Westweld ZX7-400HD User manual

ZX7-400/500/630HD
ARC WELDING MACHINE
MANUAL
INSTRUCTION
(PLEASE READ CAREFELLY BEFORE OPERATING)

Safety Depends on You
Huayuan arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be
increased by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
Special Notes (Very Important):
1. Pay attention to avoiding the machine falling down when it is placed on the gradient ground.
2. It is forbidden to unfreeze the pipeline by the cutter.
3. The shield rank of this series of cutter is IP21S, so working in rain is not suitable.
4．The cutter has external static characteristic with rated duty cycle 100%, which means the machine can work continuously at
the rated cutting current. The machine has the function of thermal protection. When the internal temperature exceeds a set
temperature, thermal protection moves on and the abnormity indicator lamp on the panel turns ON, then there is no output in
cutter. The machine can become normal and work only after the internal temperature drops down and the abnormity indicator
lamp on the panel turns OFF.
Purchase Date：____________________
Serial Number：____________________
Machine Model：____________________
Purchase Place：____________________

Caut ions
Arc and arc rays may harm health.
Arc welding can be hazardous. All performing welding workers ought to have health qualification that provided by
authority organization. Protect yourself and others from possible serious injury or death. Keep children away. Pacemaker
wearers should consult with their doctor before operating. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified individuals.
●Electric shock can kill: The electrode and work (or ground) circuits are electrically “hot” when the
welder is on. Do not touch these “hot” parts with your bare skin or wet clothing, Wear dry, hole-free
gloves to insulate hands. Users need to follow the below items to avoid electric shocks:
Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover
your full area of physical contact with work and ground. Otherwise, use automatic or semiautomatic welding
machines, DC welding machines as possible as you can.
In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically“hot”.
Always be sure the work cable makes a good electrical connection with the metal being welded. The connection
should be as close as possible to the area being welded.
Ground the work or metal to be welded to a good electrical(earth) ground.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating
condition. Replace damaged insulation.
Never dip the electrode in water for cooling.
Never simultaneously touch electrically“hot”parts of electrode holders connected to two welders, because voltage
between the two can be the total of the open circuit voltage of both welders.
When working above floor level, please do wear safety belt to avoid falling or losing balance on electric shock.
●Arc rays can burn: Use a shield with the proper filter and cover plates to protect your eyes from sparks
and the rays of the arc when welding or observing open arc welding. Head shield and filter lens should
conform to nation standards.
Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers
from the arc rays.
Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc
nor expose themselves to the arc rays or to hot spatter or metal.
●Fumes and Gases can be dangerous: Welding may produce fumes and gases hazardous to health.
Avoid breathing these fumes and gases. While working in limited room, use enough ventilation and/or
exhaust to keep fumes and gases away from the breathing zone, or use the respirator.
Shielding gases used for arc welding can displace air and cause injury or death. Always use enough
ventilation,especially in confined areas, to insure breathing air is safe.
Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying
operations.The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and
other irritating products.
Read and understand the manufacturer’s instructions for this equipment and the consumables to be used,
including the material safety data sheet (MSDS) and follow your employer’s safety practices. Make sure they are
asepsis and innocuity.

●Spatter: Welding or cutting spatter can cause fire or explosion.
Remove fire hazards from the welding area.If this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding sparks and hot materials from
welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
Where compressed gases are to be used in the field, special precautions should be used to prevent explosion.
When not welding, make certain that no electriferous part is touching the work piece or the work stage.
Accidental contact can create a fire hazard.
Do not weld containers or lines, which are not proved to be innocuity.
Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such
procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they
have been“cleaned”.
Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair
to prevent from burning by spatter. Wear the ear shield when performing sideways or face up welding. Always
wear safety glasses with side shields when being in a welding area.
The welding cables should be as close to the welding area as possible, and the short, the better. Avoid welding
cables going through the building framework, lifting chains, AC or DC cables of other welding machines and
appliances. The welding current is strong enough to damage them while having short circuit with them.
●Cylinder may explode if damaged.
Make sure that the gas in the storage cylinder is qualified for welding, and the decompression
flowmeter, the adapter and the pipe are all in good condition.
Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
Be sure to put the cylinder in the working space with no crash or shake, and far from welding area.
Never allow the electrode, electrode holder or any other electrically“hot”parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for
use.
●Power: (For electrically powered welding and cutting equipment) Turn off input power before
installation, maintenance and repair to avoid accidents.
Huanyuan welding equipment is Ι class safeguard equipment; please install the equipment in
accordance with the manufacturer’s recommendations by specific persons.
Ground the equipment perfectly in accordance with the manufacturer’s recommendations.
●Power:(For engine driven welding and cutting equipment)
Work in ventilated place or outdoors.
Do not add fuel near to fire or during engine starting or welding. When not working, add fuel
after engine is cooling down; otherwise, the evaporation of hot fuel would result in dangers. Do
not splash fuel out of the fuel tank, and do not start the engine until complete evaporation of the
outside fuel.
Make sure that all the safeguard equipments, machine cover and devices are all in a good
condition. Be sure that arms, clothes and all the tools do not touch all the moving and rotating
components including V belt, gear and fan etc.
Sometimes some parts of the equipment have to be dismantled during maintenance, but you still have to keep the
strongest safety awareness .
Do not put your hand close to fans and do not move the brake handle while operating.
Please remove the connection between the engine and the welding equipment to avoid sudden starting during

maintenances.
When engine is hot, it is forbidden to open the airtight cover of the radiator water tank to avoid hurt by the hot
vapor.
●Electromagnetic: Welding current going though any area can generate electromagnetic, as well as the
welding equipment itself.
Electromagnetic would affect cardiac pacemaker, the cardiac pacemaker users should consult
one’s doctor first.
The effect of electromagnetic to one’s health is not confirmed, and it might have some negative effect to one’s
health.
Welders may use following method to reduce the hazardous of electromagnetic:
a. Bundle the cable connected to the work piece and the welding cable together.
b. Do not enwind partially or entirely your body with the cable.
c. Do not place yourself between the welding cable and the ground (work piece) cable, if the welding cable is by your left
side, then the ground cable should be by your left side too.
d. The Welding cable and the ground cable are as short as possible.
e. D e. Do not work near to the welding power source.
●Lifting equipment: carton or wooden boxes package the welding machines supplied by Huayuan.
There is no lifting equipment in its wrapper. Users can move it to the prospective area by a fork-lift
truck, then open the box.
If there are rings, the machine can be transited by rings. While Huayuan Welding Machine
Manufacture reminds users, there is potential risk to damage the welding machine. So it is better
to push the welding machine by its rollers unless special situations.
Be sure that the appurtenances are all removed off when lifting.
When lifting, make sure that there is no person below the welding machine, and remind people
passing by at any moment.
Do not move the hoist too fast.
●Noise: Huayuan Welding Machine Manufacture reminds users: Noise beyond the limit (over 80 db)
can cause injury to vision, heart and audition depending on oneself. Please consult local medical
institution. Use the equipment after doctor’s permission would help to keep healthy.

CONTENT
1Main usage and application _________________________________________________________________ 1
2Working condition and Environment __________________________________________________________ 1
2.1 Storage and working environment condition _______________________________________________ 1
2.2 Safety precautions _____________________________________________________________________ 2
3Technical specification ______________________________________________________________________ 2
3.1 Main parameter: ______________________________________________________________________ 2
3.2 Welding electrode and related parameter setting____________________________________________ 2
4Hardware Overview ________________________________________________________________________ 2
5General description ________________________________________________________________________ 2
5.1 Working principal______________________________________________________________________ 2
5.2 Welding machine output CC/CV feature diagram ____________________________________________ 3
5.3 Principal diagram ______________________________________________________________________ 3
6Delivery and storage _______________________________________________________________________ 3
7Installation and adjustment__________________________________________________________________ 4
7.1 Open the package and check_____________________________________________________________ 4
7.2 Installation ___________________________________________________________________________ 4
7.3 Requirements table ____________________________________________________________________ 4
8Operations________________________________________________________________________________ 5
8.1 8.1 Panel instruction__________________________________________________________________ 5
8.2 Function introduction __________________________________________________________________ 5
9Maintenance______________________________________________________________________________ 6
10 Packing List _____________________________________________________________________________ 7

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1Main usage and application
This Series welding machine can be used for different types of electrode, especially suitable for hydrogen electrode to weld low
carbon steel, mid-carbon steel and their alloy work-piece. It is mainly used in the industries like ship-building, boiler, power
tower, petroleum and construction industries.
ZX7-HD series is one of our newest energy-saving power source, which with excellent technical standard and welding craft.
Its advantages as:
● Good dynamic characteristic, stable arc, good performance, little spatter
● Wide distribution voltage: 380VAC±60VAC
● Arc force adjust function
● Hot current adjust function
● Welding current preset function
● Digital controlled, Easy to operate, with remote control connector
● Lack voltage, over heat protection function
● Input voltage fluctuation compensation function, keep stable output current
● It can be controlled by a wireless network management system
● High efficiency, Low non-load loss
● Small volume, light weight, easy to move
Model specification
1.2.1 This welding machine designed and produced according to the GB15579.1-2004、JB/T7824-1995.
1.2.2 Model develop instruction:
Z X 7 —□□□ H D
Machine code
For heavy suty cycle welding
Rated welding current
Inverter type
Constant voltage
Dc type welding machine
2Working condition and Environment
2.1 Storage and working environment condition
2.1.1 Altitude less than 1000m;
2.1.2 Temperature:
Working：－10～＋40℃
Storage：－25～＋55℃
2.1.3 Relative humidity: 50% for temperature up to 40℃
90%@20℃
2.1.4 Do not locate where there is harmful gases, chemical depositions, mycete, and other explosive or corrosive substances,
prevent shaking and jolt.
2.1.5 Keep the machine inside and dry all the times, do not place it in a confined space, do not locate where the machine is
exposed to direct sunlight.

2
2.2 Safety precautions
2.2.1 Open and check the machine: only qualified personnel should perform to avoid danger or machine damage
2.2.2 Turn off input power before open the machine, do not touch the electrical conductors to avoid electric shock.
2.2.3 Dirt and dust which may cause short circuit should be kept to a minimum.
2.2.4 Welding may produce fumes and gases hazardous to health. Use enough ventilation and exhaust at the arc to keep
fumes and gases away from the breathing zone.
2.2.5 Arc rays may cause eye injury, please do not watch the arc nor expose to the arc rays.
2.2.6 Remove fire hazards from welding area, welding sparks and hot materials from welding can easily go through small
crack and cause fire.
3Technical specification
3.1 Main parameter:
Model
ZX7-400HD
ZX7-500HD
ZX7-630HD
Input Power
3～380/415V 50/60Hz
Rated input capacity（KVA）
16.5
25
34.5
Rated input current（A）
25
38
52
Open cuircuit voltage（V）
83.5
Rated welding current（A）
400
500
630
Rated duty cycle（％）
60%
Current adjust range（A）
10～400
10～500
10-630
Insulation grade
F
Dimension(L×W×H)(mm)
570×290×530
630 ×290×540
630 ×290×540
Weight（Kg）
38
42
43
* Rated duty cycle 60% means, take 10min as the working cycle, the welding machine work 6min under the rated current
status, rest for 4min. When the welding machine work more than 6min, the temperature in the machine will higher than the
setting value, the overload indicator will on, and machine no output until the temperature in the machine lower to the setting
value. When the overload indicator off, the machine can work again.
3.2 Welding electrode and related parameter setting
422 type electrode
Electrode dia.(mm)
2.5
3.2
4.0
5.0
Welding current(A)
70~110
100~150
160~210
200~260
507 type electrode
Electrode dia.(mm)
2.5
3.2
4.0
5.0
Welding current(A)
70~110
100~140
140~180
180~230
4Hardware Overview
This machine including: shell, inner part, handle and base, while the inner part include: cooling fan, main transformer,
IGBT modules, filter reactor, fast recovery diode modules and PCBs etc.
5General description
5.1 Working principal
ZX7–HD series welding machine adopts IGBT as the main circuit switch. The three-phase AC input power inverted to 20KHz

3
HF current through the rectify of the full bridge. While after the depression of the HF transformer, rectified by the FRD and
filtered by the reactor, the HF current will change to the low-voltage but high welding current.
The control circuit control the output current through the adjusting of the pulse width. The negative feedback signal, which
is the real welding current get from the output current sensor, put into the special PWM circuit after compared with the current
adjust signal, then output the driving pulse to control the IGBT, so that the output current will keep stable to get descending
external characteristic.
Force current function: the control circuit will increase the current when the welding voltage less than 15V, so that the
electrode will not stick with the work-piece to enlarge the arc penetration.
5.2 Welding machine output CC/CV feature diagram
5.3 Principal diagram
6Delivery and storage
Keep the machine away from rain and snow, the temperature should be -25~+55℃.

4
7Installation and adjustment
7.1 Open the package and check
Check if there is any damage of the machine, if all the accessories is complete according to the packing list.
7.2 Installation
●This machine requires 3 phase 380v/50Hz power input, so the related power cable and distribution box is needed, as
well as the circuit breaker and ground lead. Reliably connect the protective ground and the yellow-green wire which
on the back of the machine. The wire CSA should no less than the following table.
7.3 Requirements table
Parameter
Model
CSA for input copper wire
（mm2）
Breaker capacity
（A）
Fuse protector
(A)
CSA for ground lead
cable（mm2）
ZX7-400HD
≥4
40
32
≥4
ZX7-500HD
≥6
60
40
≥6
ZX7-630HD
≥6
60
50
≥6
Warning:
Completely read the operator's manual before installation, strictly follow the installation requirements.
The 3 phase input cable should steadily connected, any one of the three disconnect or poor connect will cause abnormal work.
Slowly and softly adjust the rotary knob, do not continue to turn when it reaches the endpoint.
If there is significantly worse of the performance during the welding process, the machine should be stopped to check.
The potentiometers on the control circuit has different functions, they have been routine tested before delivery, please do not
adjust.
Only qualified personnel should perform this welding machine.
Wear protective garments such as gloves, heavy shirts, trousers and high shoes according to the related safety precautions.
Power off immediately if the abnormal indicator on, then check the input voltage, cooling fan motor, or if there is lack-phase or
overheat. Then turn on the machine again when it cooled down, if still have problem, please contact Huayuan company.

5
8Operations
8.1 8.1 Panel instruction
Fig3 ZX7-HD Series Inverter DC welding machine panel
Fig4 Fear of machine
8.2 Function introduction
Power on,the indicator on the panel shall light.
a、Power switch: up is on,down is off.
b、Current LED:without press channel selection,It display the present current during welding,display preset without
welding.When Press channels selection,it display the storage current of channel.
c、Voltage LED:without press channel selection,it display the present voltage of channel.When Press chan
d、Channel selection: when press it,able to watch the storage parameters,include welding current,arc force,hot start.
e、Storage:press it and storage the present parameter of any channels(total 10channels),the specific operation as
Current adjust
Indicator
Current Disp
Voltage and
Channel disp
Parameter
selection
Local/Remot
e control
Channel
choosing
Selection
Positive pole
Negative pole
Storage
Power Switch
Remote
control and
wireless
management
system
interface

6
follows:adjust the required welding parameter,press channels selection knob,the voltage LED display the present
channel,if need to storage,press storage knob.If need to storage the parameter to other channels,continue to press
selection channel till find the required channel,then press storage knob.It will return to the present adjustment
parameter if without any operation within 5s.
f、Parameter selection: press the knob to select any parameter of any channels,as follows:press channel selection
knob,to select the suitable parameter,and press selection parameter knob.
g、Current selection:Press it to choose the welding current,arc force or hot start.
h、Control mode: press and choose the mode.
i、Overload: it on,mean overload,need to stop working and temperature drop.
j、Input fault: the indicator on means the power miss-phase or undervoltage,meanwhile,power off and check the
power supply.
k、welding current:the indicator on means current LED display the present welding current.
l、Arc force: the indicator on means the current LED display the arc force current.It will return to welding current
indicator without any operation within 3s.
m、Hot start: The indicator on means the current LED display the hot start current.t will return to welding current
indicator without any operation within 3s.
n、Locate: the indicator on means available to adjust the parameter on the power source.
o、Remote: the indicator on means not able to adjust any parameter on the power source,only adjust welding
parameter by remote control box.
p、Channel No.: the indicator on means voltage LED display the present channel no.
q、Voltage(V): the indicator on means voltage LED display the present voltage.
r、Current(A): “on”mean the LED of current display the actual current.
s、Preset indicator: “on “mean the LED of current display the preset current.
Note:
1、The machine have intelligent fan function,it will work after power on but without welding for 15s,then stop;Fan
keep rotating during welding,and stop after 8mins if end welding.
2、The machine have anti-electric shock function,welding machine will output the safety voltage 8-10V if machine
power on but without welding.When welding,output the normal arc voltage,but it will drop to the safety voltage if
no welding after 1s.
9Maintenance
Install and operate the machine strictly according to the operator's manual, the warranty period is one year.
Troubleshooting
TROUBLE (SYMPTOMS)
POSSIBLE CAUSE
RECOMMENDED COURSE OF ACTION
When machine energized, the
circuit breaker trip
1.Three phase bridge rectifier may
damaged
2. The capacitor which parallel with the
three phase bridge rectifier may
damaged.
3. IGBT may damaged
1. change the bridge rectifier；
2. change the capacitor.
3. Replace PCB and IGBT
2.
When machine energized, the
power indicator not on, no voltage
indication
1. The protective fuse on the back of the
machine may break
2. Lack phase
1. Replace fuse
2. Check the input power
When machine energized, the
power indicator on, but no voltage
indication
1. PCB AP1 may damage
2. IGBT module may damage
3. Voltmeter may damage
1. Replace AP1
2. Replace IGBT module
3. Replace voltmeter

7
No OCV, there is abnormal noise
from the machine
FRD on the main circuit is damaged
1. Check and replace the FRD
The OCV is OK, but sometimes the
arc will break
Lack-phase
Check the input power
Suddenly there is no welding
current during the welding process
1.welding cable and work piece with poor
connection
2.Protective fuse break
1.check the weld cable
2.Replace the fuse(1.5A)
Machine not work, but the overload
indicator on
1. Cooling fan damaged cause overheat
protection
2. Over-load use cause over heat
protection
1. Replace cooling fan
2. Stop welding, let the machine operate
for 10min without load
Machine not work, but the lack
voltage indicator on
The input lack-phase or lack voltage
Check three phase input
Attention: Only qualified technicians should perform troubleshooting work on the machine. If for any reason you do not
understand the test procedures or are unable to perform the tests/repairs safely, please contact us for technical assistance.
10 Packing List
1.ZX7-HD welding machine 1 pcs
2.Electrode holder 1 pcs
3.Fast connector 2 pcs
4.Documents (Guarantee card, operation manual, quality certificate) 1 for each

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12345678
A B C D
87654321
D C B A
QF1
C7
HYC4001
V2
SKM75GB128D
V3
SKM75GB128D
R1 R2
C14
C9
HYC3001
TM1
TA1
V4
V5
L5
C2C1
CBB21/100n/630V
C3
L1
L3
C8 HYC2001
L4
EV1 风扇
D40
＋15 V
1
Out
3
-1 5V
2
0V
4
TA2
G1 G2
G3 G4
E1 E2
E3 E4
1 2 3 0
4 5 6
7 8 916
14
17
18
20 21
19
38 39
35
20 40
41
AP1(PZ11)
V1
L2
15
C4 +C5
+C6
FU1
1.5A
XS10A XS10D
42 43
XS6A XS6B
XS3H XS3G XS3A
XS3C XS3D XS3B
XS7A XS7B
49 50 48 51
55 56
YV1
XS1A
气阀
XS1DXS1E
J2B
XS1BXS1C XS1F
J2A
J1H
XS1A
XS1D
XS1E
J1G
XS1B
XS1C
XS1F
AP2(PZ12)
XS3E XS4B XS10C XS3F XS4A
XS10B
58 59 56 57 60 61
70 68
44
45 46 47 52 52
58 59 56 57 60 61
70 68
XZ1A XZ1A
XZ1B XZ1B
40 41
XS9C
65
XS9B
XS9A
6766
无线网络管理系统
XS9D
64
XS9E
62
设计 共1张第1张
时间 修改 时间 审核 时间 批准 图号 HYZX7500HD-08-000
图纸名称 主原理图
时间
TM1
XS1C XS1D
XS3E
G1
XS3A
G2
XS4G
G3
XS4A
G4
XS3F
E1
XS3B
E2
XS4H
E3
XS4B
E4
XS1A XS1B
TA1
XS8AXS8BXS8E XS8F
AP3（PT01）
XS2E XS2BXS2A XS2F
KT1 KT2
68697071
TAa TAb KTa KTb
XS8D
XS2D
72
+ 15V-1 5VGDGNDWD
Ga Ea Eb Gb Gc Ec Ed Gd
99 98
96
97
6869707172
R9 R10 R11 R12
RCAP1 RCAP1
XS9F
63
10 11
42 43
XS2A 55 XS2C XS2B 54
53
焊枪开关
XS5A XS5E
14 17

9
The final explanation rights reserved to Westweld /Huayuan Company!
If there is any changes in the user’s manual, forgive not to inform separately!
Westweld Ltd
4-23-4, No.51, Xuefu Avenue, Nanan, Chongqing, China
E-mail: [e-mail] [e-mail]
www.westweld.com