Zapi DUALACE2 NEW GENERATION

Questions and Answers

C
Courtney JonesAug 28, 2025
What to do if Zapi Controller displays CAPACITOR CHARGE error?
- A
  adamsmichaelAug 29, 2025
  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.
S
Shawn CampbellAug 27, 2025
What to do if Zapi DUALACE2 NEW GENERATION displays CONTACTOR CLOSED error?
- C
  Courtney CummingsAug 27, 2025
  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.
J
Jessica BurtonAug 27, 2025
What causes HANDBRAKE error on Zapi DUALACE2 NEW GENERATION Controller?
- M
  martinjenniferAug 27, 2025
  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.
K
Kyle HowardAug 25, 2025
Why does my Zapi DUALACE2 NEW GENERATION show FORW + BACK error?
- S
  Stacey ReynoldsAug 26, 2025
  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.
M
Margaret SullivanAug 25, 2025
What does BATTERY LOW mean on my Zapi DUALACE2 NEW GENERATION Controller and how to fix it?
- D
  Dawn LopezAug 25, 2025
  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.

Zapi DUALACE2 NEW GENERATION Specifications

General

Brand	Zapi
Model	DUALACE2 NEW GENERATION
Category	Controller
Language	English

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.

Related product manuals

Zapi ZAPIMOS H2 96V 400A

Zapi DUALACE2 NEW GENERATION - User Manual

Table of Contents