Top Gun I-ARC 140 Assembly instructions

Manual Guide
TOPGUNWELDING.COM.AU
I-ARC 140 / I-ARC 181
MMA STICK WELDER

II
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SAFETY INFORMATION
MACHINE SPECIFICATIONS
ARC WELDING TECHNIQUES
FIXES AND FAULTS
JOINT TYPES - BASIC THEORY
ACCESSORIES AND CONSUMABLES
INSTALLATION AND OPERATION
PAGE 2
PAGE 4
PAGE 5
PAGE 6
PAGE 7
PAGE 9
PAGE 10

2
Safety Info
WARNING
ARC WELDING HAZARDS
SAFETY INFO AND TIPS
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH .KEEP CHILDREN AWAY. IF WEARING A PACEMAKER KEEP
AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE
INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, damage to other equipment or property, if the operator
does not observe all safety rules and take precautionary measures.
Safe practices are developed from past experience in the use of welding and cutting equipment. These practices must be learnt
through study and training before using this equipment. Some of these practices apply to equipment connected to mains power;
others apply to engine driven equipment. Anyone not having extensive training in the safe and proper usage of welding and cutting
equipment, should not attempt to use this equipment without proper supervision.
Safe practices are outlined in the Australian Standard AS1674.2-2007 entitled; Safety in Welding and Allied processes Part 2: Electrical.
This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety
precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
Touching live electrical parts or components can potentially cause fatal shocks or severe burns.The electrode and work circuit is a live
electrical circuit when the output is connected and machine turned on.The input power circuit and machine internals are also live when
power is connected and turned on.
In semi-automatic or automatic wire welding (eg MIG), the wire, wire reel, drive roll housing and all metal parts touching the welding
wire are electrically live. Incorrectly installed or improperly grounded equipment is a potential hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating
mats or covers,
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lock input power disconnect
switch open or remove line fuses so power cannot be turned
on accidentally.
5. Properly install and ground this equipment according to its
Owners Manual and national, state and local codes.
6. Turn o all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip the holder
in water or any other liquid, to cool it or lay it down on the
ground or on the work surface. Do not touch the holders
connected to multiple welding machines at the same time
or touch other people with the holder or electrode.
8. Do not use worn, damaged , undersized or poorly spliced
cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (Earth) ground.
11. Do not touch electrode while in contact with the work
(Ground) circuit.
12. Use only well maintained equipment. Repair or replace
damaged parts at once.
13. In conned spaces or damp locations, do not use a welder
with an AC output unless it is equipped with a voltage
reduction device. Use equipment with a DC output.
14. Wear a safety harness to prevent falling if working above
oor level.
15. Keep all panels and covers securely in place.
*PLEASE NOTE THAT ANY MODIFICATION TO THE OPERATION OF THE MACHINE IN ANY PART SMALL
OR LARGE MAY INCREASE THE RISK OF HARM OR SAFE OPERATION AND VOID WARRANTY.

3
ARC RAYS FIRE & EXPLOSIONS
SPARKS AND HOT METAL
FUMES AND GASES
ARC RAYS can burn eyes and skin; NOISE can damage hearing.
ARC RAYS from the welding process produce an intense heat
and strong ultraviolet rays that can burn eyes and skin. Noise
from some processes can damage hearing.
The WELDING operation can potentially cause re or an
explosion as Sparks and spatter are emitted from the welding
arc. The ying sparks and hot metal, weld spatter, hot
workpiece and hot equipment have potential to cause res
and burns. Accidental contact of the wire or electrode to
grounded metal objects may cause sparks, overheating or re.
Chipping and grinding can cause ying metal. As welds cool,
they can throw o slag.
FUMES and GASES can be hazardous to your health and
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
1. Use a Welding Helmet or Welding Face Shield tted with
proper shade or lter for the application, to protect your
face and eyes when welding or watching someone else weld.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens and/or barriers, to protect others from
ash and glare and warn others not to watch the arc.
4. Wear protective clothing made from durable, ame resistant
material (eg: wool and leather) and appropriate foot protection.
5. Use approved ear plugs or ear mus if the noise level is high.
6. Never wear contact lenses while welding.
1. Protect yourself and others from ying sparks and hot metal.
2. Do not weld where ying sparks can strike ammable material.
3. Remove all ammables within 35ft (10.7m) of the welding arc.
If this is not possible, tightly cover them with an approved
containment method.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for re, and keep a re extinguisher nearby.
6. Be aware that welding on a ceiling, oor, bulk-head or partition
can cause a re on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect the work cable to the workpiece as close to the welding
area as practical, to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and re
hazards.
9. Do not use a welder to thaw frozen pipes.
1. Wear an approved face shield, safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
1. Keep your head out of the path of fumes as best you can. Do not
breathe the fumes if it can be avoided.
2. If inside, ventilate the area and/or use exhaust at or as close to
the arc as possible to remove the welding fumes/gases.
3. If ventilation is poor, use an approved air supplied or ltered
respirator.
4. Read the Material Safety Data Sheets (MSDS’s) and the
manufacturer’s instruction for metals, consumables, coatings
and cleaners.
5. Work in conned space only if it is well ventilated, or while
wearing an air supplied or ltered respirator. Shielding gases
used for welding can displace air causing injury or death. Be
sure the breathing air is safe.
6. Do not weld in locations near ammable liquids (eg. degreaser,
paint, aerosol storage or cleaning chemicals), as the heat and
rays of the arc could react with vapours to form highly toxic and
irritating or ammable gases.
7. Do not weld on coated metals, such as galvanized, lead or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated and if necessary, while
wearing an air supplied or ltered respirator. The coatings and
any metals containing these elements can give o toxic fumes if
welded.
8. Protect yourself and others from ying sparks and hot metal.
9. Do not weld where ying sparks can strike ammable material.
10. Remove all ammables within a 35ft (10.7m) of the welding
arc. If this is not possible, tightly cover them with an approved
containment method.

4
This information can be found on top of the machine.
Specifications
MACHINE SPECS
I-ARC 140
I-ARC 180
DC MMA WELDING MACHINE
MODEL: I-ARC 140
70
140A
25.6V 23.4V24.4V
85A110A
15A/20.6V ~ 140A/25.6V
DC MMA WELDING MACHINE
MODEL: I-ARC 180
70
180A
27.2V 24.4V25.8V
110A145A
15A/20.8V ~ 180A/27.2V
Input Voltage (V) 240 A/C
50 Hz
15-140 A
35% @ 140A
60% @ 110A
100% @ 85A
4.2 Kg
340x155x230
3 Years
Frequency (Hz)
Output Current Range (A)
Rated Duty Cycle (%)
Machine Weight
Machine Dimensions (mm)
Warranty
Input Voltage (V) 240 A/C
50 Hz
15-180 A
35% @ 180A
60% @ 145A
100% @ 110A
4.2 Kg
340x155x230
3 Years
Frequency (Hz)
Output Current Range (A)
Rated Duty Cycle (%)
Machine Weight
Machine Dimensions (mm)
Warranty

5
ARC Welding Technique
FOR BEGINNERS
A Word To Beginners Striking An Arc
Arc Length
The Welder
Rate of Travel
For those who have not yet done any welding, the simplest way to
commence is to run beads on a piece of scrap plate. Use a mild
steel plate, around 6mm thick and a 3.2mm electrode.
Clean any paint, loose scale or other contaminants from the plate,
and set it rmly on the workbench so that welding can be carried
out in the downhand position.
Make sure that the work clamp is making good electrical contact
with the work piece, either directly or through the work table.
For light gauge material, always clamp the work lead directly to
the job, otherwise a poor circuit may result.
Practice this on a piece of scrap plate before going on to more
exacting work. You may at rst experience diculty due to the
tip of the electrode “sticking” to the workpiece. This is caused by
making too heavy a contact with the work and failing to withdraw
the electrode quickly enough. A low amperage will accentuate
this. The freezing-on of the tip may be overcome by scratching the
electrode along the surface of the workpiece in the same way a
match is struck.
As soon as the arc is established, maintain a 1.6mm to 3.2mm gap
between the burning electrode end and the parent metal. Draw
the electrode slowly along as it melts down.
Another diculty you may encounter is the tendency that after
the arc is “struck”, to withdraw the electrode so far that the arc is
broken again.
A little practice will remedy both the aforementioned faults.
The securing of an arc length necessary to produce a neat weld,
soon becomes almost automatic.
You will nd that a long arc produces more heat. A very long arc
produces a crackling or spluttering noise and the weld metal
comes across in large, irregular blobs. The weld bead is attened
and spatter will increase.
A short arc is essential if a high quality weld is to be obtained
although if it is too short, there is the danger of it being blanketed
by slag and the electrode tip being solidied in.
If this should happen, give the electrode a quick twist back over
the weld to detach it. Contact or “touch-weld” electrodes do not
stick in this way, and make welding much easier.
Place yourself in a comfortable position before beginning to weld.
Get a seat of suitable height and do as much work as possible
sitting down comfortably. Don’t hold your body tense. A taut
attitude of mind and a tense body will soon make you feel tired.
Relax and you will nd that the job becomes much easier. You
can add much to your peace of mind by wearing a leather apron
and gauntlets. You won’t be worrying then about being burnt or
sparks setting your clothes alight.
Place the work so that the direction of welding is across, rather
than to or from your body. The electrode holder lead should be
clear of any obstructions so that you can move your arm freely
along as the electrode burns down. If the lead is slung over your
shoulder, it allows greater freedom of movement and takes a lot
of weight o your hand.
Be sure the insulation on your cable and electrode holder is not
faulty, otherwise you are risking an electric shock.
After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same
rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead. The electrode is directed at the pool
at about 20’ from the vertical plane.
The rate of travel has to be adjusted so that a well-formed bead is produced. If the travel is too fast, the bead will be narrow and strung out
and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large.

6
Make sure that the supply voltage matches the voltage requirements indicated. (15% deviation is allowed)
If you increase the length of the leads, be aware that possible damage may occur with excessively long leads.
- Ground the unit with a minimum of 6mm² (10 gauge) wire to the earth ground as the drawing.
- Connect the earth lead connector to the negative (-) quick-connection terminal, and turn clockwise to tighten.
- Connect the electrode clamp holder to the positive (+) quick-connection terminal and turn clockwise to tighten.
Installation
AND OPERATION
CAUTION: Make sure the above connection for direct polarity welding; for inverse/reverse polarity , invert the connection: earth lead
CONNECTOR to the quick-connection positive (+) terminal and the electrode holder clamp connector to the negative (-) terminal.

7
Fault Resolution
Power indicator lit
Fan not running and no
Welding input
A. Ensure power is turned o.
B. Ensure power is connected properly.
C. Heat sensor resistance incorrect or faulty. (24V relay has a fault)
D. Power source board (Board has problem, no DC537V output voltage.)
i. Silicon bridge circuit faulty or cable is loose.
ii. Part of the circuit board burnt.
iii. Check cable between switch and power source board. Power board between
MOS board.
iv. Sub power source on control board faulty. Contact distributor or
manufacturer.
Fan running and Fault
indicator lit.
No output power.
A. Check all components are correctly connected.
B. Check if the output terminal has a broken circuit and poor connection.
C. Inverter circuit faulty;
1. If Fault indicator lit: MOS board faulty, check and replace.
2. If Fault indicator not lit:
i. Transformer on Middle Board faulty, measure primary inductance volume
and Q volume of main transformer by inductance bridge.
Primary volume of parallel circuit, L=1.2-2.0MH, Q>40 if inductance volume
and Q volume is low, replace it.
ii. Check the secondary rectier tube on the transformer. If faulty replace.
iii. Feedback circuit in fault.
Power indicator not lit,
fan not running and no
welding output.
A.) Make sure the power switch is turned o.
B.) Make sure power supply and all cables are securely connected and power
supply is working.
Power indicator lit, fan
not running and no weld-
ing output.
A. Connected to incorrect power source has enabled machine protection circuit,
connect to correct power supply and check machine for operation.
B. Input power not stable (input cable too small) or input cable incorrectly
connected to power supply has caused protective circuit to be enabled. Check
connections and turn o the machine for 5-10minutes. Turn the machine on and
check for operation.
C. Turning the machine power switch ON and OFF too quickly has enabled the
protection circuit. Turn the machine o for 5-10 minutes. Turn on and check for
operation.
D. Power supply cables/plugs are loose. Turn Machine o and Check for proper
connection of all power supply cables/plugs and check for operation.
Fixes and Faults
TROUBLESHOOTING

8
Fault Resolution
Fan running, welding cur-
rent not stable or out of
control, current varying
between high and low
amperage.
A. 1K potentiometer is faulty, replace
B. Output terminal is faulty or poorly connected.
Fan is running and Fault
indicator is lit but there
is no welding current.
A. Check if components have poor contact.
B. Check connection of output terminal and check for broken circuit or poor
connection.
C. Check voltage between PCB and MOS boards(VH-07)
(approx 380V DC)
D. If the green indicator light is not lit on MOS board, return to the distributor or
agent.
E. If the Control circuit faulty, please contact the distributor or agent.
Fan running and Fault
indicator is lit but no
output current.
A. Over current protection circuit enabled. Turn o the machine and wait 5-10
minutes. Once the Fault indicator is not lit, Inspect machine internally.
B. Overheat protection circuit is enabled. Wait 2-3 minutes.
C. Inverter circuit in fault.
1.) If the fault indicator is still lit, MOS damaged, check and replace.
2.) If Fault indicator not lit;
i. Middle board transformer potentially faulty. Measure primary inductance
volume and Q volume of main transformer by inductance bridge.
ii. Primary volume is parallel circuit, L=1.2-2.0Mh. Q>40 if inductance and Q
volume is low, Replace it.
iii. Secondary rectier tube of the transformer is faulty. Check for faults and
replace the rectier tube.
D. Feedback circuit is faulty.

9
Joint Preparation
Welding Position Arc Welding Practice
In many cases, It will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings,
etc, it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to
produce structurally sound joints.
In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces.
Typical joint designs are shown in Figure 6-10.
The electrodes dealt with in this publication can be used
in most positions, i.e. they are suitable for welding in at,
horizontal, vertical and overhead positions. Numerous
applications call for welds to be made in positions
intermediate between these.
The techniques used for arc welding are almost identical
regardless of what types of metals are being joined. Naturally
enough, dierent types of electrodes would be used for
dierent metals as described in the preceding section.

10
Accessories and Consumables
PARTS AND SPARES
Earth Clamps
300 Amp
400 Amp
500 Amp
ACCLP300
ACCLP400
ACCLP500
Magnetic Earth Clamps 300 Amp
800 Amp
MAWEC300
MAWEC800
Electrode Holders - Twist Lock
200 Amp
300 Amp
400 Amp
ACEHTL200
ACEHTL300
ACEHTL400
Electrode Holders - Tong Type
200 Amp
300 Amp
400 Amp
500 Amp
ACEHTT200
ACEHTT300
ACEHTT400
ACEHTT500
6013 General Purpose 2.5mm 0.5kg pack
3.2mm 0.5kg pack
CETG6013GP0525
CETG6013GP0532
316L-16 Stainless Steel 2.5mm 0.5kg pack
3.2mm 0.5kg pack
CETG316L160525
CETG316L160532
312-16 Dissimilar Metals 2.5mm 0.5kg pack
3.2mm 0.5kg pack
CETG312160525
CETG312160532
7016 Low Hydrogen 2.5mm 0.5kg pack
3.2mm 0.5kg pack
CETG70160525
CETG70160532
Hard Facing 3.2mm 0.5kg pack CETGHF0532
Cast Iron
Combo pack Contains:
5 x 2.4MM
5 x 3.2mm
10 x 4.0mm
CETGNIFECOMBO
Chipping Hammer Rubber Handle
Spring Handle
ACMCH1
ACMCH2
Welding Pliers 8” Welding Pliers TGACPLIER
Wire Brush
3 Row Steel
4 Row Steel
3 Row Stainless
4 Row Stainless
ACB3
ACB4
ACB421
ACB420
ELECTRODES
ACCESSORIES
HAND PIECE

11
Model Part No.
Topgun Warrior Series
Auto Darkening Welding Helmet
Gloss Black - TGHWARGBLK
Blue Inferno - TGHWARBLUINF
Red Inferno - TGHWARINFERNO
Carbon Fibre - TGHWARCFIBRE
Warrior Helmet Harness TGTHH
Warrior Helmet Inner Lens Pk5 TGHLWI
Warrior Helmet Outer Lens Pk5 TGHLWO
TITAN Helmet Harness TGTHH
TITAN Helmet Inner Lens Pk5 TGHLTI
TITAN Helmet Outer Lens Pk5 TGHLTO
Model Part No.
Topgun TITAN Series
Auto Darkening Welding Helmet
Shadow - TGHTSHAD
Cold Carbon - TGHTCCARB
Bionix - TGHTBION
Envious - TGHTENVI
Robot - TGHTROBO
Rich Smoke - TGHTRICH
Welding Jackets
Hi-Vis Welding Jacket
TGACWJHVL
TGACWJHVXL
TGACWJHVXXL
TGACWJHVXXXL
Professional Leather Welding
Jacket
TGACWJRBL
TGACWJRBXL
TGACWJRBXXL
TGACWJRBXXXL
Gloves
Blue/Yellow Welding Gloves TGACGBY
Gold/Red Welding Gloves TGACGRG
Premium Black/White TGACGBWP
Premium Black/Red TGACGBRP
Alumized TGACGAL
Welding Sleeves TGACSL1
Welding Apron TGACAP1
Welding Spats TGACSP1
Welding Hoods Leather
TGACLHOOD
Fire retardant cotton TGACPBHOOD
HELMETS
APPAREL

12

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