CIGWELD Transmig 185 Ultra User manual

OPERATING MANUAL
AUTO SET WELDING INVERTER
Transmig 185 Ultra
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Version No: AB | Issue Date: 05-07-2018 | Manual No: 0-5494
^
.
O m
AUTO PROCESS
AUTO
SET
MIG STICK TIG
MULTI PROCESS
MIG STICK TIG
IN31
LCD SCREEN
4.3”
DIGITAL MIG GUN
V-
V+
WS
-WS +
SPOOL GUN
WITH SGT250*
COMPATIBLE
PLUG & PLAY

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OPERATING MANUAL
Transmig 185 Ultra
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OPERATING MANUAL Transmig 185 Ultra
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WE APPRECIATE YOUR BUSINESS!
Congratulations on your new CIGWELD product. We are proud to
have you as our customer and will strive to provide you with the
best service and reliability in the industry. This product is backed
by our extensive warranty and world-wide service network. To
locate your nearest distributor or accredited service provider call
Australia: 1300 654 674, International Customers: [phone], or
visit us on the web at www.cigweld.com.au
This Operating Manual has been designed to instruct you on the correct
use and operation of your CIGWELD product. Your satisfaction with this
product and its safe operation is our ultimate concern. Therefore please
take the time to read the entire manual, especially the Safety Precautions.
They will help you to avoid potential hazards that may exist when working
with this product.
We have made every effort to provide you with accurate instructions,
drawings, and photographs of the product(s) while writing this manual.
However errors do occur and we apologize if there are any contained in
this manual.
Due to our constant effort to bring you the best products, we may make
an improvement that does not get reflected in the manual. If you are ever
in doubt about what you see or read in this manual with the product you
received, then check for a newer version of the manual on our website or
contact our customer support for assistance.
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.
We distinguish ourselves from our competition through market-leading,
dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales
and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment for industry operators.

OPERATING MANUAL
Transmig 185 Ultra
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!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
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
CIGWELD An ESAB Brand
71 Gower Street,
Preston, Victoria, Australia, 3072
Tel: [phone] Fax: [phone]
www.cigweld.com.au
Copyright 2018
CIGWELD Pty Ltd
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Publication Date: 15-05-2018
Revision Date: 05-07-2018
Record the following information for Warranty purposes:
Where Purchased: ____________________________________
Purchase Date: ____________________________________
Equipment Serial #: ____________________________________

DECLARATION OF CONFORMITY
According to
The Arc Welding Power Source Directive AS 60974.1-2006 (equivalent to IEC 60974-1 Ed. 2.1)
The EMC Directive IEC 60974-10:2014 published on 06 February 2014
Type of equipment
Welding Inverter Power Source
Type designation etc.
Welding Performance
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: [phone]
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)
IEC 60974-10-2014, Arc Welding Equipment - Part 10: Electromagnetic Compatibility (EMC) Requirements
AS 1674.2-2007, Safety in Welding and Allied Processes
Additional Information: Restrictive use, Class A equipment, intended for use in location other than resid
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety
requirements stated above.
Date Signature Position
11-05-2018 Vice President,
Ken Konopa Global Welding
2018

TABLE OF CONTENTS
SECTION 1:
ARCWELDING SAFETY INSTRUCTIONS AND WARNINGS..................................... 1-1
1.01 Arc Welding Hazards....................................................................................... 1-1
1.02 Principal Safety Standards.............................................................................. 1-5
SECTION 2:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Symbol Chart.................................................................................................. 2-2
2.05 Description ..................................................................................................... 2-3
2.06 User Responsibility......................................................................................... 2-3
2.07 Transporting Methods..................................................................................... 2-4
2.08 Packaged Items .............................................................................................. 2-4
2.09 Duty Cycle....................................................................................................... 2-4
2.10 Specifications ................................................................................................. 2-5
2.11 Options and Accessories ................................................................................ 2-7
SECTION 3:
INSTALLATION ....................................................................................... 3-1
3.01 Environment ................................................................................................... 3-1
3.02 Location.......................................................................................................... 3-1
3.03 Ventilation....................................................................................................... 3-1
3.04 Mains Supply Voltage Requirements .............................................................. 3-1
3.05 Electromagnetic Compatibility ........................................................................ 3-2
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 Overview......................................................................................................... 4-1
4.02 Transmig 185 Ultra Power Source Controls and Features............................... 4-1
1) Control Knob (Refer to Figure 4-1)........................................................... 4-2
2) Wirespeed / Amperage Control (Refer to Figure 4-1) ............................... 4-2
3) Voltage Control (Refer to Figure 4-1) ....................................................... 4-2
4) Arc Control (Inductance) (Refer to Figure 4-1)......................................... 4-3
5) LCD Screen (Refer to Figure 4-1) ............................................................. 4-3
6) Back Button (Refer to Figure 4-1)............................................................. 4-3
7) MIG Torch Adaptor (Euro Style) (Refer to Figure 4-1) .............................. 4-4
8) Positive Welding Output Terminal (Refer to Figure 4-1) ........................... 4-4
9) MIG Torch Polarity Lead (Refer to Figure 4-1).......................................... 4-4
10) Remote Control Socket (Refer to Figure 4-1) ........................................... 4-5
11) Negative Welding Output Terminal (Refer to Figure 4-1) .......................... 4-5
12) Input Supply ON/OFF Switch (Refer to Figure 4-1)................................... 4-5
13) Gas Inlet (MIG mode only) (Refer to Figure 4-1)...................................... 4-6
14) Fan on Demand (Refer to Figure 4-1)....................................................... 4-6
15) Burnback Control (located in wirefeed compartment) (Refer to Figure 4-1)...
4-6
16) 4A Circuit Breaker (Refer to Figure 4-1) ................................................... 4-6
17) Hot Start Feature (Not Shown) ................................................................ 4-6
18) Anti Stick Feature (Not Shown) ............................................................... 4-6

TABLE OF CONTENTS
4.03 LCD Screen Operation .................................................................................... 4-6
1) Information .............................................................................................. 4-6
2) Restore Factory Settings .......................................................................... 4-7
3) Memory.................................................................................................... 4-8
4) Advanced Settings.................................................................................... 4-9
a. TRIGGER MODE (MIG and Lift TIG modes) ...................................... 4-9
b. WIREFEEDER / SPOOL GUN (MIG mode) ....................................... 4-10
c. SPOT WELDING (MIG mode).......................................................... 4-10
d. STITCH (MIG mode) ....................................................................... 4-10
e. SW TIME (MIG mode)..................................................................... 4-10
f. DWELL TIME (MIG mode) .............................................................. 4-10
g. PRE FLOW (MIG mode) .................................................................. 4-10
h. POST FLOW (MIG mode) ................................................................ 4-10
i. UP SLOPE (TIG mode) .................................................................... 4-10
j. DOWN SLOPE (TIG mode) .............................................................. 4-10
k. ARC FORCE..................................................................................... 4-11
l. VRD (STICK mode) ......................................................................... 4-11
5) Error....................................................................................................... 4-11
4.04 TWECO Fusion DX250 Digital Control MIG Torch, 3M, Euro (W4018900).... 4-12
SECTION 5:
MIG (GMAW) WELDING............................................................................. 5-1
5.01 Shielding Gas Regulator/Flowmeter Operating Instructions............................ 5-1
5.02 Attaching the Tweco Fusion DX250 Digital Control MIG Torch (Euro)............. 5-4
5.03 Installing Minispool (100mm diameter) ......................................................... 5-4
5.04 Installing Handispool (200mm diameter) ....................................................... 5-5
5.05 Inserting Wire into the Wire Feed Mechanism ................................................ 5-6
5.06 Feed Roller Pressure Adjustment.................................................................... 5-7
5.07 Changing the Feed Roll ................................................................................... 5-7
5.08 Wire Reel Brake .............................................................................................. 5-8
5.09 Setup for Auto Set (Synergic) MIG (GMAW) Welding with Gas Shielded Mig Wire
5-8
5.10 Setup for Auto Set (Synergic) MIG (FCAW) Welding with Gasless MIG Wire 5-10
5.11 Setup for Manual MIG (GMAW) Welding with Gas Shielded MIG Wire......... 5-12
5.12 Setup for Manual MIG (FCAW) Welding with Gasless MIG Wire................... 5-14
5.13 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 Shielding Gas Regulator/Flowmeter Operating Instructions............................ 6-1
6.02 Setup for TIG (GTAW) Auto Set Welding......................................................... 6-4
6.03 Setup for TIG (GTAW) Manual Set Welding .................................................... 6-6
6.04 TIG (GTAW) Basic Welding Technique ............................................................ 6-9
6.05 TIG (GTAW) Welding Problems..................................................................... 6-11

TABLE OF CONTENTS
SECTION 7:
STICK (MMAW) WELDING .......................................................................... 7-1
7.01 Setup for STICK Auto Set (MMAW) Welding ................................................ 7-1
7.02 Setup for STICK (MMAW) Manual Set Welding .............................................. 7-3
7.03 Stick (MMAW) Basic Welding Technique ........................................................ 7-4
7.04 Electrode Selection Chart.............................................................................. 7-15
7.05 Stick (MMAW) Welding Troubleshooting...................................................... 7-16
SECTION 8:
ROUTINE SERVICE REQUIREMENTS AND POWER SOURCE PROBLEMS.................... 8-1
8.01 Routine Service and Calibration Requirements............................................... 8-1
8.02 Cleaning the Welding Power Source ............................................................... 8-4
8.03 Cleaning the Feed Rolls................................................................................... 8-4
8.04 Power Source Problems ................................................................................. 8-4
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 185ULTRA CIRCUIT DIAGRAM .............................................. A-1
CIGWELD - LIMITED WARRANTY TERMS
WARRANTY SCHEDULE – TRANSMIG 185ULTRA

Manual 0-5494 1-1 GENERAL INFORMATION
OPERATING MANUAL Transmig 185 Ultra
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1.01 Arc Welding Hazards
WARNING
ELECTRICSHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and
work circuit is electrically live whenever
the output is on. The input power circuit
and machine internal circuits are also live
when power is on. In semiautomatic or
automatic wire welding, 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 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 Owner’s Manual and national,
state, and local codes.
6. Turn off 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
holder in water to cool it or lay it down on the
ground or the work surface. Do not touch holders
connected to two 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 confined spaces or damp locations, do not use
a welder with AC output unless it is equipped with
a voltage reducer. Use equipment with DC output.
14.Wear a safety harness to prevent falling if working
above floor level.
15.Keep all panels and covers securely in place.
SECTION 1:
ARCWELDING 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.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or
property, if the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be
learned through study and training before using this equipment. Some of these practices apply to equipment
connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive
training in welding and cutting practices should not attempt to weld.
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.

GENERAL INFORMATION 1-2 Manual 0-5494
OPERATING MANUAL
Transmig 185 Ultra
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WARNING
ARC RAYS can burn eyes and skin; NOISE
can damage hearing.
Arc rays from the welding process produce
intense heat and strong ultraviolet rays
that can burn eyes and skin. Noise from
some processes can damage hearing.
1. Use a Welding Helmet or Welding Faceshield fitted
with a proper shade of filter (see ANSI Z49.1 and
AS 1674 listed in Safety Standards) to protect your
face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields
recommended.
3. Use protective screens or barriers to protect others
from flash and glare; warn others not to watch the
arc.
4. Wear protective clothing made from durable,
flame-resistant material (wool and leather) and
foot protection.
5. Use approved ear plugs or ear muffs if noise level
is high.
6. Never wear contact lenses while welding.
Recommended Protective Filters for Electric Welding
Description of Process Approximate Range of
Welding Current in Amps
Minimum Shade Number of
Filter(s)
Manual Metal Arc Welding - covered
electrodes (MMAW)
Less than or equal to 100 8
100 to 200 10
200 to 300 11
300 to 400 12
Greater than 400 13
Gas Metal Arc Welding (GMAW)
(MIG) other than Aluminium and
Stainless Steel
Less than or equal to 150 10
150 to 250 11
250 to 300 12
300 to 400 13
Greater than 400 14
Gas Metal Arc Welding (GMAW)
(MIG) Aluminium and Stainless Steel
Less than or equal to 250 12
250 to 350 13
Gas Tungsten Arc Welding (GTAW)
(TIG)
Less than or equal to 100 10
100 to 200 11
200 to 250 12
250 to 350 13
Greater than 350 14
Flux-cored Arc Welding (FCAW) -with
or without shielding gas.
Less than or equal to 300 11
300 to 400 12
400 to 500 13
Greater than 500 14
Air - Arc Gouging Less than or equal to 400 12
Plasma - Arc Cutting
50 to 100 10
100 to 400 12
400 to 800 14
Plasma - Arc Spraying —15
Plasma - Arc Welding
Less than or equal to 20 8
20 to 100 10
100 to 400 12
400 to 800 14
Submerged - Arc Welding —2(5)
Resistance Welding —Safety Spectacles or eye
shield
Refer to standard AS/NZS 1338.1:1992 for comprehensive information regarding the above table.

Manual 0-5494 1-3 GENERAL INFORMATION
OPERATING MANUAL Transmig 185 Ultra
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WARNING
FUMES AND GASES can be hazardous to
your health.
Welding produces fumes and gases.
Breathing these fumes and gases can be
hazardous to your health.
1. Keep your head out of the fumes. Do not breath
the fumes.
2. If inside, ventilate the area and/or use exhaust at
the arc to remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied
respirator.
4. Read the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated,
or while wearing an air-supplied 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 degreasing, cleaning,
or spraying operations. The heat and rays of the
arc can react with vapours to form highly toxic
and irritating 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 respirator. The coatings and any metals
containing these elements can give off toxic fumes
if welded.
WARNING
WELDING can cause fire or explosion.
Sparks and spatter fly off from the
welding arc. The flying sparks and hot
metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns.
Accidental contact of electrode or welding
wire to metal objects can cause sparks,
overheating, or fire.
1. Protect yourself and others from flying sparks and
hot metal.
2. Do not weld where flying sparks can strike
flammable material.
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.
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 fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead,
or partition can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks
or drums.
8. Connect work cable to the work as close to the
welding area as practical to prevent welding
current from travelling long, possibly unknown
paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10.Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal.
As welds cool, they can throw off slag.
1. Wear approved face shield or safety goggles. Side
shields recommended.
2. Wear proper body protection to protect skin.
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under
high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally
part of the welding process, be sure to
treat them carefully.
1. Protect compressed gas cylinders from excessive
heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position
by chaining them to a stationary support or
equipment cylinder rack to prevent falling or
tipping.
3. Keep cylinders away from any welding or other
electrical circuits.
4. Never allow a welding electrode to touch any
cylinder.

GENERAL INFORMATION 1-4 Manual 0-5494
OPERATING MANUAL
Transmig 185 Ultra
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5. Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the
specific application; maintain them and associated
parts in good condition.
6. Turn face away from valve outlet when opening
cylinder valve.
7. Keep protective cap in place over valve except
when cylinder is in use or connected for use.
8. Read and follow instructions on compressed
gas cylinders, associated equipment, and CGA
publication P-1 listed in Safety Standards.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed
and securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or
covers for maintenance and troubleshooting as
necessary.
4. To prevent accidental starting during servicing,
disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away
from moving parts.
6. Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
!
WARNING
This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals know to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety code Sec. 25249.5 et seq.)
NOTE
Considerations About Welding And The
Effects of Low Frequency Electric and
Magnetic Fields
The following is a quotation from the General
Conclusions Section of the U.S. Congress, Office of
Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background
Paper, OTA-BP-E-63 (Washington, DC: U.S.
Government Printing Office, May 1989): “...there is
now a very large volume of scientific findings based
on experiments at the cellular level and from studies
with animals and people which clearly establish that
low frequency magnetic fields and interact with,
and produce changes in, biological systems. While
most of this work is of very high quality, the results
are complex. Current scientific understanding does
not yet allow us to interpret the evidence in a single
coherent framework. Even more frustrating, it does
not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-
based advice on strategies to minimize or avoid
potential risks.”
To reduce magnetic fields in the workplace, use the
following procedures.
1. Keep cables close together by twisting or taping
them.
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away
from body as practical.
ABOUT PACEMAKERS:
The above procedures are among
those also normally recommended for
pacemaker wearers. Consult your doctor
for complete information.

Manual 0-5494 1-5 GENERAL INFORMATION
OPERATING MANUAL Transmig 185 Ultra
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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. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550
N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American
National Standards Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
Safety in welding and allied processes Part 1: Fire Precautions, AS 1674.1-1997 from SAI Global Limited,
www.saiglobal.com.
Safety in welding and allied processes Part 2: Electrical, AS 1674.2-2007 from SAI Global Limited, www.
saiglobal.com.
Filters for eye protectors - Filters for protection against radiation generated in welding and allied operations
AS/NZS 1338.1:1992 from SAI Global Limited, www.saiglobal.com.

GENERAL INFORMATION 1-6 Manual 0-5494
OPERATING MANUAL
Transmig 185 Ultra
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This Page Intentionally Blank.

OPERATING MANUAL Transmig 185 Ultra
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Manual 0-5494 2-1 INTRODUCTION
SECTION 2:
INTRODUCTION
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear
on a nameplate attached to the control panel. In
some cases, the nameplate may be attached to the
rear panel. Equipment which does not have a control
panel such as gun and cable assemblies is identified
only by the specification or part number printed on
the shipping container. Record these numbers on the
bottom of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the
invoice to make sure it is complete and inspect the
equipment for possible damage due to shipping. If
there is any damage, notify the carrier immediately to
file a claim. Furnish complete information concerning
damage claims or shipping errors to the location in
your area listed in the inside back cover of this manual.
Include all equipment identification numbers as
described above along with a full description of the
parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to un-
crate the unit.
2.01 How To Use This Manual
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily
recognized as follows:
NOTE!
An operation, procedure, or background infor-
mation which requires additional emphasis or
is helpful in ecient operation of the system.
!
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others in
the operating area.
!
CAUTION
A procedure which, if not properly followed,
may cause damage to the equipment.
WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a
box such as this.
!
DANGER
Means immediate hazards which, if not
avoided, will result in immediate, serious
personal injury or loss of life.
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.

OPERATING MANUAL
Transmig 185 Ultra
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INTRODUCTION 2-2 Manual 0-5494
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
Voltage Input
A
C
Single Phase
Three Phase
Three Phase Static
Frequency Converter-
Transformer-Rectifier
Dangerous Voltage
Off
On
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
S
A
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Remote
Duty Cycle
Percentage
Amperage
Voltage
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Receptacle Rating-
Auxiliary Power
Art # A-04937_AC
115V 15A
t
t1
t2
%
X
IPM
MPM
t
V
Fuse
Wire Feed Function
Wire Feed Towards
Workpiece With
Output Voltage Off.
Preflow Time
Postflow Time
Spot Time
Spot Weld Mode
Continuous Weld
Mode
Press to initiate wirefeed and
welding, release to stop.
Purging Of Gas
Inches Per Minute
Metres Per Minute
Disturbance In
Ground System
Welding Gun
Burnback Time
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
4 Step Trigger
Operation
2 Step Trigger
Operation
Spool Gun
AUTO
SET
MIG STICK TIG
Auto Settings for
MIG, STICK, TIG

OPERATING MANUAL Transmig 185 Ultra
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Manual 0-5494 2-3 INTRODUCTION
2.05Description
The Cigweld Transmig 185 Ultra takes the guess work
out of welding with an impressive AUTO SET function
that allows the user to weld like a Pro with no previous
welding experience necessary.
Simply select the material type, thickness &
consumable diameter and AUTO SET will pre-set
the Wirefeed Speed (Amperage) and Voltage (MIG)
along a pre-programmed synergic line. Experienced
welders can then customise their settings by tweaking
their speed and heat according to their technique and
other factors.
A sophisticated Memory function allows you to return
to your previous weld or save up to nine of your
favourite weld settings.
The Ultra is a 185 Amp Professional multi process
welding inverter, capable of producing outstanding
weld results in either AUTO SET or Manual Mode in
GMAW/FCAW (MIG), MMAW (Stick) and GTAW (Lift
TIG).
A 4.3” colour LCD screen allows full interactive
digital control over your weld settings in a simple to
navigate and easy to read interface. The LCD screen
is protected by recessed panelling, a screen protector
and a flip up display cover.
The 185 Ultra comes with an integrated wirefeeder
that holds up to a 200mm spool, and boasts a range
of Professional Features to ensure optimal welding
results: Burnback Control, Arc Control, 2T/4T, Spot/
Stitch Weld, Pre/Post Flow, Up/Down Slope, Arc
Force, Hot Start, Anti-Stick and VRD (applicable in
Stick mode only).
Most importantly the 185 Ultra is fitted with a 10Amp
plug, allowing you the flexibility to plug and play
anywhere in your home or workshop. The power
source weighs just over 17kg, and all accessories can
be packed inside a convenient purpose built heavy
duty backpack, making the Ultra portable and ideal
for any home or jobsite.
The Ultra package comes standard with the Tweco
Fusion DX250 Digital MIG gun which allows remote
operation of volts and wirefeed speed in the palm
of your hand. While the euro connection makes it
compatible with most other MIG Guns and also the
SGT250* Spool gun for your precision aluminium
work.
Backed by a 3 year warranty** and fully compliant to
Australian Standard AS 60974.1 and IEC 60974.1 you
know you have a safe product you can trust.
With excellent welding performance across a broad
range of applications anyone can weld like a Pro! You
set the process and the Ultra will do the rest!
The following instructions detail how to correctly
and safely set up the machine and give guidelines on
gaining the best efficiency and quality from the Power
Source. Please read these instructions thoroughly
before using the unit.
NOTE
*Wirefeed speed is adjustable from the power
source only (no remote speed control on the
Spool gun).
**Refer to the completeWarranty Schedule at
the back of the manual.
2.06 User Responsibility
This equipment will perform as per the information
contained herein when installed, operated, maintained
and repaired in accordance with the instructions
provided. This equipment must be checked periodically.
Defective equipment (including welding leads) should
not be used. Parts that are broken, missing, plainly
worn, distorted or contaminated, should be replaced
immediately. Should such repairs or replacements
become necessary, it is recommended that such
repairs be carried out by appropriately qualified
persons approved by CIGWELD. Advice in this regard
can be obtained by contacting an Accredited CIGWELD
Distributor.
This equipment or any of its parts should not be altered
from standard specification without prior written
approval of CIGWELD. The user of this equipment
shall have the sole responsibility for any malfunction
which results from improper use or unauthorized
modification from standard specification, faulty
maintenance, damage or improper repair by anyone
other than appropriately qualified persons approved
by CIGWELD.

OPERATING MANUAL
Transmig 185 Ultra
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INTRODUCTION 2-4 Manual 0-5494
2.07 Transporting Methods
This unit is equipped with a handle for carrying purposes.
WARNING
ELECTRIC SHOCK can kill. DO NOTTOUCH live electrical parts. Disconnect input power conductors from de-energized
supply line before moving the welding power source.
!
WARNING
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Lift unit with handle on top of case.
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 185Ultra Plant (Part No. W1006185)
• Transmig 185 Inverter Power Source
• Tweco Fusion DX250 MIG Torch, 3m
• Argon Regulator/Flowmeter
• Feed rolls: 0.8/0.9mm V Groove (fitted)
1.0/1.2mm U Groove; 0.8/0.9mm V Knurled
• Contact Tips: 0.8mm (fitted); 0.9mm; 1.0mm
• Twistlock Electrode Holder with 4m Lead
• Work Clamp with 4m Lead
• Shielding Gas Hose Assembly
• Accessories Backpack
• Shoulder Strap
• Operating Manual
2.09 Duty Cycle
The rated duty cycle of a Welding Power Source, is a statement of the time it may be operated at its rated
welding current output without exceeding the temperature limits of the insulation of the component parts. To
explain the 10 minute duty cycle period the following example is used. Suppose a Welding Power Source is
designed to operate at a 15% duty cycle, 90 amperes at 23.6 volts. This means that it has been designed and
built to provide the rated amperage (90A) for 1.5 minutes, i.e. arc welding time, out of every 10 minute period
(15% of 10 minutes is 1.5 minutes). During the other 8.5 minutes of the 10 minute period the Welding Power
Source must idle and be allowed to cool.

OPERATING MANUAL Transmig 185 Ultra
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Manual 0-5494 2-5 INTRODUCTION
2.10 Specifications
Description Transmig 185Ultra
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
Australian Standard AS60974-1 / IEC60974-1
Number of Phases Single Phase
Nominal Supply Voltage 240 VAC ± 15%
Nominal Supply Frequency 50 / 60Hz
Factory Fitted Supply Plug Rating 10 Amps
Effective Input Current (I1eff) [Refer Note 1] 9.5 Amps
Maximum Input Current (I1max)24.5 Amps
Minimum Single Phase Generator
Recommendation [Refer Note 3]
10 kVA (at 0.8 Power Factor)
8 kW (at 1.0 Power Factor)
Output Terminal Type DinseTM Style 50
Protection Class IP23S
Welding Environment Classification Suitable for Welding in Category C Environments;
Suitable for Indoor and Outdoor Welding
MIG (GMAW / FCAW) Welding
Welding Current Range 30 – 185A
Welding Voltage Range 15.5 – 23.3V DC
Wirefeed Speed Range (Metres per Minute) 1.5 – 16.4
Welding Output, 40ºC, 10 min 185A @ 20%, 23.3V
116A @ 60%, 19.8V
90A @ 100%, 18.5V
Nominal Open Circuit Voltage MIG Weld Mode 48V DC
(Trigger Switch Depressed when not Welding)
STICK (MMAW)
Welding Current Range 10 – 185A
Welding Output, 40ºC, 10 min. 185A @ 15%, 27.4V
95A @ 60%, 23.8V
80A @ 100%, 23.2V
Open Circuit Voltage (VRD On) <26V DC
Open Circuit Voltage (VRD Off) 48V DC
TIG (GTAW)
Welding Current Range 10 – 185A
Welding Output, 40ºC, 10 min. 185A @ 20%, 17.4V
116A @ 60%, 14.6V
90A @ 100%, 13.6V
Open Circuit Voltage (VRD On) <26V DC
Open Circuit Voltage (VRD Off) 48V DC
Table 2-1: Transmig 185 Ultra Specification

OPERATING MANUAL
Transmig 185 Ultra
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INTRODUCTION 2-6 Manual 0-5494
NOTE 1
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings, all capacities,
measurements, dimensions and weights quoted are approximate only. Achievable capacities and ratings in use and
operation will depend upon correct installation, use, applications, maintenance and service.
NOTE 2
The Eective Input Current should be used for the determination of cable size & supply requirements.
NOTE 3
Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your
situation in this regard.
NOTE 4
Minimum Generator Recommendation at the Maximum Output Duty Cycle.
Due to large variations in performance and specications of dierent brands and types of generators, CIGWELD cannot
guarantee full welding output power or duty cycle on every brand or type of generator.
Some small generators incorporate low cost circuit breakers on their outputs. These circuit breakers usually will have a
small reset button, and will trip much faster than a switchboard type circuit breaker. This may result in not being able
to achieve full output or duty cycle from the power source / generator combination. For this reason we recommend a
generator that incorporates switchboard type circuit breakers.
CIGWELD recommends that when selecting a generator, that the particular power source / generator combination be
adequately trialled to ensure the combination performs to the users expectations.
NOTE 5
CIGWELD reserves the right to change product performance and specications without notice.
NOTE 6
If an extension lead is required to be used it is recommended to use a minimum size of 1.5mm Heavy Duty Extension
Lead. Longer extension leads may impact welding performance and operation.