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Zena 150 series Operator's Manual

Manual is about: mobile welding system

Summary of 150 series

  • Page 1

    I n c o r p o r a t e d 330 club springs road elmwood, tn 38560 phone: (615) 897-2011 fax: (615) 897-2023 www.Zena.Net operator’s manual for all zena ™ backpak ™ welders equipped with wc.12 welding control module, sc101 active speed control module & series wsc welding cables/system controls or pcim ...

  • Page 3

    This document contains the latest information available at the time of preparation. Every effort has been made to ensure accuracy. However, zena, incorporated takes no responsibility for errors or consequential damages caused by reliance on the information contained herein. Zena, incorporated reserv...

  • Page 4: Table Of Contents

    Table of contents i. Introduction ...........................................................................................................................................................................................................1 ii. Important safety warnings & references .....................

  • Page 7

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 1 1 i. Introduction congratulations, you have purchased the finest portable dc arc welder in the world! And, possibly the lightest! You will find it to be one of the most versatile and useful tools that you own. Designed to m...

  • Page 8

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 2 2 ! Welding power is infinitely variable while welding -- no performance limiting pre-set power settings ! Welding power is controlled from the welding handle and can be varied while welding to insure good weld penetration ...

  • Page 9

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 3 3 ii. Important safety warnings & references a. Danger of personal injury serious injury or death may result if your welding equipment is not properly installed, used, and maintained. Welding is an inherently dangerous acti...

  • Page 10

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 4 4 order replacements. You can also order replacements via mail from the address noted on the cover, or via e-mail (support@zena.Net). E. Other safety publications/references : us govt. Printing office, washington, dc 20402 ...

  • Page 11

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 5 5 iii. Checking your package contents unless you have ordered an extra long welding cable/system control handle assembly (or a special mig or tig interface/adapter kit), your zena welding system (and any accessories which y...

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    Zena mobile welding system -- operators manual -- series 150 & 200 welders 6 6 this page intentionally left blank..

  • Page 13

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 7 7 iv. Zena welder specifications power output @ 100% duty cycle 150 amps. Typical voltage output @ full power w/arc established 20-24vdc w/high frequency waveform modulation (typically 700 modulation transitions per second)...

  • Page 14

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 8 8 v. Operator controls -- basic “stick”/arc welder configuration the zena welding system features a unique, but very simple, control system. All welding controls, except for welding polarity selection (determined when conne...

  • Page 15

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 9 9 welding polarity welding polarity is selected/determined by the attachment of the welding cables, using the supplied wing nuts, to the terminals at the rear of the power generator unit. Red cable lug to red terminal & bla...

  • Page 16

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 10 10 vi. Using your zena ™ mobile welding system the zena system is exceptionally easy to use. However, the preparation of the equipment for use varies in some small degree depending on the model and control interface that y...

  • Page 17

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 11 11 3/32 inch 1/8 inch 5/32 inch as soon as you start welding, the power control dial setting should be adjusted to yield the desired arc and proper weld penetration for the type of welding rod which is being used, the envi...

  • Page 18

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 12 12 vii. Care & maintenance the zena mobile welding system is very robust. Other than keeping components clean, no regular preventive maintenance is required. A. Lubrication not required. All moving parts are permanently lu...

  • Page 19

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 13 13 d. Do not… ! Use spray lubricants of any sort on any component; or ! Operate the unit in very dusty and or dirty conditions without insuring that cooling air reaching the unit is as dust and/or contaminant free as possi...

  • Page 20

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 14 14 viii. Trouble/fault diagnosis your zena backpak welder has been designed to be very simple to use. In addition, no expense has been spared to insure that it is also an extremely reliable and long lasting product. Howeve...

  • Page 21

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 15 15 3. Automatic electrode contact sensor/switch model ts101 -- location of internal indicators and fuses by removing 4 screws, the cover of the automatic electrode contact sensor/ switch can be removed. With the cover remo...

  • Page 22

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 16 16 will be either idle speed or welding speed. For example, before the power control on the welding handle is depressed the built-in tachometer circuit will be reading idle speed. 1.2 start the engine, allow it to warm up,...

  • Page 23

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 17 17 1.4 check for the prescence of tachometer signals by disconnecting the red male bullet connectors on the white and gray wires which exit the scm.V2 module from the red female bullet connectors on the white and gray wire...

  • Page 24

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 18 18 lamp 1. If lamp 1 is not illuminated, go on to the next step. If lamp 1 is illuminated, go to step 2.6 2.3 check the connection of the red and black wires that provide power to the module. The red wire should be connect...

  • Page 25

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 19 19 handle. Lamp #2 (and lamp #3 for a “ro” type module) should light and remain lit for as long as the power button is held down. You should also hear a very faint “clicking” sound coming from the control module. If lamp #...

  • Page 26

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 20 20 that the gray wires connecting the control module to the power generator may have been accidentally shorted to ground while connecting or disconnecting these leads with power “on” to the control module, or that a voltag...

  • Page 27

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 21 21 than 1.4 ohms, your power generator has a component failure, and must be returned for repair. Go to step 2.9. If the electrical resistance measured between the control terminals is higher than the “normal” range of 1.4 ...

  • Page 28

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 22 22 resistance between these control terminals with an ohm meter. A normal reading is between 1.4 and 2.4 ohms. If your meter shows a resistance of less than 1.4 ohms, your power generator has a component failure, and must ...

  • Page 29

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 23 23 3a. Welding power is available but is not adjustable -- control models wc.12ro & wc.24ro 3a.1 with the engine off, open the control module and observe lamp #2 and lamp #3 while holding the control handle power button “d...

  • Page 30

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 24 24 defective connector terminal, or due to some surface corrosion that may have formed on the connector surfaces. If the problem is corrosion (which may be noticeable as a slight sandy roughness/drag which can be felt as t...

  • Page 31

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 25 25 5.4 check in the electrical resistance between the power generator control terminals with an ohm meter. A normal reading is between 1.4 and 2.4 ohms. If your meter shows a resistance of less than 1.4 ohms, your power ge...

  • Page 32

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 26 26 5a.4 check in the electrical resistance between the power generator control terminals with an ohm meter. A normal reading is between 1.4 and 2.4 ohms. If your meter shows a resistance of less than 1.4 ohms, your power g...

  • Page 33

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 27 27 7. Automatic speed control will not increase engine speed 7.1 with the engine on, disconnect the green wire that is used to connect power control module to the speed control vacuum switch, turn on power to the control m...

  • Page 34

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 28 28 screw, lubricate the o-ring with some mineral oil. Failure to properly lubricate the o-ring before reassembly may result in permanent damage to the o-ring.) if a o-ring leak is not the problem, or if the o-ring seal can...

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  • Page 36

    Zena mobile welding system -- operators manual -- series 150 & 200 welders 30 30 ix. If you need help/support we want you to get the most from your new welding equipment. To this end, we are committed to providing you with whatever support you may need (starting with this manual) to insure that when...

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    Zena mobile welding system -- operators manual -- series 150 & 200 welders 31 31 this page intentionally left blank..

  • Page 38

    Zena, incorporated limited warranty terms & conditions the mobile welding system (product) that you have purchased from zena, incorporated (zena) is warranted to the original purchaser (purchaser) to be free from defects in materials or workmanship for a period of three (3) years from the date of pu...