ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders
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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 meets the
needs of professional welders, working farmers, and industrial maintenance personnel, it is well suited
to a wide range of other uses -- industrial maintenance and fabrication, marine
maintenance and fabrication, construction, nursery work, estate maintenance, arts &
crafts, residential repairs, ornamental iron work, airborne maintenance activities, and
more.
In fact, given its ultra compact design and extraordinarily light weight, in addition to
redefining the terms “mobile” and “portable”, as they apply to welding equipment -- it
is creating new areas of utility -- vastly increasing the number and types of jobs that
welding equipment can address in the field!
Your new welding system has a number of unique features which, when compared to
conventional welders, make it safer and easier to use and superior in welding
performance. Read this manual
carefully
, and
thoroughly
familiarize yourself with all
controls, design features, safety features, and specifications
before
you begin to use it.
And, don’t neglect to also focus on the engine and its specific operating/maintenance
instructions -- included both here in this manual
and
in the Operators Manual provided
by the engine manufacturer. Attention to this, will insure that you will be able to safely,
and to properly use your new welder.
The ZENA system produces a high frequency pulsating DC current for welding which
provides a number of benefits over conventional DC welders. For example:
!
Improved welding “feel” -- easier to start and maintain an arc
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Electrically “stirred” weld bead provides additional penetration, less impurities,
and easy to remove flux deposits -- producing ultra-smooth and clean welds
even when used by inexperienced operator.
!
Arc length is much less critical than past technology. Maintain an arc even with
electrode tip in puddle!
!
Use
any
welding rod (AC or DC), including aluminum, stainless , iron, nickel.
!
Weld with long cables (up to 200 ft.) without noticeable loss of power
!
Deeper than normal weld penetration for a given power setting
While it is available with conventional controls best suited to rental and ultra harsh duty
condition, most Backpak welders are shipped with the unique control system for which
ZENA welders are renowned -- one which is designed to greatly enhance user safety
and to provide the operator unprecedented control of the welding process. With this
control system:
!
Welding power is not present at the electrode tip unless a safety/control button is
depressed and held down. Change rods without any danger of shock (even when
standing on a wet surface) and remove excess flux from rod/electrode tips
without danger of inadvertent arcing
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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
still produce a good weld.
