We make both a 150A and a 200A MODULAR
welding power generator unit which can be used as ultra heavy duty replacements for
automotive or marine alternators. Both models reach their maximum output current
at about 6,000 rpm, and their most efficient operating speed range is between 5,000
to 7,000 rpm. Depending on your engine crank pulley diameter, and the diameter of
the drive pulley on the power generator, this typically equates to between 1,800
to 2,800 rpm in motor vehicle installations. CLICK
HERE for specifications.
In most automotive applications,
particularly in emergency vehicles, or other vehicles which require continuous power
for on board electronic equipment, some sort of idle up system is usually installed
and used to insure efficient generator operation. Marine applications may or may
not require this sort of system.
Multiple ZENA generator units (of
like type) may be electrically and mechanically synchronized to produce very high
welding (or charging) currents (300A, 400A, 450A, 600A, 800A, etc.).
Both generator models require heavy
duty external voltage regulators when used as alternators ($50-$150 depending on
features and application).
NOTE: When using
multiple generator systems, in synchronized combinations, to produce higher amperages,
extra control electronics will be required. Figure on about $250 for the first unit
and $120 for each other unit in the group.
The 150A power generator unit sells
for $250 and our 200A unit is $495.
NOTE: Neither the
150A or the 200A power generator units are equipped with avalanche diodes. If your
vehicle requires an alternator which is equipped with this type of component, do
not use one of our power generators as a replacement for this alternator (however,
you can safely use our alternators for supplying current to a secondary vehicle electrical
systems as noted below).
Neither of our
basic generator units will likely be a direct replacement for a stock alternator -- in either size or bracketing/mounting.
(As one would expect, most high current alternators ARE NOT direct physical replacements
for stock units.) However, if you have good fabricating skills, or if you have
a mechanic with such skills, it is usually fairly easy to adapt either unit to a
particular engine. In most larger vehicles, and in most marine applications, it is
also possible to install two 150A or two 200A generating units (for a 300A or a 400A
system). When more than two units are to be installed in an automotive system, a
hydraulic drive motor is usually the method used for driving the multiple power generators.
Marine and/or freestanding engine applications can sometimes accommodate additional
generating units without requiring a hydraulic drive system.
Our 150A generating unit uses a
2" mount/pivot point, and our 200A model uses a larger 3" mount/pivot.
The 150A unit requires a mounting location with enough space to accommodate an object
approximately 6-1/2" in length and 6" in diameter. The 200A unit, which
is about the size of a 2-1/2 lb. coffee can, is about 9" long and 6-1/2"
in diameter. While it is almost always possible to fit the 150A unit in a given automotive
application, the 200A unit which it is larger than the 150A unit, may require a bit
more bracketing work to make it fit. 200A marine installations, typically present
no such problem.
To check for size in your vehicle,
we recommend that you make up a cardboard model using the size (noted above) of the
model which you are interested in.
We sell all of our products with
a money back guarantee, so if you find that they cannot be fitted, or if you don't
like a unit for any reason, you can get a refund.
ONE FINAL NOTE:
In most applications, IF space is available, using a secondary electrical system
to supply ALL high amp components is, in our opinion, by far, the BEST solution to
This involves installing a SECONDARY
high-amp alternator which charges a SECONDARY high capacity, deep cycle battery
(or batteries). Thus creating an electrical supply circuit separate from the primary
battery's electrical system, which is used to supply the electrical needs
of all high amp nonstandard/special equipment installed on the vehicle (i.e.,
winches, high power audio systems, etc.).
Since this is also the best way
to install welding equipment on a vehicle, our power generating units are designed
to perform perfectly in this type of secondary electrical system. Best of all, we
have developed bracketing accessories which will help you in fabricating a second
alternator installation. We call this type of installation a piggyback installation,
and it is the most popular method of installing our alternators when they are used
for generating welding power. CLICK
HERE for a diagram of this type of installation.
We also have a number of pictures
available which illustrate secondary alternator installations in welding applications.
However, the same installation methods are used for secondary alternator installations.
HERE to go to our web site map for descriptions/links to the pictures available
If you are planning your piggyback
installation into a vehicle with sufficient under hood room, and if you have a serpentine
belt drive system for under hood accessories (alternator, PS, AC, etc.) consider
the use of our Add-A-Pulley
accessory which provides
a means to securely attach a second V-pulley in front of any existing alternator's
serpentine pulley - providing an easy mechanism to drive the secondary alternator
which is being installed.
and TBUCK bracketing accessories are also popular installation accessories, for 150A
unit installations, and can further simplify the installation process.
NOTE: For 200A units,
we don't usually recommend generic bracketing accessories, as it takes less under
hood space to custom fabricate all bracketing components for a given vehicle.
Finally, for a vehicle installation,
you may want to consider adding our ASC1 automatic speed control to provide a means to increase engine speed
when it is necessary to obtain full power from your alternator when the vehicle is
Hope this helps. Feel free to call
if you would like more information, or if you want to discuss your particular application
in more detail.