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This Sigma Select 400 S configuration is equipped with full MIG/MAG pulse welding. Pulsing is the key to achieving superior weld quality, especially when welding heat-sensitive materials such as stainless steel and aluminum. The pulsed process, which relies on rapid switching between high peak current and low base current, offers numerous benefits: it minimizes spatter, which reduces finishing time; reduces heat input, preventing distortion and preserving material properties, which is critical for thin sheets; provides excellent control of the weld pool, making it easier to weld in forced positions and achieve perfect fusion; and produces exceptionally aesthetic welds with a fine and even face, often comparable visually to the TIG method. For professional workshops and production facilities, the Pulse function is a guarantee of superior quality, repeatability and the ability to work with a wide range of materials.

The PowerArc™ and PowerArc Pulse™ processes are special MIG/MAG welding variants developed by Migatronic, providing an extremely concentrated and stable high energy arc. PowerArc™ has very deep penetration and the ability to achieve full penetration even in difficult joints (e.g. fillet welds in thick materials) at potentially higher welding speeds compared to a standard short-circuit or spray arc. It is ideal for welding steel structures where strength and speed are important. The PowerArc Pulse™ version combines the advantages of a focused PowerArc™ arc with the benefits of pulsed welding , offering even better weld pool control, minimal spatter and excellent weld quality, especially when welding stainless steel or aluminum in larger thicknesses. These advanced processes give professionals the tools to optimize welding in the most demanding industrial applications.

Migatronic’s patented DUO Plus™ feature takes MIG/MAG welding aesthetics to an even higher level. This technology automatically controls the arc dynamics at the end of welding, creating distinctive, fine “scales” on the weld face that are deceptively similar to the appearance of TIG welds. More importantly, DUO Plus™ also provides better control of the weld pool throughout the process, which contributes to smoother and more uniform welds. For manufacturers of stainless steel structures, visible components or in the food industry, where aesthetics are as important as quality, DUO Plus™ is an invaluable feature. It reduces the need to grind and polish welds, significantly speeding up the production process and reducing finishing costs. This feature is available in this configuration and makes it unique.

This advanced suite of features intelligently optimizes key aspects of the MIG/MAG welding process, improving quality and making work easier:

• IAC™ (Intelligent Arc Control): This feature is designed for perfect boundary layers (fusion), especially in butt joints of pipes, tanks or sheet metal. It uses a stable, modified short-circuit arc that ensures full fusion and excellent quality of the first, critical weld layer. Importantly, IAC™ is less sensitive to changes in the length of the free wire exit, making it easier for even less experienced welders. It also provides less heat input and minimizes fusion spatter, and allows faster welding in the PF (vertical down) position compared to traditional methods. The system automatically adjusts arc parameters 50,000 times per second, guaranteeing stability.
• ISC™ (Intelligent Spatter Control): This is a comprehensive process focused on maximum splatter reduction in MIG/MAG welding, especially when using a short-circuit arc. ISC™ precisely controls the moment of droplet detachment, resulting in nearly zero spatters in any welding position. For companies where high quality surface finishes and minimizing time spent cleaning after welding are important, ISC™ delivers tangible benefits, leaving a clean and smooth weld.
• ICC™ (Intelligent Current Control): This function solves the problem of current drop (and thus fusion) when increasing the length of the free wire outlet, which is typical, for example, when welding in narrow gaps or when access to the joint is difficult. ICC™ actively maintains the set welding current at a constant level, regardless of changes in the length of the wire outlet (up to 40mm). This allows the use of smaller bevel angles (e.g., 30°), which means fewer filler layers needed to fill the groove, saving time and additional materials. It provides consistent penetration and arc pressure even with a long wire exit.

Together, these smart features make welding more precise, repeatable and efficient.

The Sequence (Sequential Welding) function gives the advanced user the ability to program his own multi-step MIG/MAG welding cycle. You can define different parameters (current, voltage, duration) for each phase of the cycle, such as start, main welding (even several different steps) and finish (crater filling). In addition, the Sequence Repeat function allows you to easily repeat the programmed cycle multiple times, e.g. by pressing the button on the handle consecutively. This is invaluable for welding repetitive parts, such as on welding jigs, for intermittent welding or in automated applications. It allows perfect repeatability of parameters, minimizes operator errors and significantly increases productivity in batch production. It is a tool for those who strive for complete control and optimization of repetitive welding tasks.

This Sigma Select 400 S configuration also includes special functions dedicated to tacking (Tack Function). Traditional tacking with a standard MIG/MAG program often introduces too much heat and can lead to distortion of thin parts or problems with subsequent welding of the main weld. Sigma Select’s advanced Tack functions allow very short, precise and repeatable tack welds with minimal heat input. Various modes can offer, for example, automatic arc extinguishing after a preset time or making a series of short pulses. For structural assemblers, manufacturers of thin-walled components, or in the automotive industry, where fast and precise positioning of components is crucial, these features significantly speed up work and improve the quality of preparing workpieces for final welding, minimizing the risk of distortion.

At the heart of the Sigma Select’s MIG/MAG welding ease of use is an extensive library of DC synergy programs. After selecting the type of material (black steel, stainless steel, aluminum), wire diameter and shielding gas type on the control panel, the machine automatically selects the optimal base parameters (voltage and wire feed speed). The welder only needs to tune the arc length to his preferences or the specifics of the task. This significantly speeds up setup and guarantees good results even when changing material or wire. Migatronic’s program library is constantly evolving and includes a wide range of solid and powder wires and various gas mixtures. For the professional, synergy means speed, repeatability and the certainty that the output parameters are always close to optimum, providing an excellent basis for further fine adjustment using the advanced features of this device.

This configuration is equipped with two advanced shielding gas management systems. IGC® (Intelligent Gas Control) is a unique Migatronic technology that dynamically monitors the weld pool and adjusts the gas flow according to the current needs of the process. Unlike a fixed flow set at the regulator, IGC® optimizes gas consumption, especially at the beginning and end of welding and during current changes, which can lead to significant gas savings (up to 50%) without the risk of shielding deterioration. This ensures not only lower costs, but also higher weld quality by providing optimal protection against oxidation. In addition, the Flow Control function allows precise digital setting and monitoring of gas flow from the welder panel (requires appropriate wiring and sensor), eliminating the need to constantly check the regulator and ensuring greater process repeatability. It’s a one-stop solution for cost-conscious companies with the highest quality.

The Sigma Select 400 S in this configuration also offers full-fledged MMA (covered electrode) welding at up to 400A. This means that demanding construction, repair or field welding work can be carried out using a wide range of covered electrodes (rutile, alkaline, etc.). The device provides a stable MMA arc and is likely to have standard support functions such as Hot Start (easy ignition) and Arc Force (sticking prevention). For a workshop or manufacturing company, having this additional method in one device greatly increases its versatility and flexibility, allowing it to perform almost any welding task without investing in a separate high-power MMA welder.

Another powerful feature of this configuration is the ability to perform arc-air gouging (CAC-A / Arc Gouging). This process uses a carbon electrode to melt the metal and a stream of compressed air to blow it out. It is an extremely effective method of removing old welds, welding defects (cracks, porosity), preparing edges for welding (beveling) or removing excess material. Having a gouging function in the welder eliminates the need for mechanical methods (grinding), which are often slower, more labor-intensive and generate a lot of dust. For companies involved in overhauling heavy structures, repairing machinery or in the shipbuilding and foundry industries, the ability to gouge quickly and efficiently using the same power source as for welding is a huge asset that increases productivity and the scope of work performed.

This advanced configuration also includes management and documentation features:

• MigaJob™: Allows you to save, name and easily recall complete welding settings for specific jobs. This includes not only the basic parameters (current, voltage), but also the selected synergy program, Pulse settings, Sequence, IGC parameters and much more. Saved “Jobs” can be transferred between devices (e.g., via SD/USB card), guaranteeing 100% repeatability and standardization of production across the plant. This is an invaluable tool for technologists and quality control departments.
• MigaLog™: Allows actual welding parameters to be recorded during operation and stored in the machine’s memory or on external media. Key data such as current, voltage, wire speed, welding time, gas consumption (if IGC active) are recorded. It is an indispensable tool for quality control, creation of welding documentation (e.g. according to EN 1090, ISO 3834 standards), process analysis and troubleshooting. MigaLog™ provides full traceability and proof of the quality of welds made.

These features take the management of the welding process to a whole new digital level.

The device is based on the modular Sigma Select platform, which is its fundamental advantage. This means that the system consists of separate components (power source, wire feeder, control panel, cooler, carriage), which can be freely configured and expanded in the future. You can start with a basic configuration and then buy and activate additional features or change the wire feeder to a more advanced one. This flexibility makes Sigma Select an investment that grows with your company’s needs. Instead of buying a new machine when your production profile changes, you can simply upgrade or expand your existing system. This approach ensures long-term cost-effectiveness and adaptability to changing market requirements.

Taking full advantage of such a rich set of features (Pulse, Sequence, IGC, MigaJob, MigaLog, etc.) requires an advanced interface. That’s why configurations such as this typically feature the Migatronic Graphic control panel. It features a large, color graphic display and an intuitive navigation system. The Graphic panel allows easy access to all functions, visualization of the welding cycle, saving of settings (MigaJob™), and often offers software updates via USB or SD card and viewing of MigaLog™ data. For the technologist and advanced welder, the Graphic panel is the center of process control, allowing fine-tuning of every aspect of welding. The clear interface makes it easy to use even the most advanced options.

Sigma Select configurations labeled “V” use a separate wire feeder (such as the MWF series), connected to the power source by a compound wire. This design increases working range and flexibility. Migatronic MWF feeders are equipped with high-precision, 4-roller feeding systems with tachometer control, which guarantees stable and reliable wire feeding even with long holders and working with different types of wires. The solid, enclosed design of the feeder protects the mechanism from contamination. The separate feeder is a professional solution that provides the flexibility and highest wire feeding precision needed for advanced processes.

The entire Sigma Select platform is designed for demanding industrial environments. The robust design of the power source and feeder, the high quality of the components used and the IP23 degree of protection ensure resistance to dust, moisture and mechanical damage. The devices are suitable for multi-shift operation and intensive use. Migatronic is renowned for the reliability of its products, which for the industrial user means minimized production downtime and the assurance that the equipment will operate smoothly for many years. This is crucial for maintaining production continuity and completing orders on time.