Between ZoneFlex 9.4 and 9.6, AP Layer2 ZD discovery was deprecated. You need
to have/use DHCP or static IP in the same subnet as the ZD. Can the ZD/AP ping
each other? Do you have AP auto-join enabled? What does the ZD AP log say?
Does the ZD see the AP attempting to connect at all? If swapping APs with factory
default allows one AP to connect but not another, I would contact support for RMA.