CIGWELD Transmig 185 Ultra Operating Manual
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CIGWELD Transmig 185 Ultra Operating Manual

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MULTI PROCESS
AUTO PROCESS
.
AUTO
3 1
IN
MIG STICK TIG
O
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MIG STICK TIG
Version No: AB | Issue Date: 05-07-2018 | Manual No: 0-5494
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LCD SCREEN
DIGITAL MIG GUN
4.3"
SET
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OPERATING MANUAL
AUTO SET WELDING INVERTER
SPOOL GUN
PLUG & PLAY
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+
COMPATIBLE
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WITH SGT250
*

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Do you have a question about the Transmig 185 Ultra and is the answer not in the manual?

Questions and answers

Clive Dickinson
April 12, 2025

The wire motor doesn’t feed the wire

User image 67fa66a109dfe
0
1 comments:
Mr. Anderson
April 12, 2025

The wire motor may not feed the wire on the CIGWELD Transmig 185 Ultra due to the following reasons:

1. Bent liner – This causes friction between the wire and the liner, reducing wire feedability.
2. Loose electrical connections – If the male plug is not securely inserted into the Dinse terminal, it can cause poor electrical contact, affecting operation.
3. Poor work lead connection – If the work lead is not properly connected to the workpiece or lacks a good connection, the system may not function correctly.

Ensuring proper liner condition, secure terminal connections, and a good work lead connection can help resolve wire feeding issues.

This answer is automatically generated

0
jeff barnes
May 14, 2025

using gas wire on MIG function pull trigger wire feeds out fine then after say 3 seconds wire speed triples to an unusable rate

0

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Related Manuals for CIGWELD Transmig 185 Ultra

Summary of Contents for CIGWELD Transmig 185 Ultra

  • Page 1 OPERATING MANUAL Transmig 185 Ultra AUTO SET WELDING INVERTER MULTI PROCESS AUTO PROCESS LCD SCREEN DIGITAL MIG GUN SPOOL GUN PLUG & PLAY AUTO 4.3” COMPATIBLE MIG STICK TIG MIG STICK TIG WITH SGT250 Version No: AB | Issue Date: 05-07-2018 | Manual No: 0-5494...
  • Page 2 Transmig 185 Ultra OPERATING MANUAL REGISTER YOUR WARRANTY ONLINE FOR YOUR CHANCE TO GREAT PRIZES http://warranties.cigweld.com.au Check out our online registration for the most up to date competitions and promotions PROTECT YOUR INVESTMENT Please register your warranty online immediately after purchase for complete warranty coverage and to guarantee your proof of purchase.
  • Page 3 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. CIGWELD is a Market Leading Brand of Arc Welding Products for ESAB. We are a mainline supplier to major welding industry sectors in the Asia Pacific and emerging global markets including; Manufacturing, Construction, Mining, Automotive, Engineering, Rural and DIY.
  • Page 4 While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5494 for: Cigweld Transmig 185 Ultra Inverter Plant Part Number W1006185 Published by: CIGWELD Pty Ltd...
  • Page 5 Brand name or trade mark Cigweld Manufacturer or his authorised representative established within the EEA Name, address, telephone No: Cigweld Pty Ltd 71 Gower Street Preston, Victoria, Australia, 3072 Phone: +61 3 9474 7400 The following harmonised standard in force within the EEA has been used in the design: AS 60974.1-2006, Arc Welding Equipment - Welding Power Sources (IEC 60974-1:2000, MOD)

  • Page 6: Table Of Contents

    4.01 Overview ......................4-1 4.02 Transmig 185 Ultra Power Source Controls and Features ....... 4-1 Control Knob (Refer to Figure 4-1) ............4-2 Wirespeed / Amperage Control (Refer to Figure 4-1) ....... 4-2 Voltage Control (Refer to Figure 4-1) ............4-2 Arc Control (Inductance) (Refer to Figure 4-1) .........
  • Page 7 Setup for SPOOL GUN MIG (GMAW) Welding with Gas Shielded Mig Wire . 5-16 5.14 MIG (GMAW/FCAW) Basic Welding Technique ..........5-18 5.15 Cigweld MIG Wire Selection Chart ..............5-23 5.16 MIG (GMAW/FCAW) Welding Troubleshooting ..........5-24 SECTION 6: TIG (GTAW) WELDING ................6-1 6.01...
  • Page 8 SECTION 9: KEY SPARE PARTS ................... 9-1 9.01 Tweco Professional Fusion DX250 Digital MIG Torch ........9-1 9.02 Power Source ....................9-2 APPENDIX: TRANSMIG 185 ULTRA CIRCUIT DIAGRAM ..........A-1 CIGWELD - LIMITED WARRANTY TERMS WARRANTY SCHEDULE – TRANSMIG 185 ULTRA...

  • Page 9: Arc Welding Safety Instructions And Warnings

    Transmig 185 Ultra OPERATING MANUAL SECTION 1: ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
  • Page 10 Transmig 185 Ultra OPERATING MANUAL 2. Wear approved safety glasses. Side shields recommended. 3. Use protective screens or barriers to protect others WARNING from flash and glare; warn others not to watch the arc. ARC RAYS can burn eyes and skin; NOISE can damage hearing.
  • Page 11 Transmig 185 Ultra OPERATING MANUAL 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. WARNING 4. Be alert that welding sparks and hot materials from...
  • Page 12 Transmig 185 Ultra OPERATING MANUAL 5. Use only correct shielding gas cylinders, The following is a quotation from the General regulators, hoses, and fittings designed for the Conclusions Section of the U.S. Congress, Office of specific application; maintain them and associated Technology Assessment, Biological Effects of Power parts in good condition.

  • Page 13: Principal Safety Standards

    Transmig 185 Ultra OPERATING MANUAL 1.02 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
  • Page 14 Transmig 185 Ultra OPERATING MANUAL This Page Intentionally Blank. GENERAL INFORMATION Manual 0-5494...

  • Page 15: Introduction

    Additional copies of this manual may be purchased by contacting Cigweld at the address and phone number for your location listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment identification numbers.

  • Page 16: Symbol Chart

    Transmig 185 Ultra OPERATING MANUAL 2.04 Symbol Chart Note that only some of these symbols will appear on your model. Single Phase Wire Feed Function Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter-...

  • Page 17: Description

    Pro! You set the process and the Ultra will do the rest! The Cigweld Transmig 185 Ultra takes the guess work out of welding with an impressive AUTO SET function The following instructions detail how to correctly...

  • Page 18: Transporting Methods

    Use handcart or similar device of adequate capacity. If using a fork lift vehicle, place and secure unit on a proper skid before transporting. 2.08 Packaged Items Transmig 185 Ultra Plant (Part No. W1006185) • Transmig 185 Inverter Power Source • Tweco Fusion DX250 MIG Torch, 3m •...

  • Page 19: Specifications

    Transmig 185 Ultra OPERATING MANUAL 2.10 Specifications Description Transmig 185 Ultra Transmig 185 Ultra Plant Part Number W1006185 Power Source Dimensions H520mm x W220mm x D420mm Power Source Weight 17.4kg Plant (Package) Weight 30.0kg Cooling Fan Cooled Welder Type Multi Process Inverter Power Source...
  • Page 20 Minimum Generator Recommendation at the Maximum Output Duty Cycle. Due to large variations in performance and specifications of different brands and types of generators, CIGWELD cannot guarantee full welding output power or duty cycle on every brand or type of generator.

  • Page 21: Options And Accessories

    W4013801 TIG Torch 17V with 4m lead *Note: When using the SGT250 Spool Gun with the Transmig 185 Ultra the remote wirefeed speed control located on the Spool Gun is not operational. Wirefeed speed for the Spool Gun can only be adjusted using the 185 Ultra Power Source wire feed speed control.
  • Page 22 Prolite Auto-Darkening Welding Helmet - SPACE 454333 Prolite Auto-Darkening Welding Helmet - CLAW 454351 ProPlus Digital Auto-Darkening Welding Helmet - WEB 454353 ProPlus Digital Auto-Darkening Welding Helmet - PRO RACER Note: CIGWELD Electrodes see Page 7-15. Table 2-5 INTRODUCTION Manual 0-5494...

  • Page 23: Installation

    Transmig 185 Ultra OPERATING MANUAL SECTION 3: INSTALLATION G. The enclosure design of this power source meets 3.01 Environment the requirements of IP23S as outlined in AS60529. These units are designed for use in environments with This provides adequate protection against solid...

  • Page 24: Electromagnetic Compatibility

    Transmig 185 Ultra OPERATING MANUAL 6. Equipment used for calibration and 3.05 Electromagnetic Compatibility measurement. WARNING 7. The time of day that welding or other activities Extra precautions for Electromagnetic Compat- are to be carried out. ibility may be required when this Welding 8.
  • Page 25 Transmig 185 Ultra OPERATING MANUAL 3. Welding Cables The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level. 4. Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered.
  • Page 26 Transmig 185 Ultra OPERATING MANUAL This Page Intentionally Blank INSTALLATION Manual 0-5494...

  • Page 27: Operation

    The operator should use the welding current range values as a guide, then finally adjust the current setting to suit the application. 4.02 Transmig 185 Ultra Power Source Controls and Features 10.4 MILD STEEL 22.5...

  • Page 28: Control Knob (Refer To Figure 4-1)

    MIG welding applications. Note: When using the SGT250 Spool Gun with the Transmig 185 Ultra the remote wirefeed speed control located on the Spool Gun is not operational. Wirefeed speed for the Spool Gun can only be adjusted using the 185 Ultra Power Source wire feed speed control.

  • Page 29: Arc Control (Inductance) (Refer To Figure 4-1)

    Transmig 185 Ultra OPERATING MANUAL In Manual MIg Mode, the setup chart on the inside of the wire feed compartment door provides a brief summary of the required output settings for a basic range of MIG welding applications. In Auto MIG mode adjusting the Wire Feed Speed Control may also Synergically adjust the voltage value.

  • Page 30: Mig Torch Adaptor (Euro Style) (Refer To Figure 4-1)

    Transmig 185 Ultra OPERATING MANUAL MIG Torch Adaptor (Euro Style) (Refer to Figure 4-1) The MIG torch adaptor is the connection point for the MIG welding torch or SGT 250 Spool Gun if used. Connect the torch by pushing the torch connector into the brass torch adaptor firmly and screwing the plastic torch nut clockwise to secure in position.

  • Page 31: Remote Control Socket (Refer To Figure 4-1)

    Not Connected Table 4-1 *Note: When using the SGT250 Spool Gun with the Transmig 185 Ultra the remote wirefeed speed control located on the Spool Gun is not operational. Wirefeed speed for the Spool Gun can only be adjusted using the 185 Ultra Power Source wire feed speed control.

  • Page 32: Gas Inlet (Mig Mode Only) (Refer To Figure 4-1)

    14) Fan on Demand (Refer to Figure 4-1) The Transmig 185 Ultra is fitted with a fan on demand feature. Fan on demand automatically switches the cooling fan off when it is not required. This has two main advantages; (1) to minimize power consumption, and (2) to minimise the amount of contaminants such as dust that are drawn into the power source.

  • Page 33: Restore Factory Settings

    Transmig 185 Ultra OPERATING MANUAL Figure 4-5: Highlighted Information Icon Figure 4-6: Information Menu To consult welding setup diagrams, turn the Control Knob and select welding mode. Setup guide for the selected welding mode will be displayed. Press OK button on the screen or press Back Button in order to return to the upper level menu.

  • Page 34: Memory

    Transmig 185 Ultra OPERATING MANUAL Figure 4-13: Double Confirmation Memory Welding parameter for frequently used welding purposes can be saved to memory for future use. SAVE TO MEMORY button can be found on welding summary screen for MIG (GMAW / FCAW), TIG (GTAW) and STICK (MMAW) welding modes.

  • Page 35: Advanced Settings

    Transmig 185 Ultra OPERATING MANUAL To recall welding parameter which has been saved to Memory, select MEMORY from the Home page and press Control Knob. Figure 4-18: Memory Selected Figure 4-19: Select Memory to Recall Previous weld if selected will return to the previous weld screen either in MIG, TIG or Stick.

  • Page 36: Wirefeeder / Spool Gun (Mig Mode)

    Transmig 185 Ultra OPERATING MANUAL b. WIREFEEDER / SPOOL GUN (MIG mode) The Wirefeeder / Spool Gun selection is used in Mig Mode for wire feeding motor selection. When SPOOL GUN is ON and 8 pin plug of spool gun is connected to 8 pin socket on the front panel, the unit will detect the remote device and work accordingly.

  • Page 37: Arc Force

    Transmig 185 Ultra OPERATING MANUAL k. ARC FORCE In STICK (MMAW) mode, Arc Force control provides an adjustable amount of welding force (or “dig”) control. This feature can be particularly beneficial in providing the operator the ability to compensate for variability in joint fit-up in certain situations with particular electrodes. In general increasing the arc force control toward ‘100%’...

  • Page 38: Tweco Fusion Dx250 Digital Control Mig Torch, 3M, Euro (W4018900)

    4.04 TWECO Fusion DX250 Digital Control MIG Torch, 3M, Euro (W4018900) Tweco Fusion DX250 digital control MIG torch is supplied with Transmig 185 Ultra. It allows the user to adjust wire feed speed or voltage via buttons on the torch handle. Press and release button quickly for fine adjustment of wirespeed or voltage.

  • Page 39: Mig (Gmaw) Welding

    Transmig 185 Ultra OPERATING MANUAL SECTION 5: MIG (GMAW) WELDING 5.01 Shielding Gas Regulator/Flowmeter Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator/Flowmeter Safety This regulator/flowmeter is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 40 Transmig 185 Ultra OPERATING MANUAL Art: A-05087 Figure 5-1: Fit Regulator/flowmeter to Cylinder Installation 1. Remove cylinder valve plastic dust seal. Clean the cylinder valve outlet of impurities that may clog orifices and damage seats before connecting the regulator/flowmeter. Crack the valve (open then close) momentarily, pointing the outlet away from people and sources of ignition.
  • Page 41 Transmig 185 Ultra OPERATING MANUAL Adjusting Flow Rate Art: A-05088_AB Figure 5-2: Adjust Flow Rate With the regulator/flowmeter ready for operation, adjust working flow rate as follows: 1. Slowly turn adjusting screw/knob in (clockwise) direction until the outlet gauge indicates the required flow rate.

  • Page 42: Attaching The Tweco Fusion Dx250 Digital Control Mig Torch (Euro)

    Transmig 185 Ultra OPERATING MANUAL 5.02 Attaching the Tweco Fusion DX250 Digital Control MIG Torch (Euro) Fit the MIG Torch to the power source by pushing the MIG torch connector into the MIG torch adaptor and screwing the plastic torch nut clockwise to secure the MIG torch to the MIG torch adaptor.

  • Page 43: Installing Handispool (200Mm Diameter)

    Transmig 185 Ultra OPERATING MANUAL 5.04 Installing Handispool (200mm diameter) As delivered from the factory, the unit is set for a Handispool (200mm diameter). In order to re-fit a 200mm spool assemble parts in the sequence shown below in Figure 5-5.

  • Page 44: Inserting Wire Into The Wire Feed Mechanism

    Transmig 185 Ultra OPERATING MANUAL 5.05 Inserting Wire into the Wire Feed Mechanism Release the tension from the pressure roller by turning the adjustable wire drive tension screw in an anti- clockwise direction. Then to release the pressure roller arm pull the pressure roller arm tension screw forward to release the pressure roller arm (Figure 5-6).

  • Page 45: Feed Roller Pressure Adjustment

    Transmig 185 Ultra OPERATING MANUAL 5.06 Feed Roller Pressure Adjustment The pressure (top) roller applies pressure to the grooved feed roller via an adjustable pressure screw. These devices should be adjusted to a minimum pressure that will provide satisfactory WIREFEED without slippage. If slipping occurs, and inspection of the wire contact tip reveals no wear, distortion or burn back jam, the conduit liner should be checked for kinks and clogging by metal flakes and swarf.

  • Page 46: Wire Reel Brake

    5.01) then connect the shielding gas hose from the shielding gas regulator / flowmeter outlet to the quick connect Shielding Gas Inlet fitting gas on the rear of the Transmig 185 Ultra Power Source. Ensure that the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect fitting "locks"...
  • Page 47 Transmig 185 Ultra OPERATING MANUAL F. Place the MIG wire spool onto the spool holder. L. Select material thickness. Refer to Sections 5.03 for 100mm diameter spools or 5.04 for 200mm diameter spools. G. Feed wire through the wire drive mechanism. Refer to Section 5.05.

  • Page 48: Setup For Auto Set (Synergic) Mig (Fcaw) Welding With Gasless Mig Wire

    Transmig 185 Ultra OPERATING MANUAL O. Actual welding amperage and voltage will be displayed during welding and held for 10 seconds after welding. Figure 5-17: Welding Screen Shielding Gas Hose Shielding Gas Cylinder 240VAC, 10A Mains Supply Positive Welding Terminal (+)
  • Page 49 Transmig 185 Ultra OPERATING MANUAL F. Place the MIG wire spool onto the spool holder. L. Select welding wire diameter. Refer to Sections 5.03 for 100mm diameter spools or 5.04 for 200mm diameter spools. G. Feed wire through the wire drive mechanism. Refer to Section 5.05.

  • Page 50: Setup For Manual Mig (Gmaw) Welding With Gas Shielded Mig Wire

    Transmig 185 Ultra OPERATING MANUAL P. Actual welding amperage and voltage will be displayed during welding and held for 10 seconds after welding. Figrue 5-26: Welding Screen 240VAC, 10A Mains Supply Positive Welding Terminal (+) Negative Welding MIG Torch Terminal (-)
  • Page 51 Shielding Gas Inlet fitting gas on the rear of the Transmig 185 Ultra Power Source. Ensure that the shielding gas hose connection is sufficiently tight at the regulator connection and the quick connect fitting "locks"...

  • Page 52: Setup For Manual Mig (Fcaw) Welding With Gasless Mig Wire

    Transmig 185 Ultra OPERATING MANUAL Shielding Gas Hose Shielding Gas Cylinder 240VAC, 10A Mains Supply Positive Welding Terminal (+) Shielding Gas Hose Fitted with Quick Connect MIG Torch Negative Welding Polarity Lead MIG Torch Terminal (-) Supply Input Lead A-13705...
  • Page 53 Transmig 185 Ultra OPERATING MANUAL I. Select MIG Manual Set mode from home page. Welding summary screen displays preset value of wire feed speed, voltage and arc control. As a guide for the welding parameter settings for the welding job refer to the Weld Guide located on the inside of the wirefeed compartment door.Welding current and voltage will...

  • Page 54: Setup For Spool Gun Mig (Gmaw) Welding With Gas Shielded Mig Wire

    NOTE! When using the SGT250 Spool Gun with the Transmig 185 Ultra the remote wirefeed speed control located on the Spool Gun is not operational. Wirefeed speed for the Spool Gun can only be adjusted using the 185 Ultra Power Source wire feed speed control.
  • Page 55 NOTE! When using the SGT250 Spool Gun with the Transmig 185 Ultra the remote wirefeed speed control located on the Spool Gun is not operational. Wirefeed speed for the Spool Gun can only be adjusted using the 185 Ultra Power Source wire feed speed control.

  • Page 56: Mig (Gmaw/Fcaw) Basic Welding Technique

    Transmig 185 Ultra OPERATING MANUAL 5.14 MIG (GMAW/FCAW) Basic Welding Technique Two different welding processes are covered in this section (GMAW and FCAW), with the intention of providing the very basic concepts in using the Mig mode of welding, where a welding gun is hand held, and the electrode (welding wire) is fed into a weld puddle, and the arc is shielded by an inert welding grade shielding gas or inert welding grade shielding gas mixture.
  • Page 57 Transmig 185 Ultra OPERATING MANUAL The welding gun should be held at an angle to the weld joint. (see Secondary Adjustment Variables below) Hold the gun so that the welding seam is viewed at all times. Always wear the welding helmet with proper filter lenses and use the proper safety equipment.
  • Page 58 Transmig 185 Ultra OPERATING MANUAL Direction of Travel 30° to 60° Transverse Angle 5° to 15° Longitudinal Angle Art # A-08996 Figure 5-46 Distance from the MIG Torch Nozzle to the Work Piece The electrode wire stick out from the MIG Torch nozzle should be between 10mm to 20.0mm. This distance may vary depending on the type of joint that is being welded.
  • Page 59 Transmig 185 Ultra OPERATING MANUAL Secondary Adjustable Variables These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead formation. They are: 1. Stick-out (distance between the end of the contact tube (tip) and the end of the electrode wire). Maintain at about 10mm stick-out.
  • Page 60 Transmig 185 Ultra OPERATING MANUAL Establishing the Arc and Making Weld Beads Before attempting to weld on a finished piece of work, it is recommended that practice welds be made on a sample metal of the same material as that of the finished piece.

  • Page 61: Cigweld Mig Wire Selection Chart

    Handispool 5kg 720159 used for welding copper-silicon alloys in hot water systems, heat exchangers and marine MIG WIRE components. NOTE: MINISPOOL = 100MM DIAMETER, HANDISPOOL = 200MM DIAMETER Table 5-1: Cigweld MIG Wire Selection Chart Manual 0-5494 5-23 MIG (GMAW) WELDING...

  • Page 62: Mig (Gmaw/Fcaw) Welding Troubleshooting

    Transmig 185 Ultra OPERATING MANUAL 5.16 MIG (GMAW/FCAW) Welding Troubleshooting Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then work through to the MIG torch. There are two main areas where problems occur with GMAW, Porosity and...
  • Page 63 Transmig 185 Ultra OPERATING MANUAL Solving Problems Beyond the Welding Terminals - Inconsistent Wire Feed Wire feeding problems can be reduced by checking the following points. FAULT CAUSE 1 Feed roller driven by motor in the Wire spool brake is too tight.
  • Page 64 B Low primary voltage B Contact supply authority. C Fault in power source C Have an Accredited CIGWELD Service Provider to test then replace the faulty component. 8 Arc does not have The MIG torch has been Connect the MIG torch to the positive (+) welding...

  • Page 65: Tig (Gtaw) Welding

    Transmig 185 Ultra OPERATING MANUAL SECTION 6: TIG (GTAW) WELDING 6.01 Shielding Gas Regulator/Flowmeter Operating Instructions WARNING This equipment is designed for use with welding grade (Inert) shielding gases only. Shielding Gas Regulator/Flowmeter Safety This regulator/flowmeter is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it.
  • Page 66 Transmig 185 Ultra OPERATING MANUAL User Responsibilities This equipment will perform safely and reliable only when installed, operated and maintained, and repaired in accordance with the instructions provided. Equipment must be checked periodically and repaired, replaced, or reset as necessary for continued safe and reliable performance. Defective equipment should not be used.
  • Page 67 Transmig 185 Ultra OPERATING MANUAL Operation With the regulator/flowmeter connected to cylinder or pipeline, and the adjustment screw/knob fully disengaged, pressurize as follows: 1. Stand to one side of regulator/flowmeter and slowly open the cylinder valve. If opened quickly, a sudden pressure surge may damage internal regulator/flowmeter parts.

  • Page 68: Setup For Tig (Gtaw) Auto Set Welding

    Transmig 185 Ultra OPERATING MANUAL 6.02 Setup for TIG (GTAW) Auto Set Welding A. Switch the Power Source On/Off switch located on the rear of the Power Source to the OFF position. B. Connect the TIG Torch to the negative welding terminal (-). Welding current flows from the power source via Dinse terminals.
  • Page 69 Transmig 185 Ultra OPERATING MANUAL H. The 'TIG Setup Guide screen' will be displayed for 10 seconds. To move on to the next screen immediately - press the Control Knob. Figure 6-5: TIG Setup Guide Screen I. Select welding material type and tungsten electrode diameter.

  • Page 70: Setup For Tig (Gtaw) Manual Set Welding

    Work lead TIG Torch A-13707 Note: For recommended Cigweld Genuine TIG Torch refer to Options and Accessories Table in Section 2.11. Figure 6-12: Setup for Lift TIG (GTAW) Welding 6.03 Setup for TIG (GTAW) Manual Set Welding A. Switch the Power Source On/Off switch located on the rear of the Power Source to the OFF position.
  • Page 71 Transmig 185 Ultra OPERATING MANUAL D. Connect the TIG torch trigger switch via the 8 pin socket located on the front of the power source as shown below. The TIG torch will require a trigger switch to operate in Lift TIG Mode. Note that Remote Current Control feature is not available for 185 Ultra.
  • Page 72 TIG torch trigger connection. Work lead TIG Torch A-13707 Note: For recommended Cigweld Genuine TIG Torch refer to Options and Accessories Table in Section 2.11. Figure 6-18: Setup for Lift TIG (GTAW) Welding TIG (GTAW) WELDING Manual 0-5494...

  • Page 73: Tig (Gtaw) Basic Welding Technique

    Transmig 185 Ultra OPERATING MANUAL 6.04 TIG (GTAW) Basic Welding Technique Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten Inert Gas) as it is commonly referred to, is a welding process in which fusion is produced by an electric arc that is established between a single tungsten (non- consumable) electrode and the work piece.
  • Page 74 Grey magnesium and their range, Narrower more alloys concentrated arc. Table 6-3 NOTE! The Transmig 185 Ultra Inverter is not suited for AC Tig welding. TIG Welding Filler Rods Comweld Aust Std AWS Std Part No. Part No. Part No.

  • Page 75: Tig (Gtaw) Welding Problems

    Transmig 185 Ultra OPERATING MANUAL TIG Welding is generally regarded as a specialised process that requires operator competency. While many of the principles outlined in the previous Arc Welding section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this Operating Manual. For further information please refer to www.
  • Page 76 9 Arc start is not smooth. A Tungsten electrode A Select the right size electrode. Refer to is too large for the Table 6-1 Cigweld Electrode Selection welding current. Chart. B The wrong electrode B Select the right electrode type. Refer to...

  • Page 77: Stick (Mmaw) Welding

    Transmig 185 Ultra OPERATING MANUAL SECTION 7: STICK (MMAW) WELDING 7.01 Setup for STICK Auto Set (MMAW) Welding A. Switch the Power Source On/Off switch located on the rear of the Power Source to the OFF position. B. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer.
  • Page 78 Transmig 185 Ultra OPERATING MANUAL G. Select electrode type and diameter. Figure 7-4: STICK Electrode Menu Figure 7-5: STICK Electrode Diameter Menu H. Preset welding conditions will be displayed on welding summary screen. If necessary adjust arc force in Advanced Settings. Refer to Section 4.03.4 for detailed explanation of advanced features.

  • Page 79: Setup For Stick (Mmaw) Manual Set Welding

    Transmig 185 Ultra OPERATING MANUAL 7.02 Setup for STICK (MMAW) Manual Set Welding A. Switch the Power Source On/Off switch located on the rear of the Power Source to the OFF position. B. Connect the Electrode Holder lead to the positive welding terminal (+). If in doubt, consult the electrode manufacturer.

  • Page 80: Stick (Mmaw) Basic Welding Technique

    Electrodes are generally connected to the ELECTRODE HOLDER with the Electrode Holder connected positive polarity. The WORK LEAD is connected negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet or your nearest Accredited CIGWELD Distributor. Effects of Arc Welding Various Materials A.
  • Page 81 Transmig 185 Ultra OPERATING MANUAL C. Cast Iron Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white- heart malleable, due to the porosity caused by gas held in this type of iron.
  • Page 82 Transmig 185 Ultra OPERATING MANUAL Art A-07691 Figure 7-17: Vertical Position, Butt Weld Art # A-07692 Figure 7-18: Vertical Position, Fillet Weld Art# A-07693 Figure 7-19: Overhead Position, Butt Weld Art # A-07694 Figure 7-20: Overhead Position, Fillet Weld MANUAL ARC (MMAW) WELDING...
  • Page 83 Transmig 185 Ultra OPERATING MANUAL Joint Preparations 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 sound joints.
  • Page 84 Transmig 185 Ultra OPERATING MANUAL 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 obstruction so that you can move your arm freely along as the electrode burns down.
  • Page 85 Transmig 185 Ultra OPERATING MANUAL A. Butt Welds Set up two plates with their edges parallel, as shown in Figure 7-23, allowing 1.6mm to 2.4mm gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment.
  • Page 86 Transmig 185 Ultra OPERATING MANUAL 45° from vertical 60° - 70° from line of weld Art # A-07699_AB Figure 7-25: Electrode Position for HV Fillet Weld Art # A-07700_AB Figure 7-26: Multi-runs in HV Fillet Weld C. Vertical Welds 1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position.
  • Page 87 Transmig 185 Ultra OPERATING MANUAL Art # A-07702 Figure 7-28: Multi Run Vertical Fillet Weld Art # A-07703 Figure 7-29: Examples of Vertical Fillet Welds 2. Vertical Down The Ferrocraft 21 electrode makes welding in this position particularly easy. Use a 3.2mm electrode at 100 amps.
  • Page 88 Transmig 185 Ultra OPERATING MANUAL Distortion Distortion in some degree is present in all forms of welding. In many cases it is so small that it is barely perceptible, but in other cases allowance has to be made before welding commences for the distortion that will subsequently occur.
  • Page 89 Transmig 185 Ultra OPERATING MANUAL Overcoming Distortion Effects There are several methods of minimizing distortion effects. A. Peening This is done by hammering the weld while it is still hot. The weld metal is flattened slightly and because of this the tensile stresses are reduced a little. The effect of peening is relatively shallow, and is not advisable on the last layer.
  • Page 90 Transmig 185 Ultra OPERATING MANUAL Art # A-07709 Figure 7-35: Examples of Distortion Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool. Figure 7-36: Welding Sequence # A-07711_AB Figure 7-37: Step back Sequence...

  • Page 91: Electrode Selection Chart

    Stainless Steel type for welding of matching Mo bearing 3.2mm 2.5 kg 611663 316L-17 grades, 316 and 316L. 2.5/3.2mm Blisterpack 322215 4.0mm 2.5 kg 611664 Table 7-1: Cigweld Electrode Selection Chart continued over page Manual 0-5494 7-15 MANUAL ARC (MMAW) WELDING...

  • Page 92: Stick (Mmaw) Welding Troubleshooting

    “wetting” action than Castcraft 55. 4.0mm 2.5 kg 611734 Table 7-2: Cigweld Electrode Selection Chart Further information on CIGWELD electrodes can be found at the website www.cigweld.com.au 7.05 Stick (MMAW) Welding Troubleshooting FAULT CAUSE REMEDY 1 Welding current...
  • Page 93 Transmig 185 Ultra OPERATING MANUAL Art # A-05866_AC Incorrect Sequence Insufficient Gap Figure 40: Example of insufficient gap or incorrect sequence FAULT CAUSE REMEDY 4 A groove has been A Welding current is too A Reduce welding current. formed in the base high.
  • Page 94 Transmig 185 Ultra OPERATING MANUAL FAULT CAUSE REMEDY 6 Gas pockets or A High levels of sulphur in A Use an electrode that is designed for high voids in weld steel. sulphur steels. metal (porosity) B Electrodes are damp. B Dry electrodes before use.

  • Page 95: Routine Service Requirements And Power Source Problems

    There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
  • Page 96 2. The earth terminal of the associated plug of a transportable power source Note that due to the dangers of stray output currents damaging fixed wiring, the integrity of fixed wiring supplying Cigweld welding power sources should be inspected by a licensed electrical worker in accordance with the requirements below - 1.
  • Page 97 Output current (A) to be checked to ensure it falls within applicable Cigweld power source specifications Output Voltage (V) to be checked to ensure it falls within applicable Cigweld power source specifications Motor Speed (RPM) of wire drive motors to be checked to ensure it falls within required Cigweld power source / wire feeder specifications Accuracy of digital meters to be checked to ensure it falls within applicable Cigweld power source specifications...

  • Page 98: Cleaning The Welding Power Source

    There are extremely dangerous voltage and power levels present inside this Inverter Power Source. Do not attempt to open or repair unless you are an accredited CIGWELD Service Provider. Disconnect the Welding Power Source from the Mains Supply Voltage before disassembling.
  • Page 99 (burn-back jam). contact tip. Replace faulty components. D Internal fault in power D Have an Accredited CIGWELD source Service Provider investigate the fault. Welding wire continues to A Trigger mode selection...
  • Page 100 Transmig 185 Ultra OPERATING MANUAL FAULT CAUSE REMEDY Welding arc cannot be A MIG torch polarity lead Connect the MIG torch polarity established in MIG mode. is not connected into a lead to either the positive welding output terminal. welding output terminal or the negative welding output terminal as required.

  • Page 101: Key Spare Parts

    Transmig 185 Ultra OPERATING MANUAL SECTION 9: KEY SPARE PARTS 9.01 Tweco Professional Fusion DX250 Digital MIG Torch MIG Torch Part No: W4018900 A-13709 Figure 9-1 TWECO FUSION DX250 DIGITAL MIG TORCH PARTS ITEM PART NO. DESCRIPTION OTW22/50 Nozzle 13mm...

  • Page 102: Power Source

    Transmig 185 Ultra OPERATING MANUAL 9.02 Power Source A-13710 Figure 9-2 TRANSMIG 185 ULTRA POWER SOURCE SPARE PARTS ITEM PART NUMBER DESCRIPTION W7005570 PCBA Power W7005571 PCBA Control W7005607 PCBA Spool Gun W7005572 PCBA LCD Display W7005573 LCD Screen 4.3 Inch...
  • Page 103 Transmig 185 Ultra OPERATING MANUAL ITEM PART NUMBER DESCRIPTION W7005629 Circuit Breaker, 4A W7005635 Latch, Door W7005579 Handle W7005586 LCD Screen Protector Lens Frame W7005585 Clear LCD Screen Protector Lens (not shown) Table 9-2 Manual 0-5494 KEY SPARE PARTS...
  • Page 104 Transmig 185 Ultra OPERATING MANUAL This Page Intentionally Blank. KEY SPARE PARTS Manual 0-5494...

  • Page 105: Appendix: Transmig 185 Ultra Circuit Diagram

    Transmig 185 Ultra OPERATING MANUAL APPENDIX: TRANSMIG 185 ULTRA CIRCUIT DIAGRAM O C 2 G N D +15V +15V +24V +24V G N D G N D -24V -24V +24V +24V G N D G N D G N D...

  • Page 106: Cigweld - Limited Warranty Terms

    Any claim under this warranty must be made within the warranty period which commences on the date of purchase of the product. To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Ac- credited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.
  • Page 107 * No employee, agent, or representative of CIGWELD is authorized to change this warranty in any way or grant any other warranty, and CIGWELD shall not be bound by any such attempt. Correction of non- conformities, in the manner and time provided herein, constitutes fulfilment of CIGWELD’s obligations to purchaser with respect to the product.
  • Page 108 CIGWELD Pty Ltd Malaysia Indonesia CIGWELD An ESAB Brand Lot 151, Jalan Industri 3/5A JL Akasia II Blok A-05 No. 10A 71 Gower Street, Preston VIC 3072 Australia Rawang Integrated Industrial Park, Delta Silicon - Lippo Cikarang Customer Care Jln Batu Arang...

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