Description

FEATURES

 Nominal voltage from 24 V to 96 V.

 Two microcontrollers for main and safety

functions, 320+ kByte embedded flash memory.

 3 digital inputs.

 4 analog inputs with 10-bit resolution.

 Input for analog motor thermal sensor.

 Compatible with several types of speed sensors:

 Incremental encoder (default).

 Sin/cos sensor.

 Set of three Hall sensors.

 Resolver (adding an external interface).

 CAN bus interface up to 500 kbit/s or 1 Mbit/s (onrequest).

 11-bit and 29-bit communication supported.

 2 auxiliary supply outputs (+12V / +5V; max 100mA for +12V, max 100 mA for +5V).

 2 PWM voltage-controlled low-side outputs forline contactor and electromechanical brake.

 1 auxiliary PWM voltage-controlled low-sideoutput.

 Built-in freewheeling diodes.

 Dither injection with configurable amplitude and frequency.

 Protection from overload, short circuit, open load and ESD.

 Ambient temperature

 Operating: -40 °C ÷ +40 °C.

 Storage: -40 °C ÷ +85 °C.

 Sealed connector (23-pins Ampseal).

 Access to status and diagnostic information.

ACQUIRE ABORT (MDI/LED code = 2)

Cause:

The acquiring procedure relative to the absolute feedback sensor aborted.

ACQUIRE END (MDI/LED code = 2)

Cause:

Absolute feedback sensor acquired.

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.

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.

BATTERY LOW (MDI/LED code = 0)

Cause:

Parameter BATTERY CHECK is other than 0 (SET OPTION list,

paragraph8.2.2) 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

ACE2 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)

It is related to the capacitor-charging system:

Cause

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 A18) 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. MC (MDI/LED code = 76)

Cause

This alarm occurs when an overload of the MC driver (output NMC A16) 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 NLC (A16)

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.

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

Cause:

This fault appears when no load is connected between the NEB output (A18)

and the EB positive terminal PCOM (A17).

Troubleshooting:

– Check the EB coil.

– Check the wiring.

– If the problem is not solved, replace the logic board.

1. 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.

1. DRIV.SHRT. (MDI/LED code = 40)

Cause:

– The EB driver is shorted.

– The microcontroller detects a mismatch between the valve setpoint and 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 NEVP output (A19) 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 DRIV. SHORT. (MDI/LED code = 9)

Cause

– The EVP driver (output A19) 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.

EVP DRIVER OPEN (MDI/LED code = 9)

Cause:

The EVP driver (output NEVP) 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.

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 A18) 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. 02 (MDI/LED code = 16)

Cause:

At start-up, the hardware circuit dedicated to enable and disable the EV driver

(output NAUX1 A9) is found to be faulty.

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 A16) 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 NLC output A16 and

the positive voltage (for example +KEY).

Troubleshooting

– Check the wiring, in order to verify if LC coil is connected to the right

connector pin and if it is not interrupted.

– 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 (A1). 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.

M/S PAR CHK MISM (MDI/LED code = 97)

Cause:

At start-up there is a mismatch in the parameter checksum between the master

and the supervisor microcontrollers.

Troubleshooting:

Restore and save again the parameters list.

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