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Zena 150 series Operator's Manual

Backpak welders equipped with wc.12 welding control module, sc101 active speed control module & series wsc welding cables/system controls or pcim power control interface with ts101 electrode contact sensor/switch module
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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
ZENA
Equipped with WC.12 Welding Control Module,
SC101 Active Speed Control Module
Series WSC Welding Cables/System Controls
PCIM Power Control Interface with
TS101 Electrode Contact Sensor/Switch Module
for all
Backpak
welders
™
™
&
or

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  • 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 &...
  • 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 reserves the right to make product enhancements and/or modifications at any time without prior notice.

  • Page 4: Table Of Contents

    C. Optional Power Control Interface Module (PCIM) ................28 C. Mechanical Problems........................28 If You Need Help/Support..................................30 A . The Internet -- www.zena.net ......................30 B. E-Mail -- support@zena.net ......................30 C. Fax -- 615-897-2023 ........................30 D . Mail............................. 30 E.

  • Page 7: Introduction

    Other arc welders require you to maintain an arc length equal to the diameter of your welding rod for optimum results. With ZENA welders, you can produce excellent welds with arc lengths ranging from .1 to 2 times rod diameter. For a 1/8” rod, you can hold your rod tip in direct contact with the puddle or as far away as 1/4” and...
  • Page 8 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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...

  • Page 9: Important Safety Warnings & References

    We recommend that it be kept with the equipment at all times. Should it become damaged and/or otherwise unusable, replacement copies will be provided at no charge. Call 877 ZENA INC or 615-897-2011 to...

  • Page 10: Other Safety Publications/References

    ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders order replacements. You can also order replacements via mail from the address noted on the cover, or via e-mail (support@zena.net). Other Safety Publications/References US Govt. Printing Office, Washington, DC 20402 -- Code of Federal Regulations (OSHA) -- Section 29 Part 1910.95, 132, 133, 134, 139, 251, 252, 253, 254, and 1000.

  • Page 11: 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 you have ordered) will typically be packaged in a single container designed to protect the product from the normal hazards of domestic and/or international shipping.
  • Page 12 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders This page intentionally left blank.

  • Page 13: Zena Welder Specifications

    ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders ZENA Welder Specifications Power Output @ 150 amps. 100% Duty Cycle Typical Voltage Output 20-24VDC w/High (Typically 700 modulation transitions per @ Full Power Frequency Waveform second)

  • Page 14: Operator Controls -- Basic "Stick"/Arc Welder Configuration

    ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 connecting welding...
  • Page 15 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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.

  • Page 16: Using Your Zena Mobile Welding System

    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 you are using, the method of installation used to attach the welder to your engine or vehicle -- and, whether or not your are using one of our cable extension accessories.
  • Page 17 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 environmental conditions, and the type of material being welded.

  • Page 18: Care & Maintenance

    ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 lubricated.

  • Page 19: Do Not

    ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 possible;...

  • Page 20: Trouble/Fault Diagnosis

    ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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.

  • Page 21: Welding Power Problems

    ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 Lamp #2...
  • Page 22 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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.
  • Page 23 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 wires in the BPW150’s wiring harness, and using a multimeter to determine is there is an...
  • Page 24 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders Lamp 1. If Lamp 1 is NOT illuminated, go on to the next step. If Lamp 1 IS illuminated, go to step 2.6 Check the connection of the red and black wires that provide power to the Module.
  • Page 25 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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”...
  • Page 26 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 voltage higher than 14.5VDC (or 29VDC in 24V systems) has been accidentally applied to the...
  • Page 27 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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”...
  • Page 28 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 be returned for repair.
  • Page 29 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 “down”...
  • Page 30 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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...
  • Page 31 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 Generator has a component failure, and must be returned for repair.
  • Page 32 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 Generator has a component failure, and must be returned for repair.
  • Page 33 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 7. Automatic Speed Control Will NOT Increase Engine Speed 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 Module, and observe throttle control actuator while temporarily grounding the green wire which goes to the Vacuum Switch.

  • Page 34: Optional Power Control Interface Module (Pcim)

    ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 cannot be reestablished, the actuator will require replacement.
  • Page 35 ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders This page intentionally left blank. 29 29...

  • Page 36: If You Need Help/Support

    ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders 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 you are done with your installation your new equipment will be perfectly installed and ready to provide you with the best welding experience of your life.
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  • Page 38: Zena, Incorporated Limited Warranty

    The technician will determine if the problem can be solved over the telephone or if return for repair is required. Upon determining that the product has failed under the terms of the warranty, and that return to the repair facility is required, ZENA will provide you with the following information: •...

This manual is also suitable for:

200 seriesBackpak 150 seriesBackpak 200 series

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