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ZAPI CONTROLLERS

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ZAPI - motor controller
4Q error codes

MDI Description
AL02 Electric brake driver fault
AL08 Watchdog, logic circuit fault
AL13 EEPROM fault
AL32 VMN voltage not ok, motor short circuit
AL37 Contactor closed
AL49 Current sensor error - no current
AL53 Current sensor fault, high current but no PWM
AL60 Capacitor charge fault
AL62 Thermal protection
AL66 Battery low
AL73 Main relay or aux output short circuit
AL74 Main relay short circuit
AL75 Contactor driver fault
AL78 Accelerator voltage is not ok
AL79 Incorrect start, wrong sequence of switches and accelerator
AL80 Both direction inpust are active
AL86 Pedal wire open-circuit, no potentiometer
AL96 Too high motor current
AL98 MDI and chopper - different MTH counter value
AL99 Check-up needed

ZAPI - motor inverter
AC-1, AC-2 error codes

RED LED Description
1 BLINK Logic failure, EEPROM error, watchdog circuit trigerred, check up needed
2 BLINKS Wrong starting sequence, both directions active, encoder error
3 BLINKS Incorrect phase voltage or wrong capacitor charge
4 BLINKS Accelerator voltage fault, pedal wire open
5 BLINKS Failure current sensor
6 BLINKS Failure of contactor driver or coils
7 BLINKS Excessive controller temperature, motor temperature too high
8 BLINKS Can bus error or safety circuit problem
LONG BLINK Battery low
NO BLINK No keyswitch voltage, internal error or problem in a remote module

ZAPI - motor controller, traction + pump
COMBIAC2 error codes

err number (AL) error string (CONSOLE) Description
8 WATCHDOG Watchdog circuit has been trigerred
13 EEPROM KO Eeprom fault in controller
17 LOGIC FAILURE #3 Too high current or current sensor fault
18 LOGIC FAILURE #2 Wrong voltage feedback - phase U, V or W
19 LOGIC FAILURE #1 Undervoltage or overvoltage condition
30 VMN LOW Power output voltage too low, check motor circuit, MOSFET error - short circuit B-
31 VMN HIGH Power output voltage too high, check motor circuit, MOSFET error - short circuit to B+
37 CONTACTOR CLOSED Line contactor is stuck
38 CONTACTOR OPEN Line contactor doesn't pull-in
53 STBY I HIGH Wrong current sensor voltage - no PWM and current over 0A
60 CAP CHARGE Capacitor voltage doesn't increase after power up, power section failure, wrong wiring
61 HIGH TEMPERATURE Traction or Pump temperature over 75 deg. C
65 MOTOR TEMPERATURE Traction or pump motor temperature high
66 BATTERY LOW Battery charge level below 20%
74 DRIVER SHORTED Line contactor coil is shorted
75 CONTACTOR DRIVER Line contactor coil is open
76 COIL SHORTED Damaged protection circuit - line contactor or brake coil circuit, coil is shorted - too high current
78 VACC NOT OK Accelerator signal is higher than VACC MIN + 1V, while traction enable switch is open
79 INCORRECT START Wrong traction request sequence
80 PUMP KO Traction processor detects Pump processor malfunction
82 ENCODER ERROR Motor speed sensor doesn't work properly
86 FORWARD + BACKWARD Forward and reverse inputs are both active
242 PUMP WARNING Traction processors signals that pump processor has detected a fault in pump power stage
243 PUMP INC. START Pump incorrect start sequence
244 PUMP VACC NOT OK Pump accelerator voltage is 1V greater than programmed minimum value
245 WRONG SET BATTERY Battery voltage doesn't correspond to SET BATTERY parameter value
246 PUMP KO Traction processor detects Pump processor malfunction
246 MASTER KO Pump processor detects Traction processor malfunction or mismatch between inputs status
247 NO CAN MESSAGE #5 Traction processor has lost CAN communication with Pump processor
247 NO CAN MESSAGE #3 Pump processor has lost CAN communication with Traction processor
249 THERMIC SENSOR KO Traction or pump temperature sensor is out of range
250 INPUT MISMATCH Pump processor has detected a mismatch between inputs status and input status transmitted via can-bus by traction processor
251 WAITING FOR NODE#5 Traction processor signals that pump processor is in alarm status
251 WAITING FOR NODE#3 Pump processor signals that traction processor is in alarm status
253 AUX OUTPUT KO Brake coil shorted or open-circuit

ZAPI - dual motor controller
B1 error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog circuit has been trigerred
2 BLINKS Incorrect start, wrong sequence - eg. keyswitch, directions, accelerator, function switch active after key-on
3 BLINKS Wrong VMN output voltage R or L, short to B-
4 BLINKS Accelerator high in standby, steering potentiometer voltage not in valid range
5 BLINKS Error in read motor current R or L, sensor inside controller
6 BLINKS Malfunction of contactor driver circuit
7 BLINKS Temperature too high, more than 80 deg. C
8 BLINKS Contactor don't open or VMN voltage is high in stanby
9 BLINKS Contactor contact didn't close or high VMN voltage in rest condition
32 BLINKS Flat battery - charge low, less than 10%
ON Forward and reverse direction inputs are both active

ZAPI - traction + pump motors controller
C1 error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog circuit has been trigerred
2 BLINKS Incorrect start, wrong sequence - eg. keyswitch, directions, accelerator, function switch active after key-on
3 BLINKS Wrong VMN output voltage, short to B-
4 BLINKS Accelerator high in standby or lift potentiometer not calibrated
5 BLINKS Error in read motor current, sensor inside controller
6 BLINKS Malfunction of contactor driver circuit, short-circuit
7 BLINKS Temperature too high, more than 80 deg. C
8 BLINKS Contactor don't open or VMN voltage is high in stanby
9 BLINKS Contactor contact stucks
32 BLINKS Battery charge low, less than 10%
ON Forward and reverse direction inputs are both active

ZAPI - motor controller
H0 error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog circuit has been trigerred
2 BLINKS Incorrect start, wrong sequence - eg. keyswitch, directions, accelerator, function switch active after key-on
3 BLINKS Wrong VMN output voltage, short to B-
4 BLINKS Accelerator high in standby
5 BLINKS Error in read motor current, sensor inside controller
6 BLINKS Malfunction of contactor driver circuit
7 BLINKS Temperature too high, more than 76 deg. C
8 BLINKS Contactors do not close, error in coil driver circuit
9 BLINKS Tiller or inversion switch active at starting
32 BLINKS Battery discharged
ON Forward and reverse input, both active

ZAPI - motor controller
H1, H1DN error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog circuit has been trigerred
2 BLINKS Incorrect start, wrong sequence - eg. keyswitch, directions, accelerator, function switch active after key-on
3 BLINKS Wrong VMN output voltage, short to B-
4 BLINKS Accelerator high in standby
5 BLINKS Error in read motor current, sensor inside controller
6 BLINKS Malfunction of contactor driver circuit
7 BLINKS Temperature too high, more than 75 deg. C
8 BLINKS Contactors do not close
32 BLINKS Battery charge low, less than 10%
ON Forward and reverse direction inputs are both active

ZAPI - motor controller, traction / pump
H2B error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog circuit has been trigerred
2 BLINKS Incorrect start, wrong sequence - eg. keyswitch, directions, accelerator, function switch active after key-on
3 BLINKS Wrong VMN output voltage, short to B-
4 BLINKS Accelerator high in standby
5 BLINKS Error in read motor current, sensor inside controller
6 BLINKS Malfunction of contactor driver circuit
7 BLINKS Temperature too high, more than 80 deg. C
8 BLINKS Contactor don't open or VMN voltage is high in stanby
9 BLINKS Contactor contact stucks
32 BLINKS Battery charge low, less than 10%
ON Forward and reverse direction inputs are both active

ZAPI - motor controller, traction / pump
H3D error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog circuit has been trigerred
2 BLINKS Incorrect start, wrong sequence - eg. keyswitch, directions, accelerator, function switch active after key-on
3 BLINKS Wrong VMN output voltage, short to B-
4 BLINKS Accelerator high in standby
5 BLINKS Error in read motor current, sensor inside controller
6 BLINKS Malfunction of contactor driver circuit
7 BLINKS Temperature too high, more than 80 deg. C
8 BLINKS Contactor don't open or VMN voltage is high in stanby
9 BLINKS Contactor contact stucks
32 BLINKS Battery charge low, less than 10%
ON Forward and reverse direction inputs are both active

ZAPI - pump & EVs controller
HPRC error codes

RED LED Description
1 BLINK EEPROM error
2 BLINKS Bad start sequence or pressure input active
3 BLINKS Joystick switch input off, but analog value high
4 BLINKS Second microcontroller locked or KO
5 BLINKS Pump motor current or coil current incorrect
6 BLINKS Driver error - short circuit
7 BLINKS Thermal cut-out allarm
8 BLINKS Wrong joystick programming
32 BLINKS Battery low alarm

ZAPI - motor controller
SEM X error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog circuit, logic error
2 BLINKS Incorrect start, wrong sequence, function switch active after key-on
3 BLINKS Wrong VMN or field voltage, short to B-, capacitor charge fault
4 BLINKS Accelerator high in standby, accelerator wire open
5 BLINKS Error in read motor armature or motor field current
6 BLINKS Malfunction of contactor driver circuit
7 BLINKS Thermal protection
8 BLINKS Contactor or brake coil shorted
9 BLINKS Contactor or brake coil driver fault
32 BLINKS Battery charge too low

ZAPI - motor controller
SEM ZERO error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog circuit, logic error
2 BLINKS Incorrect start, wrong sequence, function switch active after key-on
3 BLINKS Wrong VMN or field voltage, short to B-
4 BLINKS Accelerator high in standby, accelerator wire open
5 BLINKS Error in read motor armature or motor field current
6 BLINKS Malfunction of contactor driver circuit
7 BLINKS Thermal protection
32 BLINKS Battery charge low, less than 10%

ZAPI - motor controller
SEM-1C error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog circuit, logic error
2 BLINKS Incorrect start, wrong sequence, function switch active after key-on
3 BLINKS No capacitor charge, wrong VMN or field voltage, short to B-
4 BLINKS Accelerator high in standby, accelerator wire open
5 BLINKS Error in read motor armature or motor field current
6 BLINKS Malfunction of contactor driver circuit, contactor closed
7 BLINKS Thermal protection
32 BLINKS Battery low

ZAPI - motor controller
SEM-2 & SEM-3 error codes

RED LED Description
1 BLINK EEPROM error, wrong parameters, watchdog, logic error, safety processor fault
2 BLINKS Incorrect start, wrong sequence, handbrake applied
3 BLINKS No capacitor charge, wrong VMN or field voltage, short to B-
4 BLINKS Accelerator high in standby, accelerator wire open
5 BLINKS Error in read motor armature or motor field current
6 BLINKS Malfunction of contactor driver circuit, contactor closed
7 BLINKS Controller thermal protection, motor temperature high
32 BLINKS Battery low

HAULOTTE - scissor lift COMPACT 8-8W-10-10N-12-14 & OPTIMUM 6-8
ZAPI PPE error codes

MDI display Description
AL01 Proportional valve coil not ok
AL06 Serial communication error between variator and upper box or MDI
AL10 Weighing card signal not ok
AL13 EEPROM fault
AL32 VMN voltage not ok, short-circuit in pump motor
AL37 Contactor is always closed
AL38 Contactor is always open
AL49 Current sensor fault, no current
AL53 Current sensor fault, high current in standby
AL60 Controller capacitor charge fault
AL62 Thermal protection
AL73 Short-circuit in valves coils or horn
AL74 Positive voltage driver is shorted
AL75 Contactor coil driver fault
AL78 Joystick voltage is not ok, joystick not in neutral position
AL79 Incorrect start sequence
AL80 Forward and reverse signals are both active
AL90 Driver1 coil YV6 fault, open or short-circuit
AL91 Version not ok, check overload sensor parameter
AL93 Wrong input configuration
AL94 Mismatch between master and slave processor
AL95 Pressore not ok, platform overload
AL96 Traction is cutted - platform over 8m
AL97 Current too high - pump motor
AL98 MDI and variateur MTH not equal
AL99 Check up needed

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