1. Introduction
This manual provides essential information for the safe and efficient operation, maintenance, and troubleshooting of your JASIC ZX7-400D (Z290II) Portable Industrial Inverter DC Manual Arc Welding Machine. Please read this manual thoroughly before operating the machine to ensure proper usage and to prevent injury or damage.
2. Safety Instructions
Always adhere to general welding safety practices. Failure to do so can result in serious injury or death.
- Electric Shock: Welding current can kill. Do not touch live electrical parts. Wear dry, insulating gloves and protective clothing.
- Fumes and Gases: Welding fumes and gases can be hazardous to your health. Keep your head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone.
- Arc Rays: Arc rays can burn eyes and skin. Wear a welding helmet with a proper shade of filter lens to protect your face and eyes when welding or watching. Wear appropriate protective clothing to protect your skin.
- Fire and Explosion: Welding sparks can cause fire or explosion. Keep flammable materials away from the welding area. Have a fire extinguisher nearby.
- Hot Parts: Hot parts can cause severe burns. Do not touch hot parts with bare hands.
3. Setup
3.1 Unboxing and Inspection
Carefully remove the welding machine and all accessories from the packaging. Inspect the machine for any signs of damage during transit. If any damage is found, do not operate the machine and contact your supplier immediately.
3.2 Placement
Place the welding machine on a stable, level surface. Ensure adequate ventilation around the machine to prevent overheating. Do not block the air vents located on the front, sides, and rear of the unit.
3.3 Power Connection
The ZX7-400D (Z290II) supports both 220V and 380V input voltages. Ensure the power supply matches the machine's requirements and that the circuit breaker on the rear panel is in the 'OFF' position before connecting to power.
Figure 1: Rear panel with power input and circuit breaker.
3.4 Electrode Holder and Ground Clamp Connection
Connect the electrode holder cable and the ground clamp cable to the quick plug terminals on the front panel of the welding machine. Ensure a secure connection. The machine comes with a pair of quick plugs as standard accessories.
Figure 2: Front panel with quick plug terminals.
4. Operating Instructions
4.1 Powering On
After ensuring all connections are secure and the work area is safe, switch the circuit breaker on the rear panel to the 'ON' position. The digital display on the front panel will illuminate.
4.2 Setting Welding Parameters
Use the control knob on the front panel to adjust the welding current (Amperage). The digital display will show the selected current. The welding current/voltage range is 40-270A. Select an appropriate current based on the electrode diameter and material thickness.
Figure 3: Front panel display and controls.
4.3 Electrode Selection
The machine is designed to work with electrode diameters ranging from 2.5mm to 4.0mm. Choose the correct electrode for your welding task.
4.4 Welding Process
Once parameters are set, you can begin welding. Always wear full personal protective equipment (PPE) including a welding helmet, gloves, and protective clothing.
4.5 Powering Off
After completing your welding tasks, switch the circuit breaker on the rear panel to the 'OFF' position. Disconnect the power cable from the main supply.
5. Maintenance
Regular maintenance ensures the longevity and optimal performance of your welding machine.
- Cleaning: Periodically clean the exterior of the machine and ensure the cooling fan vents are free from dust and debris. Use compressed air to gently clear internal dust if accessible, ensuring the machine is unplugged.
- Cable Inspection: Regularly inspect all cables (power, electrode holder, ground clamp) for cuts, fraying, or damaged insulation. Replace damaged cables immediately.
- Connection Check: Ensure all electrical connections, especially the quick plugs, are tight and free from corrosion.
- Storage: Store the machine in a dry, clean environment, away from excessive dust, moisture, and corrosive materials.
6. Troubleshooting
This section outlines common issues and their potential solutions. For problems not listed here, contact qualified service personnel.
| Problem | Possible Cause | Solution |
|---|---|---|
| Machine does not power on | No power supply; Circuit breaker tripped; Faulty power cable | Check power outlet; Reset circuit breaker; Inspect/replace power cable. |
| No welding output | Poor ground connection; Incorrect current setting; Faulty electrode holder/cable | Ensure good ground contact; Adjust current; Check/replace electrode holder/cable. |
| Machine overheats (thermal overload indicator on) | Exceeded duty cycle; Blocked ventilation; High ambient temperature | Allow machine to cool down; Clear ventilation openings; Operate in a cooler environment. |
| Unstable arc / Poor weld quality | Incorrect current; Improper electrode; Contaminated workpiece; Poor technique | Adjust current; Use correct electrode; Clean workpiece; Improve welding technique. |
7. Specifications
The following table details the technical specifications for the JASIC ZX7-400D (Z290II) welding machine:
| Attribute | Specification |
|---|---|
| Model | ZX7-400D (Z290II) |
| Brand | JASIC (SEVENMOONS) |
| Origin | Mainland China |
| Rated Input Voltage | 220V/380V |
| Input Frequency | 50-60Hz |
| Max. Load Power Capacity | 11.5KVA |
| Rated Output Voltage | 65 V |
| Rated Output Current | 60A |
| Welding Current/Voltage Range | 40-270A |
| Thrust Adjustment Range | 40-270A |
| No-load Voltage | 65V |
| No-load Loss | 60W |
| Rated Duty Cycle @40°C | 40% |
| Load Duration Rate | 85% |
| Efficiency | 85% |
| Power Factor | 0.73 |
| Electrode Diameter | 2.5-4.0mm |
| Insulation Class | Class F |
| Shell Protection Class | IP21 |
| Protection Level | IP21S |
| Motor Type | DC MOTOR |
| Feature | Integrated Display |
| Product Dimensions (L*W*H) | 660*260*490mm |
| Product Weight | 13.1 KG |
| Package Weight | 14.5 KG |
| Usage | Welding (Construction/Equipment Installation/Civil Decoration/Home Maintenance/Mechanical Repair) |
| Machinery Test Report | Provided |
| Video Outgoing-Inspection | Provided |
| Standard Accessories | A pair of quick plug |
8. User Tips
- Cleanliness is Key: Always ensure your workpiece is clean and free of rust, paint, or oil for the best weld quality.
- Practice Makes Perfect: If you are new to welding, practice on scrap pieces of metal to get a feel for the machine and different settings before working on important projects.
- Ventilation: Even with a portable machine, good ventilation is crucial. Work in an open area or use local exhaust ventilation to minimize fume exposure.
- Ground Connection: A strong, clean ground connection is vital for a stable arc. Ensure the ground clamp is securely attached to bare metal on the workpiece or welding table.
9. Warranty and Support
The JASIC ZX7-400D (Z290II) welding machine comes with a 2-year warranty. For warranty claims or technical support, please contact your original point of purchase or the manufacturer's authorized service center. Keep your purchase receipt as proof of warranty.
The product includes a Machinery Test Report and Video Outgoing-Inspection, ensuring quality control prior to shipment.
