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sarahvillanuevaSep 18, 2025
What does CHECK UP NEEDED mean on Zapi Controller?
- AAndre PittsSep 18, 2025
To solve the CHECK UP NEEDED error, turn on the CHECK UP DONE option after the maintenance service.
What does CHECK UP NEEDED mean on Zapi Controller?
To solve the CHECK UP NEEDED error, turn on the CHECK UP DONE option after the maintenance service.
What does BATTERY LOW mean on my Zapi DUALACE2 NEW GENERATION Controller and how to fix it?
The BATTERY LOW error on your Zapi Controller indicates that the battery charge is lower than the BATT.LOW TRESHOLD, and the BATTERY CHECK parameter is enabled. To resolve this, first check the battery charge and charge it if needed. If the battery is charged, measure its voltage with a voltmeter and compare it to the BATTERY VOLTAGE reading in the TESTER function. If there's a difference, adjust the ADJUST BATTERY parameter to match the voltmeter reading. If the problem persists, the logic board may need replacement.
Why does my Zapi DUALACE2 NEW GENERATION show FORW + BACK error?
The Zapi Controller shows a FORW + BACK error because both travel requests (FW and BW) are active simultaneously. To fix this: * Ensure that travel requests are not active at the same time. * Check the FW and BW input states using the TESTER function. * Inspect the wirings related to the FW and BW inputs. * Check the microswitches for failures. If the problem continues, the logic board may need to be replaced.
What causes HANDBRAKE error on Zapi DUALACE2 NEW GENERATION Controller?
The HANDBRAKE error on the Zapi Controller is triggered when the handbrake input is active. To resolve this: * Ensure the handbrake is not active by mistake. * Check the SR/HB input state using the TESTER function. * Inspect the wirings. * Check for failures in the microswitches. If the issue persists, the logic board may need replacement.
What to do if Zapi DUALACE2 NEW GENERATION displays CONTACTOR CLOSED error?
If the Zapi Controller displays a CONTACTOR CLOSED error, it means the controller has detected that the contactor is stuck before driving the LC coil. It is suggested to check the power contacts of the LC. If they are stuck, it is necessary to replace the LC.
What to do if Zapi DUALACE2 NEW GENERATION Controller displays CONTACTOR DRIVER error?
If the Zapi Controller displays a CONTACTOR DRIVER error, it indicates that the LC coil driver is unable to drive the load, meaning the device itself or its driver circuit is damaged. This issue is not related to external components, and the logic board should be replaced.
What does FIELD ORIENT. KO error mean on Zapi DUALACE2 NEW GENERATION?
The FIELD ORIENT. KO error on the Zapi Controller means that the error between the estimated Id (d-axis current) and the relative setpoint is out of range. To resolve this, it is recommended to ask for assistance from a Zapi technician to correctly adjust the motor parameters.
What does EVP DRIVER OPEN error mean on Zapi DUALACE2 NEW GENERATION?
The EVP DRIVER OPEN error on the Zapi Controller indicates that the EVP driver (output NEVP, pin A23) is unable to drive the EVP coil, meaning the device itself or its driving circuit is damaged. This fault is not related to external components, and the logic board should be replaced.
What does AUX BATT. SHORT error mean on Zapi DUALACE2 NEW GENERATION Controller and how to fix it?
The AUX BATT. SHORT error on the Zapi Controller means the voltage on the PEB output (pin A27) is at a high value when it should not be. Verify that the POSITIVE E.B. parameter is set correctly according to the actual coil positive supply. If no issues are found, the controller likely has a problem and needs to be replaced.
What does MOTOR TEMP. STOP. mean on my Zapi DUALACE2 NEW GENERATION and how do I resolve it?
The MOTOR TEMP. STOP. warning on your Zapi Controller indicates that the temperature sensor is open (if digital) or has exceeded the TEMP. MOT. STOP threshold (if analog). To resolve this, check the temperature reading from the thermal sensor inside the motor using the MOTOR TEMPERATURE reading in the TESTER function. Also, check the sensor's ohmic value and its wiring. If the sensor is working correctly, improve the motor's cooling. If the warning appears when the motor is cool, the controller may need to be replaced.
General| Brand | Zapi |
|---|---|
| Model | DUALACE2 NEW GENERATION |
| Category | Controller |
| Language | English |
Provides information about the DUALACE2 NEW GENERATION controller, including scope, terms, and warnings.
Discusses controller safety, OEM responsibility, and technical support aspects for proper usage.
Outlines the primary features of the DUALACE2 NEW GENERATION controller for various applications.
Details critical technical data such as motor type, operating frequency, and temperature ranges.
Provides a table of nominal DC voltage and corresponding maximum 2-min and continuous current ratings.
Lists nominal DC voltage ranges and operational over/undervoltage limits for safe operation.
Presents physical dimensions and layouts for different controller versions (Standard/Premium).
Illustrates wiring diagrams for various controller configurations and their applications.
Describes the terminal names and descriptions for power connections on the controller.
Details the pin assignments and default functions for the 23/35-pole Ampseal connector.
Lists the pinout and descriptions for the internal controller connector used for specific functions.
Explains inputs and outputs for external devices like encoders, sensors, and CAN bus communication.
Lists required materials for proper controller installation, including cables and torque specifications.
Provides guidelines for mounting, wiring, and connecting the controller hardware securely.
Discusses Electromagnetic Compatibility (EMC) and Electrostatic Discharge (ESD) considerations for installation.
Describes the controller's operational capabilities, including speed control and self-diagnostics.
Explains dual traction motor management for improved vehicle maneuverability and reduced wheel scrub.
Details the control aspects for pump motors, similar in principle to traction motor control.
Defines operation where the controller maintains constant motor torque output for a given throttle.
Defines operation where the controller maintains constant motor speed as long as torque is sufficient.
Covers protection mechanisms against electrical faults and essential safety functions for reliable operation.
Lists essential pre-power checks to ensure safe and correct initial controller operation.
Guides on setting up controller parameters for specific vehicle applications and functions.
Provides an organized view of the inverter's adjustable parameters categorized by function.
Details the function, allowable range, and setting suggestions for each parameter.
Explains how to use the Tester function for real-time monitoring of controller status and variables.
Enables adjustment of accelerator potentiometer levels for better asymmetry compensation.
Allows adjustment of lift/lower signal levels to compensate for mechanical asymmetry.
Enables adjustment of steering control signal levels for asymmetry compensation.
Describes how the controller handles different potentiometer types and their voltage output.
Defines acceleration rate based on speed set-point and ACCEL MODULATION settings.
Sets deceleration rate based on speed set-point variation upon travel release.
Configures parabolic profiles for acceleration/deceleration ramps near 0 Hz.
Defines speed-reduction profiles dependent on the steering-wheel angle.
Maps throttle voltage to speed set-point using a non-linear polygonal chain.
Explains PWM modulation for main contactor and electromechanical brake outputs.
Describes controller battery charge detection using voltage and parameter settings.
Manages the EVP output, setting current points for analog or ON/OFF valves.
Sets limits for maximum torque demand in the weakening area for performance matching.
Allows calibration of steering rotation based on truck geometry parameters.
Implements thermal protection by monitoring motor temperature and reducing current.
Protects the controller by monitoring DC-link voltage and adjusting the torque profile.
Details the controller's alarm logbook structure and the information recorded for each alarm.
Explains the controller's continuous monitoring and diagnostic procedures for fault detection.
Lists and describes specific alarms originating from the master microcontroller.
Lists and describes specific alarms originating from the supervisor microcontroller.
Guides on using the PC CAN Console software for inverter diagnostics and parameter management.
Explains the operation, features, and navigation of the Zapi Smart Console for configuration.
