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330 Club Springs Road
Elmwood, TN 38560
Phone: (615) 897-2011
Fax: (615) 897-2023
E-Mail:
contact@zena.net

 

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I have one of your competitors products -- an alternator type combination welder and power unit with 120V DC power on a Ford Diesel 3/4 ton 4x4. The unit is very marginal in its ability to weld. My diesel engine red lines at 3700 rpm -- not fast enough to get enough welding power. (I had to put a 2 pulley on the alternator to get it to do as well as it does.)
I need to know at what engine rpm your ZENA unit needs to turn to get at least close to full power.

You do not need to run your engine that fast to get super results from any ZENA welder -- about half that speed will do nicely (maybe even less).

Our Power Generator must run at about 6500 rpm. Once the generator reaches a minimum speed to for 150A, 100% duty operation, more speed (up to 18000+ rpm) is OK, but will not provide significant additional power and is not necessary.
Engine speed needed usually depends on crank pulley diameter (assuming that initial drive is from this source). There is a chart for determining this in the ZENA Installation Manual and, if you do not have a tach., there is an alternate method that can be used with a high degree of accuracy to determine proper operating speed. For example:

As to your vehicle, most diesels that we have looked at only need to run at about 1800-1900 RPM for proper welding operation. However, with most of the newer, turbo diesels, customers report that the trucks are hard to hold reliably at RPM settings in this range (because that is where the turbo starts to come on), so they often choose to set their welding speed to 2500-2600. The welder doesn't care -- and provides excellent results at either setting. (Remember, we use electronic means to control power rather than engine speed.)

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Why don't I have to vary the engine speed when I'm welding?

Because, our proprietary (patents pending) solid-state electronic controls make all power adjustments electronically. As long as a certain minimum engine speed is maintained, the system does the rest -- maintaining and regulating power output to provide a constant current and a stable welding arc.

In addition, thanks to our revolutionary technology, the electronic controls work with the system's power generating components to:

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Is the ZENA system easy to service?

YES! The system utilizes modular components which are easy to replace in the field. Instead of having to remove the entire system, only the defective component need be removed.

Troubleshooting the system is also easy, thanks to special built in diagnostic circuitry and indicator lamps which report on the operation of key system elements and detailed trouble analysis instructions in the Operator's Manual

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Is installation difficult?

Not when performed by a competent installer who follows the instructions and guidelines provided. Sometimes, installation can be as simple as just bolting the ZENA system onto an existing, unused engine bracket and hooking up two wires to the vehicle's electrical system.
To assist in the process, we suggest techniques which makeinstallation relatively simple. To further assist the installer, we have available a number of prefabricated brackets designed specifically for the ZENA system, and we also have pre-engineered custom installation kits available for a number of popular vehicles and universal generic installation kits which are designed specifically for a typical class of vehicle (tractors, trucks, etc.).

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Is a MIG welding torch attachment available for your welders?

We do not offer a MIG attachment for our welding system at this time. MIG is admittedly the choice for thin gauge sheet metal and production line shop welders. However, gas shielded MIG welders do not usually work well in windy or wet conditions, and (in our experience) flux core MIG welders do not produce really good quality joints, and the limited availability of wire that is not either mild steel or aluminum greatly limits the utility of MIG systems in the field.

Stick systems are excellent for outdoor/rough conditions/thicker metal components, and offer a very wide range of easy to obtain of rod material choices. (Stainless, cast iron compatible alloys, aluminum, low hydrogen steel, mild steel, just to name a few.)

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Is there a ZENA welder with 115V AC output?

Since Y2K and the availability of ultra low cost/high quality AC inverters (i.e., 600W units which will easily operate 4" grinders and 3/8" drills for under $150), we no longer offer a AC power option except as a special order item. It's just too expensive (or AC generator accessory is about $600) and (in most cases) quite wasteful / inefficient to operate an engine to drive a high current producing device like a welding power generator to produce low current for small power tools.

For people who need continuous AC power production (for days/hours) a engine driven generator exactly sized to the load is the most efficient and cost effective solution.

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I've been looking at your welding system. I didn't see any information about MIG, TIG, or Flux Core welding using your welder as the supply. I'm more interested in the MIG and Flux Core possibilities than the TIG.

We do not make a portable MIG spool at this time. We just haven't figured out how to make one, at a low cost, which is as waterproof and as durable as we would like. However, our systems have been used in the field with high quality spool guns. We can provide you with free tech support and can also fabricate control adapters in our shop (on a time and material basis).

Without a doubt, MIG is great for sheet metal work and for production work in the shop. And TIG, in the hands of a skilled operator, produces a great looking, high quality weld. However, for outdoor repair work stick offers a number of advantages. This is why most commercial quality engine driven welders (even those units which provide TIG and MIG functions also) are constructed to provide stick functionality .

Most of our customers buy the ZENA system for field repair work where the job of the hour might be on a cast iron farm implement, a engine block, a front end loader mount, a grader blade, pipe or pipe casing welding, gouging/cutting, hard surfacing a digging or cutting tool, etc. Typically, working with thicker materials (often with improper cleaning and/or preparation) -- with most repair beads being relatively short (often taking less than 5 rods to accomplish). For this sort of repair, stick can be just about as fast as MIG.

A number of different rod types (i.e., various types and sizes of mild steel, low hydrogen, stainless, Nomacast, nickel, aluminum, hard surfacing, etc.) can be easily carried into the field in moisture proof rod carriers (or in small sealed manufacturer's pack) where carrying a wide variety of spools (and keeping them rust/moisture/corrosion free) can be difficult or impractical for the average farmer or service person. Also our early focus group research indicated a lot of dissatisfaction with the quality of flux core MIG welds when working with thicker materials. Most seemed to feel that gas shielding was much better for quality work. Of course both MIG and TIG weld quality can suffer in windy (and/or wet) conditions where shielding gas effectiveness decreases and where the weld may cool improperly. Because of this, and because all weather reliability and cost are very important to most of our customers, our prime focus has been stick.

With all this said, we would be happy to work with you to add MIG capabilities to any ZENA welder which you may purchase. Just let us know.

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The ZENA mobile welding system is manufactured in the USA by ZENA, Incorporated and is sold with a three year limited warranty.

You have no risk if you buy on-line, all units are sold with a 60-day money back guarantee of satisfaction.



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

US & Foreign Patents Pending

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