code

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.

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.

EB. COIL OPEN (MDI/LED code = 43)

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.

EB. DRIV.OPEN (MDI/LED code = 42)

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.

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