ZENA mobile welding system -- Operators Manual -- Series 150 & 200 Welders
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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. Go to Step 5a.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 5a.5.
5a.5 You have a problem which requires the assistance of our tech support
department (877-ZENA INC or 615-897-2011).
5a.6 It is likely that your Control Handle/Control Cable Assembly is malfunctioning.
To troubleshoot further, go on to step 3a.1.
6. Automatic Speed Control Stays at High Idle Constantly When Welder Power is ON -- Welder
Operates Normally -- Control Models
WC.12 & WC.24
6.1
With the engine ON, temporarily 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.
If engine speed stays at high idle it is possible that the Vacuum Switch is
malfunctioning, or that the vacuum actuator has become physically “jammed”
in some way. If no physical or mechanical problem is noted, go to Step 6.2.
If engine speed returns to low/normal idle when the green wire is disconnected,
it is likely that the Control Module is malfunctioning. Go to Step 6.4.
6.2
The connection of the vacuum lines to the two connection points on the Speed
Control Vacuum Switch is important. One of the points is to be connected to the
vacuum source/supply, the other is connected to the actuator. Carefully check
the diagram in APPENDIX E to insure that your vacuum lines are properly
connected. If the connections are correct, go to the next step.
6.3
Temporarily disconnect the vacuum line going from the Speed Control Vacuum
Switch to the Control Actuator (at either end) which observing the actuator. If
the Control Actuator returns to its “rest” position, your Speed Control Vacuum
Switch is likely to be malfunctioning. If the Actuator remains activated, and if it
is not physically “jammed” the actuator will need replacement. In either case,
go on to the next step.
6.4
You have a problem which requires the assistance of our tech support
department (877-ZENA INC or 615-897-2011).
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