e-Mail: contact@zena.net

Go to:  

<-- Previous Page

 

Search Web Site

Get Product Literature

 

SITE MAP

 

Welder Specs

Online Store

 

Welder FAQ's

 

Welding Accessories

Detailed ZENA tm Welder Installation Notes

PAGE UNDER CONSTRUCTION

Overview

A ZENA portable welding system can be attached to any suitable engine, or installed into virtually any vehicle (tractors, ATV's, trucks, emergency vehicles, forklifts, construction equipment, water craft, lawn tractors, etc.) capable of producing sufficient power for the chosen generator. Once installed in a vehicle, the entire vehicle is transformed into a self-contained portable welding station -- with performance and operating features that equal, or exceed, heavy, bulky, and very expensive transportable engine-driven industrial welders.

When properly installed, the ZENA power generating equipment is completely isolated from the vehicle or drive engine's electrical system, reducing the chance of damage to the electrical system when welding, and allowing standard polarity (negative electrode) welding -- even on the vehicle in which the welder is installed.

The information presented here is meant to be general in nature -- composed for individuals with the technical competency necessary for the installation and/or retrofit of electrical, mechanical, and/or electromechanical equipment to an engine, or into a motorized vehicle.

NOTE:
While this section is more detailed than our installation overview page, it is not to be considered a replacement for the
Operators Manual which has more information than is presented here.

Particularly in the case of post 1985 automotive installations, where sensitive microcomputer devices are in use, we recommend that installation be performed by individuals who are familiar with a given vehicle's electrical systems. Some of these vehicles have electrical systems which are so fragile that they can be seriously damaged by maintenance activities as simple as routine battery replacement.

Actual installation of the ZENA system is usually quite simple and straightforward in its concept, but there is a high degree of variation from one vehicle to another. Further, in any particular vehicle, there can be many “correct” installations. Therefore, we often simply advise what not to do, rather than trying to provide specific instructions which would, in all likelihood, only apply to a single situation.


Mechanical Installation

Mechanical installation is typically simple and straightforward.

Keep these points in mind when planning your installation:

  1. Power Generator Welding Speed
    1. Welding performance can be effected by low engine/generator speed. The minimum engine speed for welding is not the same for all installations. For a given set of Power Generator and engine drive pulleys, there is a proper MINIMUM welding speed range (higher speeds have no effect on welder performance, though running a generator at too high a speed can create mechanical difficulties). Recommended operating speeds (from charts and formulas in the Installation/Operator's Manual are typically set to insure that problems with low -- or exceptionally high speeds will be avoided. Therefore, you should always refer to the data provided in your Installation / Operator's Manual to determine the engine speed that you will need for your particular installation.
    2. In most cases, the stock Power Generator and engine drive pulleys will perform adequately. However, sometimes the use of non-stock pulleys, or the ZENA Add-A-Pulley™ universal alternator power take off kit, can improve performance characteristics for certain installations. (When you place your order, we will be happy to help you to determine just what pulley combination will be best for your planned installation.)

      For example, engine welding speed for a powerful tractor (40-100 HP) might be determined to be approximately 2,500 RPM. However, in this case, by selecting and installing an inexpensive larger diameter secondary crank pulley in front of the engines stock crank pulley, engine welding speed could be reduced to approximately 1,600 RPM. OR, with this same tractor, the use of the Add-A-Pulley, and a smaller than stock drive pulley on the tractor's existing alternator can reduce engine speed even more -- in this example, welding speed could be at as little as 1,250 rpm.

    3. Idler Pulley

      Spring Loaded
      Tensioner Part#
      AI RT1001

      When making your calculations, remember that if you are driving your Power Generator from an existing alternator using a ZENA Add-A-Pulley™ alternator power take off pulley, in most cases, there will be a built-in 10-40% reduction of needed engine speed for welding (reduction determined by ratio of existing alternator pulled diameter to Add-A-Pulley pulley diameter). This means that if 2,500 RPM would be the proper engine speed (per the engine speed for welding determination charts), you would only need a speed of 2,000 to 1,500 RPM when using the Add-A-Pulley accessory.

      NOTE:
      When using smaller than normal pulleys, the use of idler pulleys and spring loaded tensioners may be necessary to insure that belts do not slip or experience accelerated wear.

d) Since the method of drive chosen, may effect the positioning of components and the design of bracketing for a particular installation, it is important to make these decisions BEFORE beginning the installation. Your dealer, or our technical support personnel, will be happy to assist you in developing an installation plan for your application.

CAUTION / NOTE:
DO NOT make the mistake modifying drive pulley ratios to the point that an engine welding speed which is less than approximately 50% of maximum engine rpm is achieved. Doing this can cause the welding power generator to over-speed when engine speed is increased to maximum during normal vehicle use.


2. Power Generator Positioning / Rotation
a) ZENA's proprietary power generating technology (and a very efficient forced air cooling system which draws cool air in from the rear and exhausts heated air from the front) provides such an efficient power generating system that, in free air conditions, even when welding continuously at full power, ZENA's Power Generator stays remarkably cool -- usually cool enough so that it can be touched without undue discomfort. However, real-world conditions are never perfect, so the ZENA system has been designed to operate reliably in the very high ambient air temperatures that exist under the hood in motor vehicles.
For maximum performance, trouble-free operation, and a long service life, plan to mount the Power Generator so that ample cool air is available to supply its forced air cooling system. For example, avoid mounting positions where air is hot and not “moving” and/or where the superheated air from an engine's exhaust system will be drawn into the rear of the Power Generator. Such a heat source can, by itself, heat the Generator to temperatures which will damage internal components..
b) In automotive installations, a supply of relatively cool air for the welding system's Power Generator can be obtained by installing a well positioned, high efficiency, electric radiator cooling fan and/or large diameter non-collapsible duct hose so that cool air from outside the engine compartment will be directed to the rear of the Power Generator, or (in some cases) by simply insuring that the vehicle's engine compartment hood in its “open” position when welding.
c) If possible, insure that the chosen mounting point is one which allows the operator to easily attach welding and control cables to the Power Generator. Where this is not possible, or where extra convenience is desired, consider the installation of one of ZENA's external welding cable quick disconnect kits (model BJ150 or BJ200).
d) Drive pulley/belt alignment is critical for vibration free operation and long belt life. Every effort should be made to insure precise alignment between components.
e) Consider a “piggyback” installation. This most popular type of installation uses the existing engine alternator (which is fitted with a double pulley) as the drive element for the Power Generator (which is mounted in close proximity to the alternator) -- often using the existing alternator bracketing as part of the new Power Generator bracketing. The double pulley on the alternator allows a short (typically 21-26”) drive belt to be attached between the Power Generator and the alternator.
To make this sort of installation possible for engines which use a serpentine drive belt system, and to make installations onto V-belt equipped engines even easier, we have developed the Add-a-Pulley™ retrofittable secondary alternator pulley . The Add-a-Pulley fits almost all existing automotive alternator designs, and come with all necessary parts to retrofit an existing alternator or with a secondary drive pulley that can be used to drive the Power Generator. See Appendix E for more information.
f) The direction of rotation AND the physical (front to rear) positioning of the Power Generator, relative to the engine, are not critical. The Power Generator will operate properly when rotating in either its normal clockwise direction or in a counterclockwise direction and/or when mounted with its “front” (the end with the pulley and cooling fan) pointing towards the rear or the front of the engine.
CAUTION / NOTE:
The shaft end nut which secures the cooling fan and the drive pulley to the front of the Power Generator is self tightening/locking in normal CLOCKWISE rotation.
If the Power Generator is used in a mode where COUNTERCLOCKWISE rotation occurs, the shaft end nut MUST be secured to the threaded portion of the Power Generator drive shaft with an appropriate high strength, high temperature chemical threadlocker. (LOCTITE® type 272 high strength, high temperature threadlocker recommended.) Also, the points of contact between the fan and the drive pulley and the drive pulley and the nut should be strengthened/reinforced with an appropriate stud locking compound. (LOCTITE® type 648 high strength, high temperature retaining compound recommended.)
These recommended locking chemicals are designed for permanent assembly. Disassembly can be difficult and requires the use of tools, and the application of heat to soften the locking material for removal.
DO NOT APPLY THREADLOCKERS UNTIL AFTER YOU ARE COMPLETELY SATISFIED WITH YOUR FULLY COMPLETED WELDER INSTALLATION (including any clocking operation -- see item #6 which follows).
3. Bracketing
There are a number of vehicles in which a bolt-in installation, using existing brackets, can be accomplished. More typically, however, new brackets will be required for mounting the belt-driven Power Generator -- positioning the Power Generator as noted previously, and so that a clear path is available for the attachment of the existing drive belt (or a new drive belt) from the Power Generator to
l the engine's crankshaft pulley, or
l to the engine's existing alternator (using a secondary pulley),
l to the engine's flywheel, or
l to some other appropriate drive/power takeoff point.
Remember that your welding Power Generator is air cooled, and that it should be mounted in a position which is as far as possible from the engine exhaust system or other areas in which high ambient air temperatures may be found. Where this is not possible, metal heat shields should be used to protect the unit from excessive heat and/or ducting can be provided to route cool air to the cooling air intake vents at the rear of the Power Generator.
Initial consideration should be given to using an existing (factory installed), but unused, mounting bracket and/or bracket mounting fittings. For example, many vehicle engines are designed to accommodate a second alternator, a belt-driven air compressor, or a high capacity hydraulic pump. If these devices are not installed, the ZENA welding Power Generator can often be mounted to these existing fittings using either simple custom-fabricated brackets and/or parts of accessory installation kits which are often available from the vehicle's manufacturer. For example, many tractors are designed to have optional air conditioning systems installed. It is often possible to use the brackets and idlers which come with these kits for a Power Generator installation that will require little or no additional modification.
If you are not able to use existing mounting brackets, custom brackets must be fabricated. To assist you, prefabricated universal mounting brackets such as the model A300 and other bracket fabrication components which can be used to construct your custom brackets, are available from ZENA, or through other commercial sources . Often an installation may require both prefabricated mounting brackets and some other simple parts and/or brackets which must fabricated by the installer. See Appendix A and Appendix B for examples.
Make your bracket(s) strong-- when installed, your Power Generator must be mounted in a way which leaves it just as firmly placed as your existing alternator, air conditioning compressor, or power steering pump.
Typically we recommend that bracket parts be constructed from steel stock which is at least 5/16 inch thick (3/8 inch or even 1/2” is even better). All bar stock used should be at least 1” in width (1-1/4” is even better). When using angle stock, we recommend 2” x 5/16” angle for most applications. When in doubt, always choose materials which will result in a stiffer/stronger support system, rather than materials which will yield a less stiff/weaker support.
Brackets may be welded together to insure maximum strength (or may be assembled quite successfully with nuts and bolts). However, we strongly recommend that the Power Generator's mounting bracket(s) be first mounted with removable fasteners and that bolt holes be oversize or slotted. Use at least two 5/16” bolts to attach the Power Generator bracket to other bracketing components. Using bolts for Power Generator attachment allows you to make adjustments, before any welding), necessary to insure perfect alignment of the Power Generator to the power take off point on the engine.
Most automotive engines are mounted to the vehicle frame using some sort of flexible shock mount. When attaching a Power Generator to this type of engine, the Power Generator's mounting bracketing MUST be attached exclusively to the engine and/or to other components which are attached exclusively to the engine. Failure to do this can result in severe, and potentially damaging, vibration and very short drive belt life.
When mounting a Power Generator to tractors and other vehicles which directly, and firmly, mount the engine to the frame of the vehicle, the bracketing for the Power Generator may be attached directly to any part of the vehicle which is sturdy enough to provide proper support. Do not, however, attach any portion of the Power Generator bracketing to any mounting point or frame member which is also used to attach a front end loader or other similar equipment to the vehicle. This sort of equipment is subject to slight, but continuous, movement on the vehicle. This slight movement can easily cause belt alignment to vary to an unacceptable degree when mounting points are shared.
4. Bracket Fabrication Tips
Save money, save time, and minimize wear and tear to your tools:
a) Use heavy CARDBOARD to work out bracket designs. And, by taking cardboard forms with you to buy steel, you may get your vendor to do the rough cutting.
(Cardboard pieces can also insure proper welder to hood clearance. Place a couple of thickness of cardboard where clearance are tight, and close the hood, a bit at a time, observing the cardboard for indentations which indicate too little clearance.)
b) Installers report the most used sizes of steel used in fabricating brackets are: 2”x5/16” angle, 3”x5/16” angle, 1-1/4”x5/16” bar, 1”x5/16” bar, 1-1/4”x3/8” bar, and 1”x3/8” bar.
c) If you don't have a supply of steel on hand, consider purchasing what you need from a local machine shop, welding shop, trailer fabricator, or other business involved in steel fabrication work. Their prices will be much less than hardware stores and (since you'll be buying small pieces of their scrap stock) you won't have to buy more metal than you need (as is be the case with bulk steel suppliers).
Check to insure that the pulleys are in parallel alignment with a straightedge, making sure that the straightedge contacts both the Power Generator pulley and the pulley to which it is being aligned at two points on the surface of each. Using the same straightedge, make sure that the “V's” of both pulleys are in perfect alignment as well.
Make sure that V-belts run straight and true. Belts which are mis-aligned will also cause excessive frictional heating of the V-belt and excessive mechanical wear which will result in premature belt failure. It is very important that the path of the drive belt be straight. Brackets should always be made (and installed) so that initial adjustment is possible. Often, this may just mean using slightly oversize mounting holes or simple slots. (After initial adjustment, tack welding may be done to prevent unwanted motion.)
Finally, insure that all pulleys in drive path have appropriate drive belt “wrap”/surface area contract (at least 40% of circumference for larger pulleys -- 55-70% for smaller).
5. Drive Belts
After the brackets are installed and the Power Generating unit has been properly and securely mounted, a correctly sized drive belt (.3750 inch for the Series 150 / .5 inch belt for Series 200 welders) is attached to the chosen drive source , and properly tensioned.

NOTE:
In some cases, it may be desirable to fit dual drive pulleys and use dual drive belts -- less tension is required, adjustment intervals may be longer, and belt life may be extended. A wide range of special double V pulleys are available from our parts department -- call to discuss your specific needs.
DO NOT USE lawn mower/agricultural implement type V-belts (fabric covered) to drive the ZENA welding Power Generator. They slip during operation and produce a large amount heat when used with small pulleys operating at high speeds. Use ONLY high-quality, soft rubber (rather than hard, inflexible rubber “premium”/HD), automotive type V-belts. We have found the “bottom-cog” type belt (available from most after-market auto parts suppliers in the USA) to be most effective.
Don't over or under tighten drive belts. This will cause excessive frictional heating of the V-belt and drive pulleys, extra strain on bearings and internal electrical components, and will result in premature belt failure. A slipping belt is sometimes hard to detect -- a “hot” pulley is a sure sign of slipping. Tighten belts just enough to prevent any slipping or squealing when operating your welder at full power.
ALWAYS static test belt tension by using a properly sized wrench on the power generator's pulley bolt to try to rotate the power generator in a CW direction. It should be quite difficult to turn using moderate hand pressure. Often a small engine will “turn over” before any belt slip will be noted. If any slippage is noted, the point of failure will be easy to determine.
ALWAYS recheck belt tightness after the first couple of hours of welding. We DO NOT recommend the use of belt dressings for most applications -- particularly those where the system is operated in dirty or dusty conditions.

NOTE -- V-belt “wrap” around pulleys is more important than belt tension:
For example, some trucks, and other vehicles with serpentine belt accessory drive systems may have alternators which have BOTH a very small (2.5” diameter) alternator drive pulley fitted AND provide only very minimal belt “wrap” around this drive pulley (30% of diameter or less).
In this case, if using as Add-A-Pulley power take off accessory, serpentine belt slipping at the alternator pulley may occur when welding at higher power settings. This sort of slipping CANNOT be prevented by simply tightening or replacing worn OEM serpentine belts.
To obtain proper “drive” for your welder, it may be necessary to install an “idler” pulley to redirect the V and/or the serpentine belt path to insure a good “wrap” around ALL small pulleys (55-70%). (If this is necessary, it may also be necessary to obtain different length serpentine or V belts).
6. “Clocking” Power Generator and/or Repositioning Control Module
In some cases, installation of the Power Generator will leave it oriented so that the operator cannot easily attach the welding cables, or you may find that the Control Module will physically interfere with some existing component unless it is relocated.
Other than to avoid heat, Control Module mounting is not critical. It may be moved to any of the four bolts which hold the front and rear case parts of the Power Generator together or to any other convenient point on the vehicle near the Power Generator.
Changing the orientation of the welding cable terminals to the Power Generator's mounting points is called “clocking”. This procedure allows the installer to reposition the external welding lead terminals by rotating the front portion of the Power Generator 90°, 180°, or 270° from its “stock” position relative to the rear case portion. “Clocking” the Power Generator is a simple process:
a) Using an impact wrench, remove the large nut which holds the V-belt pulley and cooling fan to the front of the Power Generator.
b) Taking care NOT to separate the front and rear case parts, remove the four bolts which hold the front and rear case parts together.
c) Place the Power Generator on a workbench with the shaft pointing “up”, and with the welding lead terminals “down” taking care to protect the terminals from damage.
d) While maintaining pressure on the shaft to keep it from moving away from the rear case, lift the front case up slightly and rotate it so that proper orientation is achieved.
e) Reinstall and tighten the bolts which hold the case parts together, attaching the Control Module to the Power Generator case with one of the screws (if so desired).
f) Complete by reinstalling fan and pulley. Tighten the nut with an impact wrench.
7. Final Check / Other Considerations
a) Check that bracketing is strong, that all bolts (including drive pulley nut -- use impact wrench) are tight, and that cooling air is available at rear of generator. Check all electrical connections. Insure that wires are secure and routed properly.
b) In some cases, simple sheet metal covers may be used to further dress-up the installation, to shield hands and arms from moving components, etc.
c) Also, we recommend that some means of carrying welding rods and welding cables, helmet, and other tools be provided. A medium sized plastic utility chest is ideal.
7. Multi-Generator Welding Systems --- 300A and larger
l Generators which have outputs combined for higher amperages must be driven at the same speed. Electrical connections are standard with each generator. The only special wiring requirement is to interconnect all generators using the yellow control lead, built into master and slave control modules, with the yellow hookup wire, and connectors, supplied with your multiunit welding system. Power output leads are all run to a central connection point to which welding cables are then attached.
l Multi generator systems designed, for use by multiple operators, which do not feature combined outputs can have generators turning at different speeds -- though, the “slowest” unit in the group must be turning at a proper welding speed. No special interconnection is required.
C. Determining Proper Operating Speed (Tachometer Available)
The Welding Power Generator has been designed to provide optimum performance when rotating at approximately 6,500 RPM. Operating faster than this has no ill effect whatsoever. Operating slower will still allow you to weld, but will produce less welding power than may be needed for larger size rods/electrodes. (Faster is better than slower.)
“Low engine speed” is the culprit in 99% of “welding power” trouble reports.
To determine the proper engine operating speed range for welding for your vehicle:
1) Measure the diameter of your motor's crank pulley and find that diameter on one of the following four charts (Read chart and column headings carefully to insure that you are using the correct chart for your intended installation.)
2) Your desired operating speed range is found to the right of your crank pulley diameter.








3. If using one of our Add-A-Pulley universal alternator power take off units, the following formula can be used to determine the effect of the AAPK on welding speed:
1 - (alt. drive pulley diameter / Add-A-Pulley diameter ) = % reduction in speed
For example, if you have an existing alternator with a 2.75” pulley, and you are using an Add-A-Pulley in your installation, the formula
1 - (2.75 / 3.5) = 21%
shows that you can expect a 21% reduction in welding speed when using the Add-A-Pulley.
Therefore, if the Speed Chart, for your particular welder model series, shows a target speed of 2,000 rpm, using the Add-A-Pulley would reduce this target welding speed by approximately 420 rpm [ 2,000 * .21 = 420 ]
4. If your target engine speed for welding is not at least 2-1/2 times your engine's idle speed, sufficient power for welding may not be available. In this case, a LARGER diameter Power Generator drive pulley (usually 3 to 3. 5” in dia.) must be fitted.
D. Determining Proper Operating Speed (Tachometer NOT Available)
If a tachometer is not available an appropriate welding speed can be determined by performing a test weld under controlled conditions:
1. Set the Power Control dial on the electrode holder to a position approximately 2/3 to 3/4 of maximum (CW).
2. Set the engine (by ear) to a fast idle (2,000-2,500 rpm).
3. Make a test weld on a clean (not rusty or painted) piece of mild steel 1/4” bar, plate, or angle stock using a 1/8” type 7018, 6011, or 6014 welding rod.
4. Speed is correct when arc starts easily, and weld penetration of 99-100% can be accomplished. (Set the speed a little on the high side to compensate for engine loading.)
E. Engine Speed Control

ZENA™ Automatic Engine Speed Control
(for engines w/vacuum supply)
In many cases, an appropriate engine speed control mechanism is already in place. For example, most tractors and mowers come with hand operated throttle controls. ATV’s and many commercial vehicles may also come with built in speed controls that can be used to easily set the speed of the vehicle's engine for welding.
For gasoline fueled trucks and other motor vehicles without such built-in speed controls, there are both low-tech and high-tech solutions. An example of a low tech means of speed control is to simply use a simple wedge to block the vehicles throttle open sufficiently to achieve the desired speed (by using a wedge instead of a fixed thickness shim for this purpose, infinite variability is achieved). A sample of a higher-technology speed control mechanism, is a mechanical, electro-pneumatic, automatic throttle control device, such as the ZENA automatic engine speed control, which was developed specifically for use with the ZENA welding system. Complex, fully electronic automatic speed controls which work directly with a vehicle's onboard computer/engine controls are also available from both OEM and after market suppliers.
For small free standing engines equipped with governors for speed control, small constant duty solenoids can be used to directly act on the governor mechanism to control engine speed.
For diesel engine powered vehicles with vacuum systems and mechanical throttle controls, the same speed controls that are used with a gasoline engine will usually work. For diesels with electronically controlled engine speed, we recommend using the ZENA automatic engine speed control's vacuum actuator to directly control the accelerator pedal. (If your accelerator pedal has a very strong spring, a second vacuum actuator, or a helper spring, may be used to overcome excessive spring pressure.)
The appropriate ZENA automatic engine speed control for your installation may be ordered from our parts department via our web site (www.zena.net) or by calling toll-free 877-ZENA INC. We can also help you to determine exactly which method is best for your application.
F. Electrical Installation/Hook-Up -- Welder Operated IN ADDITION to an Existing Vehicle's Electrical Generating Equipment -- Standard/Recommended Method
1. General Instructions
Standard electrical installation is easy! If you are not replacing the vehicle's existing alternator with the ZENA power generating unit, NO modification to the vehicle's electrical system is required. Only connection (using supplied wires) of the Power Generator to a switched and fused power source capable of providing the voltage and current that the control system requires and to chassis ground is required. Typical current required from the vehicle when welding is approximately 4 amps. When not welding, the system does not draw significant power from the vehicle. A switched electrical supply can often be accomplished by connection to an appropriate point of the vehicle's ignition circuit. Typically, a 7.5A or a 8A fuse should be installed in line with the input power connection to the Welding Power Control Module.
When you want to weld, just attach the ZENA mobile welding system's cables to the Welding Power Generator (selecting positive or negative welding polarity) and plug in the system control cable to the Control Module .

NOTE:
The ZENA welding system's output is electrically isolated from the vehicle -- allowing positive or negative polarity welding -- even to parts of the vehicle in which it is installed.

2. Wiring

a. Connect the 2 gray wires which extend out of the Control Module to the Power Generator as shown in the photo to the right.
b. Using the supplied Red wire and female bullet connector, connect the Red wire from the Control Module to a point in the vehicle's electrical system which can supply 12V @ 8A. (or 24V @ 4 A ) which is switched on with the vehicle's ignition.
NOTE: The welder is internally fused, and can be operated without an external fuse. However, installation of an external fuse (of the type used in your vehicle) is recommended. When using an external fuse, use a “slow blow” type &mdash; either 7.5 amp. or 8 amp. value/size.
c. Using the supplied Black wire and male bullet connector, connect the Black wire extending out of the Control Module to the point at which the negative post of the vehicle's battery system is connected to the vehicle's chassis (or to another suitable ground point).
d. Some Control Modules have both a green and a yellow wire extending from the Control Module. These wires are used to connect the Control Module to accessories. The green wire is used to control to the ZENA automatic speed control, the yellow wire is used to control one or more ZENA Slave Welding Control Modules -- used in high power welders which use multiple Power Generators, connected together, to generate large welding currents.
If you are not using these features or accessories, be careful to NOT connect either wire to any other device. It is permissible to fold, or to coil, either or both wires, using a wire tie or electrical tape to secure their position, to insulate them from other system components, and to make a neater looking installation -- but take care to insure that neither wire is accidentally shorted to chassis ground in the process.
e. Some Power Generators which have been ordered for custom applications may also have multiple external terminals or from one to three gray wires extending from the generator's rear case, terminating in a connector, which are used to connect special accessories and/or test equipment.

CAUTION:
To prevent blowing internal fuses, or causing damage to your welder, make sure that electrical power IS NOT applied to the Power Generator, OR to the Control Module, while connecting or disconnecting wires or while otherwise working with system wiring.

G. Electrical Installation/Hook-Up -- Replacing Vehicle's Electrical Generator
If you've chosen to replace an existing alternator or generator with any Series 150 or Series 200 welding system, the electrical installation is still quite simple but it will vary from case to case depending on your vehicle's electrical system.
In most cases, a suitable external voltage regulator is required. This component can be purchased directly from our parts department, or you can contact us for the specifications that you will need to identify and purchase a suitable unit locally.
The simplest installation of this sort is one in which the external voltage regulator is installed using “quick disconnect” connectors identical to the connectors used by the Welding Power Generator's Control Module thereby providing a simple mechanism for manually connecting and disconnecting the external voltage regulator to and from the Power Generator and to and from the vehicle's electrical system.
Typically, the voltage regulator is connected to the vehicle's ground, the vehicle's battery, and to the Power Generator (replacing the two gray wires with the regulator's rotor control wires). When the voltage regulator is so connected, the gray wires from the welding system's Control Module will be disconnected.
The connections from the Power Generator's positive and negative output terminals to the vehicles battery/electrical system are made using appropriately sized wire and 5/16 inch lugs.
Remember that BOTH of these charging wires MUST be DISCONNECTED before using the Power Generator for welding (and prior to the connection of the ZENA system's supplied welding and control cables).

CAUTION:
Failure to disconnect these charging wires prior to welding can result in battery explosion or severe damage to the vehicle's battery and/or its electrical system.
In other cases you will connect your vehicle's existing alternator wiring to the ZENA mobile welding system power unit and to the external voltage regulator following instructions specific to your vehicle type.

CAUTION / NOTE:
It is possible to connect an external regulator to the ZENA system in such a way as to make all interconnections and disconnection's of the external voltage regulator and the Power Control Module noted above a semiautomatic procedure using relays to effect the required actions. A schematic diagram illustrating this sort of installation is provided in Appendix B of this manual. This information is provided purely as a service to our customers. ZENA, Inc. makes NO REPRESENTATIONS or GUARANTEES WHATSOEVER as to the suitability of such information for any specific vehicle or installation.

A typical bracket set

repair welding jobs usually require only a few minutes. However, when you are doing commercial welding, much of your time is spent preparing your work pieces for actual welding. It is wasteful, in these circumstances, for your engine to be operate continuously at a fast idle. With this in mind, we have developed a an automatic speed control accessory that completely eliminates the need for an operator to worry about setting engine speed while using a ZENA welder.

For more information,

The ZENA mobile welding system is manufactured in the USA and is sold with a
36 month limited warranty.

You have no risk if you buy on-line or order by phone.

ALL welders sold direct to end users come with a 60-day money back guarantee of satisfaction.


Prices & Specs Installation Photos

<---- Go Back

  Go to Top of Page



ZENA is a trademark owned by ZENA, Inc. for its welding systems and related products.

US & Foreign Patents Pending

© Copyright 1998,-2005 by ZENA, Incorporated. All rights reserved.

[an error occurred while processing this directive]