Riland ZX7 400GT User manual

ZX7 400GT WELDING
MACHINE
USER MANUAL

Preface
This manual includes hardware description and operation introduction of the equipments. For your and other
people’s safety, please read the manual carefully.
Pay attention
Pay attention to the words after the signs below.
Sign
Description
The words after this sign means there is great potential danger, which may
cause major accident, damage or even death, if it is not followed.
The words after this sign means there is some potential danger, which may
cause hurt or property lose, if it is not followed.
The words after this sign means there is potential risk, which may cause
equipment fault or break, if it is not followed.
Version
Version YF-TAE-0036, A5, Released on 12th, Dec., 2019.
The contents of this manual are updated irregularity for updating of product. The manual is only used as
operation guide, except for other promises. No warranties of any kind, either express or implied are made in
relation to the description, information or suggestion or any other contents of the manual.
The images shown here are indicative only. If there is inconsistency between the image and the actual product, the
actual product shall govern.

2
CONTENTS
SAFETY WARNING······················································································································································ 3
MACHINE DESCRIPTION············································································································································· 8
TECHNICAL PARAMETERS TABLE··············································································································································9
INSTALLATION INSTRUCTION ··································································································································· 12
OPERATION INSTRUCTION ······································································································································· 14
PANEL FUNCTION INSTRUCTION······························································································································ 15
NOTES OR PREVENTIVE MEASURES························································································································· 16
QUESTIONS TO BE RUN INTO DURING WELDING ···································································································· 17
MAINTENANCE ························································································································································ 18
TROUBLESHOOTING AND FAULT FINDING ··············································································································· 19
APPENDIX ⅠCIRCUIT DIAGRAM ······························································································································ 20

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SAFETY WARNING
The safety notes listed in this manual is to ensure correct use of the machine and to keep you and other people
from being hurt.
The design and manufacture of welding machine considers safety. Please refer to the safety warning listed in
the manual to avoid accidents.
Different damage would be caused by wrong operation of the equipment as follows. Please read the user
manual carefully to reduce such damage.
Sign
Description
Any contact of electric parts may cause fatal electric shock or burnt.
Gas and fumes are harmful to health.
Operation in narrow space may cause choke .
Spark and hot workpiece after welding may cause fire.
Bad connected cable may cause fire.
Incompletion connection of workpiece side circuit may cause fire.
Never weld on the case of tinder stuff, or it may cause explode.
Never weld airtight containers such as slot, pipe etc., or it may break.
Arc ray may cause eye inflammation or skin burnt.
Spark and residue will burn your eyes and skin.
Toppling over of the gas cylinder will cause body hurt.
Wrong use of the gas cylinder will lead to high-pressure gas eruption
and cause human hurt.
Never let fingers, hair, clothes or etc. near the moving parts such as
the fan.
The wire shoot out of the torch may stab eyes, face and other naked
parts.
Never stand in front of the swang equipment or under it, or it may fail
and cause injury.

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Please follow the rules below to avoid heavy accidents.
 Never use the equipment to do other things but welding.
 Follow related regulations for the construction of the input-driven power source, choice of place,
usage of high-pressure gas, storage, configuration, safe-keeping of workpiece after welding and
disposal of waste, etc.
 Nonessentials do not enter the welding area.
 People using heart pacemaker is not allowed to get close to the welding machine or area without
doctor’s permission. The magnetism created by energizing the welding machine can have a bad
effect to the pacemaker.
 Install, operation, check and maintain the equipment by profession personnel.
 Understanding the contents of the user manual for safety.
Please follow the rules below to avoid electric shock 。
 Keep away from any electric parts.
 Earth the machine and workpiece by professional personnel.
 Cut off the power before installation or checking, and restart 5 minutes later. The capacitance is
chargeable device. Please ensure it has no voltage before start again even if the power source is cut
off.
 Do not use wire with inadequate section surface or damage insulation sleeve or even exposed
conductor.
 Do ensure well isolation of wire connection.
 Never use the device when the enclosure is removed.
 Never use broken or wet insulation gloves.
 Use firenet when work at high position.
 Check and maintain regularly, don’t use it until the broken parts are fixedwell.
 Turn off the power when not in used.
 Follow the national or local related standard and regulations when using the AC welding
machine at narrow or high position.

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Please follow the below notes to avoid fire and explode, etc.
 No combustible in welding area.
 Keep off combustible when welding.
 Keep hot workpiece after welding away from flammablegas.
 Do move away the combustible around when weld the dooryard, ground andwall,.
 The wire connection of base metal should be as close to the welding place aspossible.
 Never weld those facilities with gas pipe or airtight slot.
 Put fire extinguisher around the welding area to preventfire.
The gas and fumes are harmful to health, please wear protective device
according to regulations.
 Wear exhaust equipment and breathe preventive facilities to prevent gas poisoning orchoke.
 Use suggested part exhaust equipment and breathe preventive facilities to prevent hurt or
poisoning by gas and other powder, please.
 To prevent oxygen-deficiency, air out the gas-filled room which is full of CO2 and argon on the
bottom, When operating on trunks, boilers, cabins,etc.
 Please accept the supervisor’s inspection when operating in narrow space. Air the room and wear
breathe preventive facilities.
 Never operate in degrease, washing or spray space.
 Using breathe preventive facilities when weld shielded steel for it will cause poisonous dust and
gas.
The arc, spark, residue and noise are harmful to health, please wear
protective appliance.
 Eye protection against arc is recommended when welding or supervisewelding.
 Please wear preventive spectacles.
 Welder’s gloves, welder’s goggles, long sleeve clothes, leather apron, and other standard protection
equipments must be worn for welding operation.
 A screen to protect other people against the arc must be set in the weldingplace.

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Please follow the notes below to avoid gas cylinder toppling over or
broken.
 Use the gas cylinder correctly.
 Use the equipped or recommended gaseous regulator.
 Read the manual of gaseous regulator carefully before using it, and pay attention to the safety notes.
 Fix the gas cylinder with appropriative holder and other relative parts.
 Never put the cylinder under high temperature or sunshine environment.
 Keep your face away from the gas cylinder exit when openingit.
 Put on the gas shield when it is notused.
 Never put the torch on the gas cylinder. The electrode can not meet the gascylinder.
Any touch of the switch part will cause injury, please note the
following.
 Never use the machine when the enclosure is off.
 Install, operate, check and maintain the machine by professionalperson.
 Keep your fingers, hair, clothes etc. away from the switch parts such as thefan.
The wire end may deal damage, please note thefollowing.
 Never look into the electric conduction hole when checking the wire feeding is normal or not, , or the
shooting wire may stab your eyes andface.
 Keep your eyes, face or other naked parts away from the end of torch when feeding the wire manually
or pressing the switch.
For better work efficiency and power source maintenance, please
note the following.
 Precautions against toppling over.
 Never use the welding equipment for pipe thawing.
 Lift the power source from side when use the up-down forklift truck to avoid topplingover.
 When using the crane for lift, tie the rope to the ears with an angle no more than φ15 to the
vertical direction.
 When lifting the welding machine which equipped with gas cylinder and wire feeder,download

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them from the power source and ensure the horizontal of the machine. Do fix the gas cylinder with
belt or chain when moving it to avoid body hurt.
 Ensure fastness and insulation when lifting the wire feeder through the swing ring forwelding.
Electromagnetic interference needing attention.
 It may need extra preventive measures when the equipment is used in particularlocation.
 Before the installation, please estimate the potential electromagnetism problems of the
environment as follows.
a) Upper and lower parts of the welding equipments and other nearby power cable, control cable,
signal cable and phone cable.
b) Wireless electric as well as TV radiation and reception equipment.
c) Computer and other control equipments.
d) Safety-recognition equipment etc. Such as supervise of industrialequipments.
e) Health of people around. Such as personnel using the heart pacemaker oraudiphone.
f) Equipments for adjustment and measurement.
g) Anti-disturb capability of other used equipments .Users should ensure these equipments and
the environment are compatible, which may need extra preventivemeasures.
h) Practical state of the welding and other activities.
 Users should observe the following dos and don’ts to decrease radiation interference.
a) Connect the welding equipments to the power supply lines.
b) Maintain the welding equipments regularly.
c) The cable should be short enough to be close to each other and theground.
d) Ensure the safety of all the welding metal parts and other parts nearby.
e) The workpiece should be well earth.
f) Shield or protect the other cable and equipments to decrease the effects of disturbances. The
welding equipments can be complete shielded in some specialconditions.
 Users are responsible for interference due to welding.

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WARNING！
The machine is mainly used in industry. It will produce radio wave, so the worker should make fully
preparation for protection.
MACHINE DESCRIPTION
The welding machine is a rectifier adopting the most advanced inverter technology.
The development of inverter welding equipment profits from the development of the inverter power supply
theory and components. The inverter welding power source utilizes high-power component single tube IGBT to
transfer 50/60Hz frequency up to 15KHz, then reduce the voltage and commutate, and output high-power
voltage via PWM technology. Because of the great reduce of the main transformer’s weight and volume; the
efficiency increases by 30%. The appearance of inverter welding equipment is considered to be a revolution for
welding industry.
The welding power source can offer stronger, more concentrated and more stable arc. When stick and work
piece get short, its response will be quicker. It means that it is easier to design into welding machine with
different dynamic characteristics, and it even can be adjusted for specialty to make arc softer or harder.
The welding machine has the following characteristics: effective, power saving, compact, stable arc, good
welding pool, high no-load voltage, and good capacity of force compensation and multi-use. It can weld stainless
steel, alloy steel, carbon steel, copper and other color metal. It can apply to electrode of different specifications
and materials, including acidity, alkalescency, and fibre. It can apply in high altitude, the open air and inside and
outside decoration. Compared with the same products of home and abroad, it is compact in volume, light in
weight, easy to install and operate.
The welding machine is most suitable for welding tube, boiler, vacuum pressure vessel or the higher quality for
welding, which can gain perfect welding quality. In addition, this series machine have enough no-load voltage
and the ability of output, ideal for long cable welding.
Thanks for purchasing our product and hope for your precious advice. We will be dedicated to produce the best
products and offer the best service.

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TECHNICAL PARAMETERS TABLE
Model
Parameters
ZX7 400GT
Power voltage （ V ）
Three Phase AC
380V±15%
±15%
Three Phase AC
400V±15%
±15%
Three Phase AC
415V±15%
±15%
Three Phase AC
440V±15%
±15%
Frequency （ Hz ）
50/60
50/60
50/60
50/60
Rated input current （ A ）
27.7
24.6
25.4
24
No-load voltage （ V ）
62
66
68
72
VRD voltage (V)
15
Output current （ A ）
40-380
Rated output voltage （ V ）
35.2
Force range （ A ）
0-10
Duty cycle
40%
No-load loss （ W ）
80
Efficiency
85
Power factor
0.93
Insulation grade
H
Housing protection grade
IP21
Weight （ Kg ）
22
Dimensions （ mm ）
508*244*423

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INSTALLATION INSTRUCTION
The machine is equipment with power voltage compensation equipment. When power voltage moves
between±15% of rated voltage, it still can work normally.
When use long cable, in order to prevent voltage form going down, bigger section cable is suggested. If cable is
too long, it may affect the performance of the power system. So we suggest you to use configured length.
1. Make sure intake of the machine not blocked or covered, lest cooling system could notwork.
2. Make sure the earth end of power interface has been reliably and independentlygrounded.
3. Correctly connect the arc torch or holder according to the sketch. Make sure the cable, holder and fastening
plug have been connected with the ground. Put the fastening plug into the fastening socket at the “-
”polarity and fasten it clockwise.
4. Put the fastening plug of the cable to fastening socket of “+” polarity at the front panel, fasten it clockwise,
and the earth clamp at the other terminal clamps the work piece.
5. Please pay attention to the connecting polarity, DC welding machine has two connecting ways: positive
connection and negative connection.
Positive connection: holder connects with “-” polarity, while work piece with the “+”polarity.
Negative connection: work piece with the “-”polarity, holder with the “+” polarity.
Choose suitable way according to working demands. If unsuitable choice, it will cause unstable arc, more
spatters and conglutination. If such problems occur, please change the polarity of the fastening plug.
6. According to input voltage grade, connect power cable with power supply box of relevant voltage grade.
Make sure there is no mistake and make sure the voltage difference among permission range. After the
above job, installment is finished and welding isavailable.
Negative Connection
Power Supply
Positive Connection
Earth Clamp
Electrode Holder
Workpiece

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If distance of work piece and machine is too far (50-100m), and the cables (torch
cable and earth cable) are too long, please choose cable of bigger section to
minimize the reduction of the voltage.
Attached components type list
Mode
ZX7 400GT
Rated current of Power
switch
40A
Cable
Input side
≥4mm2
Output side
50mm2
Earth cable
≥4mm2
Electrode holder
Electrode holder
above 500A is
suggested.

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WARNING!
Before connecting operation please make sure all the power is turned off. The right
order is to connect the welding cable and ground cable to the machine first, and make
sure they are firmly connected and then put the power plug to the power source.
OPERATION INSTRUCTION
1. Open the power switch, screen will show set current volume and ventilator is beginning torevolve.
2. Adjust knobs of welding current and arc-striking push, make welding function complies with
demands.
3. Generally, welding current is adequate to welding electrode according with asfollowing.
Specification
（mm）
Φ1.6
Φ2.0
φ2.5
φ3.2
φ4.0
φ5.0
Φ6.0
Current （ A ）
25~40A
40~65A
50-90A
90-130A
140-210A
190-270A
260~300A
4. Knob of arc-striking drive is use to adjust welding function, specially in low current arrange, that is
cooperated with knob of welding current adjustment, they may adjust current of arc striking and be out of
control of knob of welding current adjustment .So machine can grain powerful energy and push current
can achieve effect that may.
5. If the anti-shock device is installed in the machine. When the switch of back panel is put "ON" position, the
VRD indictor is lit, and when the switch is put "OFF" position, the VRD indicator isoff.

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PANEL FUNCTION INSTRUCTION
ZX7 400GT Front Panel Layout
No.
Description
1
VRD switch
2
VRD indicator
3
Abnormal indicator
4
Current meter
5
Current adjustment knob
6
ARC force adjustment knob
7
Hot start adjustment knob
8
Positive output terminal
9
Remote control output terminal
10
Negative output terminal

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2. Safety norms
Note: The images shown here are indicative only.
NOTES OR PREVENTIVE MEASURES
1）The machine can perform in environment where conditions are dry with a dampness level of max 90%.
2）Ambient temperature is between -10 to 40 degrees centigrade.
3）Avoid welding in sunshine or drippings. Do not let water enter the gas. 4 ）
Avoid welding in dust area or the environment with corrosive gas.
5 ） Avoid gas welding in the environment with strong airflow.
Our welding machine has installed protection circuit of over voltage, over current and over heat. When
voltage, output current and temperature of machine are exceeding the rated standard, welding machine will
stop working automatically. Because this will be damage to welding machine, user must pay attention to
following.
1）The working area is adequately ventilated ！
Our welding machine is powerful machine, when it is being operated, it generated high currents, and
natural wind cannot satisfy with machine cool demands. So there is a fan inside the machine for its
cooling demands. Make sure the intake is not in block or covered, There should be 0.3 meter distance
from welding machine to objects of environment. User should make sure the working area is adequately
ventilated. It is important for the performance and the longevity of the machine.
2）Do not over load ！
The operator should remember to watch the max duty current (Response to the selected duty cycle)
Welding current should not exceed max duty cycle current. Over-load current will damage and burn up
the machine.
3）No over voltage ！
Power voltage can be found in diagram of main technical data. Automatic compensation circuit of
voltage will assure that welding current keeps is in allowable range. If power voltage is exceeding
allowable range limits, it can damage the components of machine. The operator should understand this
situation and take preventive measures.
4）If welding time is exceeding duty cycle limited, welding machine will stop working for protection.
Because machine is overheated, temperature control switch is on “ON’’ position and the
1. Environment

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A. Arc-striking is difficult and easy to pause:
B. Output current is not to rated value:
C. Current is not stabilizing when machine is being operated:
D. Too much spatter during MMA welding:
indicator light is red. In this situation, you don’t have to pull the plug, let the fan cool the machine.
When the indicator light is off, and the temperature goes down to the standard range, it can weld again.
QUESTIONS TO BE RUN INTO DURING WELDING
Fittings, welding materials, environment factor, supply powers maybe have something to do with welding. User
must try to improve welding environment.
1. Make sure quality of tungsten electrode is high.
2. If the electrode is not dried, it will cause unstable arc, welding defect increases and the quality is down.
3. If use extra-long cable, the output voltage will decrease, so please shorten thecable.
When power voltage departs from the rated value, it will make the output current not matched with rated value;
when voltage is lower than rated value, the max output may lower than rated value.
This may be caused by the following factors:
1. Electric wire net voltage has been changed.
2. There is harmful interference from electric wire net or otherequipment.
1. Maybe current is too heavy while welding rod diameter is toosmall:
2. Output terminal polarity connection is wrong. The positive connection should be applied at the normal
technique, that is to say, welding rod connects with the negative polarity while the work piece with the
positive polarity. So please change the polarity.

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WARNING！
Connected welding machine to dynamotor directly will damage machine. The heavy
voltage pulse which is produced by dynamotor will burn out machine when machine
connected to dynamotor, only can use asynchronous dynamotor whose frequency
and voltage both are steady. Because of connecting welding machine to dynamotor
directly lead to damage and malfunction, which is not in guarantee.
MAINTENANCE
1. Remove dust by dry and clean compressed air regularly, if welding machine is operating in environment
where is polluted with smokes and pollution air, the machine needs to be cleaned once a month.
2. Pressure of compressed air must be within the reasonable range in order to prevent damaging to small
components of inner-machine.
3. Check internal circuit of welding machine regularly and make sure the circuit connections are connected
correctly and tightly (especially plug-in connector and components). If scale and rust are found, please clean
it, and connect again tightly.
4. Prevent water and steam from entering into the machine. If that happens, please blow it dry and check
insulation of machine.
5. If welding machine will not be used for long time, it must be put into the packing box and stored in dry and
clean environment.

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TROUBLESHOOTING AND FAULT FINDING
Notes: The following operations must be performed by qualified electricians with valid certifications. Before
maintenance, please contact with us for professional suggestion.
Fault symptom and solution.
Fault symptom
Solution
Meter doesn’t display, fan
doesn’t work, no welding
output.
1.
2.
3.
Make sure power switch is off.
Make sure the power source connecting to input cable is working alright.
Make sure the input voltage is 3 phase.
Meter is normal, fan is
working, no welding output.
1.
2.
3.
Check if all kinds of components of machine are poor contact. Check if
connector of output terminal is broken or damaged.
Check if the control board is damaged (contact with the supplier or
manufacturer).
1.
IGBT is damaged.
2.
Rectifier of quick recovery is damaged.
Abnormal indicator is on, fan is
working, meter is normal
3.
4.
Control board is broken.
The feedback circuit is in fault. Please contact with the supplier or
manufacturer.
Too much spatter during
MMA welding
Output terminal polarity connection is wrong. So please change the
polarity.
Erratic welding output
1.
The potentiometer is damaged.
current or out of control of
2.
All kinds of connectors are poor contact, especially plugs. Check
potentiometer.
them.
1.
Power switch is broken.
Power switch doesn’t work
2.
Three phase rectifier bridge is broken, replace it.
3.
Check if there is any short circuit of inner-machine.

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If the welding machine doesn’t work after the above examination and repair, please contact the local dealer or
after-sales service department of our company.
APPENDIX ⅠCIRCUIT DIAGRAM