What to do if my Zapi Controller shows DRIVER SHORTED error?
If your Zapi Controller displays a DRIVER SHORTED error, it indicates that the driver of the LC coil is shorted. Check for a short circuit or a low impedance pull-down between NLC (pin A12) and -B. If found, the driver circuit is damaged, and you should replace the logic board.
What does EB. COIL OPEN error mean on Zapi DUALACE2 NEW GENERATION Controller?
The EB. COIL OPEN error on the Zapi Controller indicates that no load is connected between the NEB output (pin A28 (A18)) and the EB positive terminal PEB (pin A27). To solve this, check the EB coil and its wiring. If the problem continues, the logic board needs to be replaced.
What to do if Zapi Controller shows BUMPER STOP error?
If the Zapi Controller displays a BUMPER STOP error, it means that both digital inputs dedicated to the bumper functionality are high at the same time. First, turn off one or both inputs. If the alarm persists even when the inputs are in the rest position, inspect the microswitches for any sticking issues. If the problem remains unresolved, the logic board should be replaced.
How to resolve LOGIC FAILURE #1 on Zapi DUALACE2 NEW GENERATION Controller?
LOGIC FAILURE #1 on the Zapi Controller indicates an undervoltage condition at the KEY input. This can be caused by key input signal pulses below the undervoltage threshold, possibly due to external loads like DC/DC converters starting up, relays or contactors during switching, or solenoids energizing or de-energizing. Try removing such loads. If no voltage transient is detected and the alarm persists, the controller hardware may be faulty, requiring replacement of the logic board.
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.
What does MOTOR TEMPERAT. mean on my Zapi Controller and how do I resolve it?
The MOTOR TEMPERAT. warning on your Zapi Controller indicates that the temperature sensor has exceeded the MAX. MOTOR TEMP. threshold. 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.
What causes BRAKE RUN OUT error on Zapi DUALACE2 NEW GENERATION Controller?
The BRAKE RUN OUT error on the Zapi Controller occurs when the CPOT BRAKE input read by the microcontroller is outside the range defined by the SET PBRK. MIN and SET PBRK. MAX parameters. To resolve this, check the mechanical calibration and the functionality of the brake potentiometer. Acquire the minimum and maximum potentiometer values.
What does CONTACTOR OPEN error mean on my Zapi DUALACE2 NEW GENERATION Controller?
The CONTACTOR OPEN error on your Zapi Controller means that the LC coil is being driven by the controller, but the power contacts do not seem to be closing. First, replace the LC if its contacts are not working. If the LC contacts are working correctly, it is recommended to contact a Zapi technician for further assistance.
What to do if Zapi Controller displays CAPACITOR CHARGE error?
If the Zapi Controller shows a CAPACITOR CHARGE error, check for an external load in parallel with the capacitor bank that might be drawing current and preventing proper charging. Look for lamps, DC/DC converters, or auxiliary loads connected in parallel. Also, inspect the charging resistance or PTC for damage. You can insert a power resistance across line-contactor power terminals; if the alarm disappears, the charging resistance is likely damaged. If these steps don't resolve the issue, there may be a failure in the charging circuit or power section, and the controller may need to be replaced.
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.
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.
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