Zapi DUALACE2 NEW GENERATION

Questions and Answers

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Casey CampbellSep 9, 2025
What does EB. DRIV. SHORT. error mean on Zapi Controller?
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  Lisa CowanSep 9, 2025
  The EB. DRIV. SHORT. error on the Zapi Controller indicates that the EVP driver (output NEVP, pin A23) is shorted. Check for a short circuit or a low-impedance conduction path between the negative of the coil and -B. Collect information about the voltage applied across the EVP coil, the current in the coil, and features of the coil. Contact Zapi for assistance to verify that the software diagnoses are in accordance with the type of coil employed.
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Mrs. Christine ToddSep 8, 2025
How to fix CONTROLLER MISM. error on Zapi DUALACE2 NEW GENERATION?
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  Angela SheltonSep 8, 2025
  The CONTROLLER MISM. error on the Zapi controller indicates that the software is not compatible with the hardware. To fix this, upload the correct firmware. It is recommended to seek assistance from a Zapi technician to ensure the firmware is correct.
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Angelica NguyenSep 7, 2025
What to do if my Zapi Controller shows DRIVER SHORTED error?
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  jwilcoxSep 7, 2025
  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.
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Jennifer KingAug 22, 2025
What to do if Zapi Controller shows BUMPER STOP error?
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  Katherine MossAug 23, 2025
  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.
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heathercoleSep 4, 2025
What does AUX BATT. SHORT error mean on Zapi DUALACE2 NEW GENERATION Controller and how to fix it?
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  Andrea JonesSep 4, 2025
  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.
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Cindy SanchezSep 3, 2025
How to resolve LOGIC FAILURE #1 on Zapi DUALACE2 NEW GENERATION Controller?
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  Marcus JohnsonSep 3, 2025
  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.
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Christopher RojasSep 2, 2025
What does MOTOR TEMP. STOP. mean on my Zapi DUALACE2 NEW GENERATION and how do I resolve it?
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  Justin MaciasSep 2, 2025
  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.
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Lisa CastanedaSep 1, 2025
What does MOTOR TEMPERAT. mean on my Zapi Controller and how do I resolve it?
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  Laura ReyesSep 1, 2025
  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.
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Robert FordAug 31, 2025
What causes BRAKE RUN OUT error on Zapi DUALACE2 NEW GENERATION Controller?
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  Steven WiseAug 31, 2025
  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.
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Dr. Annette JacksonAug 29, 2025
What does CONTACTOR OPEN error mean on my Zapi DUALACE2 NEW GENERATION Controller?
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  jason57Aug 30, 2025
  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.

Summary

1 Introduction

1.1 About This Document

Provides information about the DUALACE2 NEW GENERATION controller, including scope, terms, and warnings.

1.2 About the Controller

Discusses controller safety, OEM responsibility, and technical support aspects for proper usage.

2 Specifications

2.1 General Features

Outlines the primary features of the DUALACE2 NEW GENERATION controller for various applications.

2.2 Technical Specifications

Details critical technical data such as motor type, operating frequency, and temperature ranges.

2.3 Current Ratings

Provides a table of nominal DC voltage and corresponding maximum 2-min and continuous current ratings.

2.4 Voltage Ratings

Lists nominal DC voltage ranges and operational over/undervoltage limits for safe operation.

3 Drawings

3.1 Mechanical Drawings

Presents physical dimensions and layouts for different controller versions (Standard/Premium).

3.2 Connection Drawings

Illustrates wiring diagrams for various controller configurations and their applications.

4 I;O Interface Description

4.1 Power Connectors

Describes the terminal names and descriptions for power connections on the controller.

4.2 Ampseal Connector

Details the pin assignments and default functions for the 23/35-pole Ampseal connector.

4.3 Internal Connector

Lists the pinout and descriptions for the internal controller connector used for specific functions.

4.4 External Devices

Explains inputs and outputs for external devices like encoders, sensors, and CAN bus communication.

5 Installation Hints

5.1 Material Overview

Lists required materials for proper controller installation, including cables and torque specifications.

5.2 Installation of the Hardware

Provides guidelines for mounting, wiring, and connecting the controller hardware securely.

5.3 EMC

Discusses Electromagnetic Compatibility (EMC) and Electrostatic Discharge (ESD) considerations for installation.

6 Features

6.1 Operational Features

Describes the controller's operational capabilities, including speed control and self-diagnostics.

6.2 Dual Traction Motor

Explains dual traction motor management for improved vehicle maneuverability and reduced wheel scrub.

6.3 Pump Motor

Details the control aspects for pump motors, similar in principle to traction motor control.

6.4 Torque Mode

Defines operation where the controller maintains constant motor torque output for a given throttle.

6.5 Speed Mode

Defines operation where the controller maintains constant motor speed as long as torque is sufficient.

6.6 Protection and Safety Features

Covers protection mechanisms against electrical faults and essential safety functions for reliable operation.

7 Start-Up Hints

7.1 Check Prior to Initial Power Up

Lists essential pre-power checks to ensure safe and correct initial controller operation.

7.2 Configuring Motor Controller for the Application

Guides on setting up controller parameters for specific vehicle applications and functions.

8 Programming & Adjustments

8.1 Settings Overview

Provides an organized view of the inverter's adjustable parameters categorized by function.

8.2 Settings Description

Details the function, allowable range, and setting suggestions for each parameter.

8.3 Tester Function

Explains how to use the Tester function for real-time monitoring of controller status and variables.

9 Other Functions

9.1 Program VACC Function

Enables adjustment of accelerator potentiometer levels for better asymmetry compensation.

9.2 Program Lift; Lower Function

Allows adjustment of lift/lower signal levels to compensate for mechanical asymmetry.

9.3 Program STEER Function

Enables adjustment of steering control signal levels for asymmetry compensation.

9.4 Potentiometers

Describes how the controller handles different potentiometer types and their voltage output.

9.5 Acceleration Time

Defines acceleration rate based on speed set-point and ACCEL MODULATION settings.

9.6 Release Modulation

Sets deceleration rate based on speed set-point variation upon travel release.

9.7 Acceleration Smoothness

Configures parabolic profiles for acceleration/deceleration ramps near 0 Hz.

9.8 Steering Curve

Defines speed-reduction profiles dependent on the steering-wheel angle.

9.9 Throttle Profile

Maps throttle voltage to speed set-point using a non-linear polygonal chain.

9.10 MC and EB Modulation

Explains PWM modulation for main contactor and electromechanical brake outputs.

9.11 Battery-Charge Detection

Describes controller battery charge detection using voltage and parameter settings.

9.12 EVP Setup

Manages the EVP output, setting current points for analog or ON/OFF valves.

9.13 Torque Profile

Sets limits for maximum torque demand in the weakening area for performance matching.

9.14 Steering Table

Allows calibration of steering rotation based on truck geometry parameters.

9.15 Motor Thermal Protection

Implements thermal protection by monitoring motor temperature and reducing current.

9.16 Overvoltage and Undervoltage Limitations

Protects the controller by monitoring DC-link voltage and adjusting the torque profile.

10 Diagnostic System

10.1 Alarms Menu

Details the controller's alarm logbook structure and the information recorded for each alarm.

10.2 Diagnoses

Explains the controller's continuous monitoring and diagnostic procedures for fault detection.

10.3 Alarms from Master µC

Lists and describes specific alarms originating from the master microcontroller.

10.4 Alarms from Supervisor µC

Lists and describes specific alarms originating from the supervisor microcontroller.

11 Recommended Spare Parts

12 Periodic Maintenance

13 Appendices

13.1 Appendix A: PC CAN Console User Guide

Guides on using the PC CAN Console software for inverter diagnostics and parameter management.

13.2 Appendix B: Zapi Smart Console User Guide

Explains the operation, features, and navigation of the Zapi Smart Console for configuration.