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CIGWELD Transmig 185 Ultra Operating Manual Download Page 1

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

IN

3 1

LCD SCREEN

4.3”

DIGITAL MIG GUN

V-

V+

WS

-

WS

+

SPOOL GUN

WITH SGT250

*

COMPATIBLE

PLUG & PLAY

Summary of Contents for Transmig 185 Ultra

Page 1: ...8 8 8 8 8 8 8 8 8 8 8 8 i i i i i i i i i i i i i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 m m m m m m m m m m m m m m m m m m m m m m m m m m m s s s s s s s s s s s s s s s s s s s s s s s s s s n n n n n n n n...

Page 2: ...g g g g g g T T T T T T T T T T T T T T T T T T T T T T T T T T T Tr r r r r r r r r r r r r r r r r r r r r r r ra a a a a a a a a a a a a a a a a a a a a a a a a a a a a an n n n n n n n n n n n n n...

Page 3: ...LD 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...

Page 4: ...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 i...

Page 5: ...g 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...

Page 6: ...r 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...

Page 7: ...stalling 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...

Page 8: ...ng 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 Rol...

Page 9: ...e 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...

Page 10: ...ed 3 Use protective screens or barriers to protect others from ash and glare warn others not to watch the arc 4 Wear protective clothing made from durable ame resistant material wool and leather and f...

Page 11: ...wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded WARNING WELDING can cause re or explosion Sparks and spatter fly off from th...

Page 12: ...ing 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 nished and...

Page 13: ...02 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...

Page 14: ...s s s s s s s s s s s s s s s s s s s s s s s s s s sm m m m m m m m m m m m m m m m m m m m m m m m m m m m m mi i i i i i i i i i i i i i i i i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 8 8 8 8 8 8 8 8 8...

Page 15: ...the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to le a claim Furnish complete information concerning damage claims or shipping errors to the lo...

Page 16: ...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 Th...

Page 17: ...nti Stick and VRD applicable in Stick mode only Most importantly the 185 Ultra is tted with a 10Amp plug allowing you the exibility to plug and play anywhere in your home or workshop The power source...

Page 18: ...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...

Page 19: ...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 Suppl...

Page 20: ...rent 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...

Page 21: ...tion Chart on Page 5 23 W4011250 SGT250 Spool Gun 7977036 Feed Roll 0 6 0 8mm V groove hard 7977660 Feed Roll 0 9 1 2mm V groove hard 7977731 Feed Roll 0 8 0 9mm U groove soft 7977264 Feed Roll 1 0 1...

Page 22: ...l l l l l l lt t t t t t t t t t t t t t t t t t t t t t t tr r r r r r r r r r r r r r r r r r r r r r r r ra a a a a a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i INTRODUCTION 2 8...

Page 23: ...a supply voltage will cause components to overheat and possibly fail The Welding Power Source must be Correctly installed if necessary by a quali ed electrician Correctly earthed electrically in acco...

Page 24: ...n IEC 60974 13 ArcWelding Equipment Instal lation and use under preparation B Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob...

Page 25: ...of all metallic components in the welding installation and adjacent to it should be considered However Metallic components bonded to the work piece will increase the risk that the operator could recei...

Page 26: ...s s s s s s s s s s s s s s s s s s s s s s s s sm m m m m m m m m m m m m m m m m m m m m m m m m m m m m mi i i i i i i i i i i i i i i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 8 8 8 8 8 8 8 8 8 8 8...

Page 27: ...r r r ra a a a a a a a a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i i i SECTION 4 OPERATION 4 01 Overview Conventional operating procedures apply when using the Welding Power Sourc...

Page 28: ...o Figure 4 1 In MIG GMAW FCAW mode the amperage knob adjusts the speed of the wire feed motor which in turn adjusts the output current by varying the amount of MIG wire delviered to the welding arc Th...

Page 29: ...ol may also Synergically adjust the voltage value In Auto MIG mode adjusting the voltage control knob will adjust the heat setting off the Auto MIG synergic line which is set at 0 on the Heat Control...

Page 30: ...directions 8 Positive Welding Output Terminal Refer to Figure 4 1 The positive welding terminal is used to connect the welding output of the power source to the appropriate welding accessory such as...

Page 31: ...e 2 Trigger Switch Input 3 Trigger Switch Input 4 Spool Gun Motor Positive 5 Not Connected 6 Not Connected 7 Not Connected 8 Not Connected Table 4 1 Note When using the SGT250 Spool Gun with the Trans...

Page 32: ...s and will automatically switch off when not required 15 Burnback Control located in wirefeed compartment Refer to Figure 4 1 The burnback control is used to adjust the amount of MIG wire that protrud...

Page 33: ...a a a a a a a a a a a a a a a a a a a i i i i i i i i i i i i Figure 4 5 Highlighted Information Icon Figure 4 6 Information Menu To consult welding setup diagrams turn the Control Knob and select wel...

Page 34: ...l l l l l l l lt t t t t t t t t t t t t t t t t t t t t t tr r r r r r r r r r r r r r r r r r r r r r r r r r ra a a a a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i Figure 4 13 Do...

Page 35: ...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...

Page 36: ...or more components by stitch or interval weld together The weld time is set by the Stitch Time and the non weld time is set by the Dwell Time e SW TIME MIG mode SW Time refers to spot time when Spot...

Page 37: ...or variability in joint t up in certain situations with particular electrodes In general increasing the arc force control toward 100 maximum arc force allows greater penetration control to be achieved...

Page 38: ...lt t t t t t t t t t t t t t t t t t t t t t tr r r r r r r r r r r r r r r r r r r r r r r r r r ra a a a a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i 4 04 TWECO Fusion DX250 Digit...

Page 39: ...with the safe practices prescribed in this instruction SPECIFIC PROCEDURES for the use of regulators owmeters are listed below 1 NEVER subject the regulator owmeter to inlet pressure greater than its...

Page 40: ...connecting check that the regulator owmeter label and cylinder marking agree and that the regulator owmeter inlet and cylinder outlet match NEVER CONNECT a regulator owmeter designed for a particular...

Page 41: ...ready for operation adjust working ow rate as follows 1 Slowly turn adjusting screw knob in clockwise direction until the outlet gauge indicates the required ow rate NOTE It may be necessary to re che...

Page 42: ...r and screwing the plastic torch nut clockwise to secure the MIG torch to the MIG torch adaptor A 13698 MIG Torch Adaptor MIG Torch Connector Figure 5 3 Attaching MIG Torch 5 03 Installing Minispool 1...

Page 43: ...om the factory the unit is set for a Handispool 200mm diameter In order to re t a 200mm spool assemble parts in the sequence shown below in Figure 5 5 Adjustment of the nut with nylon insert will cont...

Page 44: ...oller 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 pressu...

Page 45: ...ller 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 cont...

Page 46: ...k into contact tip A 13704 Wire Reel Brake Adjustment Nut Figure 5 10 Wire Reel Brake 5 09 Setup for Auto Set Synergic MIG GMAW Welding with Gas Shielded Mig Wire A Switch the Power Source On Off swit...

Page 47: ...a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i i i i i i F Place the MIG wire spool onto the spool holder Refer to Sections 5 03 for 100mm diameter spools or 5 04 for 200mm diameter s...

Page 48: ...e 5 18 Setup for Mig Welding with Gas Shielded Mig Wire 5 10 Setup for Auto Set Synergic MIG FCAW Welding with Gasless MIG Wire A Switch the Power Source On Off switch located on the rear of the Power...

Page 49: ...MIG wire spool onto the spool holder 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 H Switch the...

Page 50: ...elding Terminal Work Lead Figure 5 27 Setup for Mig Welding with Gasless Mig Wire 5 11 Setup for Manual MIG GMAW Welding with Gas Shielded MIG Wire A Switch the Power Source On Off switch located on t...

Page 51: ...onnect tting locks into place correctly on the rear of the power source WARNING Secure the welding grade shielding gas cylinder in an upright position by chaining it to a suitable stationary support t...

Page 52: ...e Power Source Refer to Section 5 02 Attaching the Tweco Fusion DX250 MIG Torch C Connect the Mig Torch polarity lead to the negative welding terminal If in doubt consult the electrode wire manufactur...

Page 53: ...r r r r r r r r r r r ra a a a a a a a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i i i i i i I Select MIG Manual Set mode from home page Welding summary screen displays preset value...

Page 54: ...r of theWelding Power Source B Fit the Euro Spool Gun to the power source using the front panel EURO torch adaptor refer also to Section 5 02 Attaching the Tweco Fusion DX250 Mig Gun Connect the 8 pin...

Page 55: ...a a a a a a i i i i i i i i i i i i i i i G Select Advanced Settings Set Wirefeeder OFF and Spool Gun ON Figure 5 37 MIG Advanced Settings Menu H Welding summary screen displays preset value of wire f...

Page 56: ...ess which fuses together the parts to be welded by heating them with an arc between a solid continuous consumable electrode and the work Shielding is obtained from an externally supplied welding grade...

Page 57: ...a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i i i i i i The welding gun should be held at an angle to the weld joint see Secondary Adjustment Variables below Hold the gun so that the...

Page 58: ...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 Travel Speed The speed at which the molten pool tra...

Page 59: ...hey 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 2 Wire Feed Speed Increase in wire feed speed increases weld cur...

Page 60: ...ntrol settings that have to balance These are the Wirespeed control refer to Section 4 02 2 and the welding Voltage Control refer to Section 4 02 3 The welding current is determined by the Wirespeed c...

Page 61: ...medium gauge sheet and tubular steel sections Note that a suitable shielding gas is required 0 6mm Handispool 5kg 721108 0 8mm Minispool 0 8kg 721105 0 8mm Handispool 5kg 721109 0 9mm Handispool 5kg...

Page 62: ...Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidi cation of the molten metal Contaminants range from no gas around the welding...

Page 63: ...unts of swarf are produced by the wire passing through the feed roller when excessive pressure is applied to the pressure roller adjuster B Swarf can also be produced by the wire passing through an in...

Page 64: ...ve voltage too high A Adjust voltage and current by adjusting the voltage control and the wirespeed control B Wire is wandering B Replace contact tip C Incorrect shielding gas C Check shielding gas D...

Page 65: ...regulator owmeter is designed to reduce and control high pressure gas from a cylinder or pipeline to the working pressure required for the equipment using it If the equipment is improperly used hazard...

Page 66: ...contaminated should be replaced immediately The user of this equipment will generally have the sole responsibility for any malfunction which results from improper use faulty maintenance or by repair b...

Page 67: ...ection solution or soapy water 3 Purge air or other unwanted welding grade shielding gas from equipment connected to the regulator owmeter by individually opening then closing the equipment control va...

Page 68: ...D Connect the work lead to the positive welding terminal Welding current ows from the Power Source via Dinse terminals It is essential however that the male plug is inserted and turned securely to ac...

Page 69: ...t t t tr r r r r r r r r r r r r r r r r r r r r r r r r r r ra a a a a a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i i i i i H The TIG Setup Guide screen will be displayed for 10 se...

Page 70: ...ulator flowmeter Negative welding terminal Positive welding terminal 240VAC 10A Mains Supply A 13707 Note This 8 pin connection plug is for TIG torch trigger connection Note For recommended Cigweld Ge...

Page 71: ...gger Switch only E Fit the welding grade shielding gas regulator owmeter to the shielding gas cylinder refer to Section 6 01 then connect the shielding gas hose from the TIG torch to the regulator owm...

Page 72: ...t t t t t t t t t t tr r r r r r r r r r r r r r r r r r r r r r r r r ra a a a a a a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i I Welding summary screen displays preset welding curr...

Page 73: ...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 wor...

Page 74: ...Grey Table 6 3 NOTE TheTransmig 185 Ultra Inverter is not suited for ACTig welding TIG Welding Filler Rods Comweld Rod Aust Std AWS Std Part No 1 6mm Part No 2 4mm Part No 3 2mm Type Application LW1 L...

Page 75: ...7 6 05 TIG GTAW Welding Problems FAULT CAUSE REMEDY 1 Excessive beard build up or poor penetration or poor fusion at edges of weld Welding current is too low Increase weld current and or faulty joint...

Page 76: ...rod material A Clean the electrode by grinding off the contaminates B Work piece surface has foreign material on it B Clean surface C Shielding Gas contaminated with air C Check shielding gas lines fo...

Page 77: ...ode Holder lead to the positive welding terminal If in doubt consult the electrode manufacturer Welding current ows from the Power Source via Dinse terminals It is essential however that the male plug...

Page 78: ...U U U U U U U U U U U U U U U U U U Ul l l l l l l l l l l l l lt t t t t t t t t t t t t t t t t t t t t t tr r r r r r r r r r r r r r r r r r r r r r r r r ra a a a a a a a a a a a a a a a a a a a...

Page 79: ...Dinse terminals It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection C Connect the work lead to the negative welding terminal If in doub...

Page 80: ...se smaller electrodes otherwise the arc may burn holes through the job A little practice will soon establish the most suitable electrode for a given application Storage of Electrodes Always store elec...

Page 81: ...Trouble may also be experienced when welding white heart malleable due to the porosity caused by gas held in this type of iron Suitable Electrode types are Castcraft 55 or Castcraft 100 D Copper and...

Page 82: ...m mi i i i i i i i i i i i i i i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 85 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 U U U U U U U U U U U U U...

Page 83: ...t designs are shown in Figure 7 21 Gap varies from 1 6mm 1 16 to 4 8mm 3 16 depending on plate thickness Joint Open Square Butt 1 6mm 1 16 max 1 6mm 1 16 Single Vee Butt Joint Not less than 70 Double...

Page 84: ...e electrode along the plate surface in the same way as 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...

Page 85: ...joint in thin plate turn the job over clean the slag out of the back and deposit a similar weld Art A 07697_AB Tack Weld 20 30 Electrode Tack Weld Figure 7 23 Butt Weld Art A 07698 Figure 7 24 Weld B...

Page 86: ...Position for HV Fillet Weld Art A 07700_AB 1 2 3 4 5 6 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 upri...

Page 87: ...ing in this position particularly easy Use a 3 2mm electrode at 100 amps The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip o...

Page 88: ...overcome the effect of shrinking volume and still be attached to the edge of the joint If the restraint is very great as for example in a heavy section of plate the weld metal may crack Even in cases...

Page 89: ...cting a welding sequence which will distribute the stresses suitably so that they tend to cancel each other out See Figures 7 36 through 7 39 for various weld sequences Choice of a suitable weld seque...

Page 90: ...1 1 1 1 1 1 18 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 85 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 U U U U U U U U U U U U U U U U U U U U U U U Ul l l l l l l l l l l l l lt t t t t t...

Page 91: ...se electrode suitable for all positional welding and galvanised steel Ferrocraft 12XP 2 0mm 2 0mm 2 5mm 2 5mm 3 2mm 3 2mm 4 0mm 1kg 2 5kg 1kg 2 5kg 1kg 2 5kg 5kg 322128 612231 322129 612232 322138 612...

Page 92: ...for repair and maintenance welding of a wide range of cast irons It has better wetting action than Castcraft 55 Table 7 2 Cigweld Electrode Selection Chart Further information on CIGWELD electrodes c...

Page 93: ...tal undercut A Welding current is too high A Reduce welding current B Welding arc is too long B Reduce the length of the welding arc C Angle of the electrode is incorrect C Electrode should not be inc...

Page 94: ...i i i i i i i i i FAULT CAUSE REMEDY 6 Gas pockets or voids in weld metal porosity A High levels of sulphur in steel A Use an electrode that is designed for high sulphur steels B Electrodes are damp B...

Page 95: ...st to ensure the integrity of the unit is compliant with Cigweld s original speci cations If equipment is to be used in a hazardous location or environments with a high risk of electrocution as outlin...

Page 96: ...ransportable equipment at least once every 3 months and 2 For outlets wiring and associated accessories supplying xed equipment at least once every 12 months D Voltage Reduction Device VRD Units tted...

Page 97: ...le equipment at least once every 3 months and 2 For xed equipment at least once every 12 months If equipment is to be used in a hazardous location or environments with a high risk of electrocution as...

Page 98: ...ves on the upper feed roll After cleaning tighten the feed roll retaining knobs CAUTION Do not use compressed air to clean theWelding Power Source Compressed air can force metal particles to lodge be...

Page 99: ...TIG Torch control plug securely and correctly to the 8 Pin control socket of the front of the Transmig 185 Ultra Power Source Note that Remote Current Control feature is not available for 185 Ultra 8...

Page 100: ...conduit liner 9 No gas ow in MIG mode A Gas hose is damaged A Replace or repair B Gas passage contains impurities B Disconnect gas hose from the rear of power source or wirefeeder and blow out impuri...

Page 101: ...r r r r r r r r r r r r r ra a a a a a a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i i i i i Manual 0 5494 9 1 KEY SPARE PARTS SECTION 9 KEY SPARE PARTS 9 01 Tweco Professional Fusio...

Page 102: ...r r r r ra a a a a a a a a a a a a a a a a a a a a a a a a i i i i i i i i i i KEY SPARE PARTS 9 2 Manual 0 5494 9 02 Power Source A 13710 Figure 9 2 TRANSMIG 185 ULTRA POWER SOURCE SPARE PARTS ITEM P...

Page 103: ...1 1 1 1 1 1 1 18 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 85 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 U U U U U U U U U U U U U U U U U U U U U U U U U U Ul l l l l l l l l l l l l l l l l l...

Page 104: ...s sm m m m m m m m m m m m m m m m m m m m m m m m m m mi i i i i i i i i i i i i i i i i i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 18 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 85 5 5 5 5 5 5 5 5 5 5...

Page 105: ...0T 3 8X2 3 300UH 3 5 mm distance V8 A 1 K 2 D9 C27 R58 A 1 K 2 D4 R59 R65 R64 C20 QD6 DC V8 1 A 1 K 2 D3 VFB PFC R69 R66 R67 R32 R31 R30 C16 1uF QD6 BOP 1uF C24 C10 FAN Logic Control PCB 1 2 3 4 IFB 1...

Page 106: ...ny goods covered by or furnished by CIGWELD whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of...

Page 107: ...and work lead 3 Months MIG torch consumable items NIL Gas regulator owmeter excluding seat assem bly pressure gauges elastomer seals and O rings 1 Year Regulator seat assemblies and pressure gauges 6...

Page 108: ...ies Tel 61 3 9474 7508 Fax 61 3 9474 7488 Malaysia Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Tel 60 3 6092 2988 Fax 6...

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