Description

ZAPI FH2120B-CHOP.H0 24V230A Controller alarms

CONSOLE DISPLAYED ALARMS: DECODING

In this paragraph console alarm message meanings, both those displayed during an

alarm in progress and those stored into memory within ALARM menu are reported.

1) WATCHDOG

The test is made in both running and standby. It is a self-diagnosis test within the

logic, and executes a cross software and hardware verify. If this alarm should occur,

replace the logic.

2) EEPROM PAR.KO

Fault in the area of memory in which the adjustment parameters are stored. This

alarm inhibits machine operation. If the defect persists when the key is switched off

and on again, replace the logic. If the alarm disappears, remember that the param

eters stored previously have been cancelled and replaced by the default values.

3) EEPROM CONF.KO

Fault in the area of memory in which the special chopper configuration data is

stored. If the defect persists when the key is switched off and on again, replace the

logic. Otherwise, keep in mind that the chopper configuration has been reset to the

default values; thus it must be reprogrammed. consult the console manual.par 4.4,

4.5, 4.6.

4) EEPROM DATA KO

The data in the area of memory for the hour-metre is incorrect. This alarm does not

shut down the machine. If the alarm disappears when the key is switched off and on

again, keep in mind that the hour-metre data has been reset to zero.

5) EEPROM OFF LINE

Fault in the nonvolatile memory that contains data relative to the area for the hour

metre, the alarms stored and the programming parameters.

If the alarm persists when the key is switched off and on again, replace the logic.

6) INCORRECT START

An incorrect starting sequence. The machine only starts if this sequence is followed:

1 key / 2 handle / 3 running (if safety switch = handle)

1 key / 2 running (if safety switch = free)

1 key + seat / 2 running (if safety switch = seat)

Possible causes:

1. a) Running microswitch stuck.
2. b) Error in sequence executed by the operator, id est running request previous to

key start-up or before pulling down tiller.

1. c) Incorrect wiring. If nothing wrong is detected may be the fault is inside chopper,

which has to be replaced.

7) VMN LOW

It shows that voltage on VMN bar is low (<30% VD); usually this voltage should rate

1/2 battery voltage, when contactors are open. The test is carried out at standby

and in running up to 80% of PWM.

Possible causes:

1. a) If main contactor is installed either it does not close and it’s likely not connected

or resistor, presumably placed in parallel to contacts, is blown up.

1. b) Check if there are metallic particles thus causing short circuit between VMN

cabling and battery negative cabling (-B).

1. c) Power mosfet shorted or continuously piloted by logic: to verify that disconnect

the cable away from VMN bar, then start the device; if the fault is lasting replace

the chopper.

1. d) If by-pass contactor is installed, verify either it’s not stuck or excessively slow

when opening.

8) VMN HIGH

It indicates that voltage on VMN bar is high (> 70% VB); usually this voltage should

be 1/2 battery voltage.

Possible causes:

1. a) Running contactor is ever closed for either it’s stuck or it is ever supplied due to a

wrong wiring toward coil.

1. b) Either a current dispersion or a short circuit between stator and rotor winding is

found out: to verify it disconnect VMN bar cable and the alarm should disappear.

Motor is to be repaired.

1. c) Motor cabling connection error: check carefully that rotor and stator are exactly

cabled as shown on schemes.

1. d) Defects on chopper power board due to either flywhell or braking diode, which

may be shorted. To verify that defect is on chopper, disconnect VMN bar cable,

then if alarm remains replace chopper.

9) VACC NOT OK

The test is made in standby. The alarm indicates that the accelerator voltage is

greater than 1V with respect to the minimum value stored with PROGRAM VACC

function. Most likely reason is that either potentiometer or inductive sensor (in pedal

or tiller) become unsettled.

10) I=0 EVER

Test carried out in running. Checks that the current during running is greater than a

minimum value. If not, an alarm is signalled.

Possible causes:

1. a) Motor resistance is too high due to motor fault or more often brushes contacts.
2. b) The current sensor is faulty. Replace the power unit.

11) HIGH CURRENT

Chopper discovers current signal greater than 50A when the machine is in standby

with open contactors. It’s most likely chopper current sensor is faulty; replace the

chopper.

12) PEDAL WIRE KO

On NPOT pin (A12), where potentiometer negative is connected, no voltage is

detected, thus indicating that potentiometer is not supplied due 1 of 2 supply wires

cut off.

Possible causes:

1. a) wire toward PPOT (A14) is disconnected
2. b) wire toward NPOT (A12) is disconnected
3. c) Potentiometer resistance is cut off.
4. d) Potentiometer presents a resistance greater than 47Kohm

13) TEMPERATURE

It’s an indication that the chopper temperature has exceeded 76°C.

The maximum current is gradually reduced, reaching 0 at a temperature of 86°C.

1. a) If the alarm occurs at key start-up, while chopper is cold, most likely cause is a

break down on power or logic board thermal detection circuit: replace chopper.

1. b) If the alarms occurs many times soon after begin working, it’s likely due to insuffi

cient heat dissipation: check fixing nuts and correct installation.

14) NO FULL COND.

The test is carried out in full conduction. If, in this condition, the VMN is found to be

greater than 1/3 VBATT, the diagnostic circuit is faulty, causing a safety risk, and

thus machine operation is inhibited. If the defect persists, replace the logic.

15) DRIVER 1 KO

Indicates that NT1 (A11) connector voltage is not consistent with the expected

value; the machine is inhibited.

Possible causes:

1. a) either wire toward NT1 connector is disconnected or backward contactor coil is

break off.

1. b) Inside chopper mosfet is shorted; replace chopper.

16) DRIVER 1 SIC KO

It indicates a current overload on driver of contactor connected to NT1 (A11); the

machine is inhibited.

Possible causes:

1. a) Short circuit between positive and the wire toward NT1.
2. b) Contactor coil shorted or coil current uptake greater than 5A.

17) DRIVER 2 KO

Same as point 15 but with reference to NT2 (A4) connector.

18) DRIVER 2 SIC KO

Same as point 16 but with reference to NT2 (A14) connector and relative load.

19) DRIVER SHORTED

It’s the same alarms as described at point 15, but can be found exclusively on

STANDARD TRACT. configuration.

20) CONTACTOR OPEN

It attests that either one or both contactors do not close while running is requested;

test is carried out checking VMN signal.

To discovery fault follow diagnosis procedure reported below.

A1)

There is not a good contact either on TA (=forward contactor) NA (normally

open) or on TI (=backward contactor) NC (normally closed), due to dust, dirt

or any particles which prevent a valid contact.

Clean contacts by means of compressed air; if necessary remove dirt apply

ing a soft abrasive movement.

21) POSITION HANDLE

It indicates that tiller was lowered into running position prior to key-start-up. This

alarm is not activated if SAFETY SWITCH is programmed FREE.

Possible causes:

1. a) tiller microswitch stuck.
2. b) Operator error relating to correct sequence.

22) INVERSION

It indicates that quick inversion key is being pressed at key-start-up.

Possible causes:

1. a) Quick inversion microswitch stuck.
2. b) Operator action error.
3. c) Error either in quick inversion microswitch cabling or in programming; this alarm

occurs, for example, whenever, following scheme, it’s cabled to use IRZ input,

while chopper is programmed for IRE or viceversa. See par 4.5 and drawings

chapter 6.

23) FORW + BACKW

It indicates a double running request. Possible causes:

1. a) fault in cabling
2. b) Operator action error.
3. c) If no external irregularities are found it may be necessary to replace the chopper.

24) BATTERY

It indicates that supply voltage has gone down below 60% nominal voltage.

When the alarm appears the machine doesn’t move.

To start again it would be enough press again butterfly: alarm remains and the

machine proceeds at 50% programmed maximum current rating

DIAGRAMS LEGENDA

AUX = Auxiliaries (loads)

AV = Forward

BEF = Electrobrake coil

BTA = Forward running contactor coil

BTBY = By-pass contactor coil

BTG = Main contactor coil

BTI = Backward running contactor coil

CH = Key

DF = Braking diode

DV = Flywhell diode

EV = Solenoid valve

IN = Backward

MA = Forward microswitch

MCL = Horn microswitch

MD = Lowering microswitch

MEF = Electrobrake microswitch

MI = Backward microswitch

MIR = Quick inversion microswitch

MS = Lifting microswitch

MSED = Seat microswitch

MSIC = Safety microswitch

MT = Tiller microswitch

MUM = Dead man microswitch

NT = Contactor negative

POT = Potentiometer

RV = Speed reduction

TA = Forward running contactor

TBY = By pass contactor

TG = Main contactor

TI = Backward running contactor

VMN = Motor negative voltage

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