Description

ZAPI ACE0 Controller fault code

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 debuggingthe 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 andthe 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.

EPS RELAY OPEN (MDI/LED code = 70)

Cause:

The controller receives from EPS information about the safety contacts beingopen.

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.

EVP2 DRIVER OPEN (MDI/LED code = 10)

Cause:

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 thecontroller.

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.

– Check the SR/HB 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.

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).

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