ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders
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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 Generator
has a component failure, and must be returned for repair. Go to Step 5.5.
If the electrical resistance measured between the control terminals is
higher
than the “normal” range of 1.4 to 2.4 ohms
(for example, 10 ohms or 20
ohms or more) it is an indication of grease or some similar material which has
caused “fouling” coating of the brushes and or internal slip-rings. Fouled
brushes, can cause low welding power and should be corrected, but this will not
cause the problem which is be in diagnosed in this section. Cleaning can be
accomplished in the field, if necessary, but is best done under factory
conditions. Such cleaning, will usually be performed free of any labor charge,
with charges only for return freight cost (call our tech support department (877-
ZENA INC or 615-897-2011) for more information).
If a low resistance readings at the control terminals is found, you have a
Malfunctioning Power Generator. If a the resistance readings at the control
terminals is not low, you have a Malfunctioning Control Module. Reconnect all
wires, and go to step 5.5.
5.5
You have a problem which requires the assistance of our tech support
department (877-ZENA INC or 615-897-2011).
5.6
It is likely that your Control Handle/Control Cable Assembly is malfunctioning.
To troubleshoot further, go on to step 3.1.
5a. Welding
Power
is
on
CONTINUOUSLY -- Control Models
WC.12RO & WC.24RO
5a.1 Temporarily disconnect the plug that is used to connect the Control
Handle/Control Cable Assembly to the Power Control Module. If welding
power is now “OFF”, go on to the next step.
If welding power is still “ON” continuously, go to step 5a.3.
NOTE: If you are using a cable extension, or a quick disconnect system, of any
sort, with your welder, remove it temporarily to insure that the problem noted is
not caused by a wiring fault in the cable extension.
5a.2 Reconnect the plug used to connect the Control Handle/Control Cable Assembly
to the Power Control Module.
With the engine OFF, open the Control Module cover, rotate the Power Control
Dial on the Control Handle/Control Cable Assembly to its full counter clock
wise position (CCW), turn on power to the Control Module and observe Lamp
#2 and Lamp #3. If Lamp #2 is illuminated and Lamp #3 is not OR if Lamp #3
is illuminated and Lamp #2 is not, go to step 5a.3. If BOTH Lamp #2 AND
Lamp #3 are illuminated, go to step 5a.6.
5a.3 It is likely that either your Power Generator or your Control Module is defective.
You can easily check for a component failure in the Power Generator by
disconnecting the two Gray wires which are used to connect the Control Module
to the Power Generator’s control terminals, and check in the electrical
resistance between
either
of the terminals and the case of the Power
Generator. A normal reading is an “open” circuit (an infinite resistance).
If your meter shows
any
measurable resistance, your Power Generator has a
component failure, and must be returned for repair. Go to Step 5a.5.
If your meter shows
no
measurable resistance, go to the next step.
