Sigma2 300 | 400 | 500

New welding generation – the future starts here

Migatronic Sigma2 is the second generation of the popular Sigma range of power sources with a maximum output of 300, 400 and 500 A respectively. Available in C (Compact) or S (with separate wire-feed unit) versions and combinable with four different control panels. With or without pulse and with infinitely variable adjustment of all parameters, the Sigma2 machines are designed for advanced MIG/MAG welding of all types of materials - in trades and assembly, heavy industry, offshore and automation.

intelligent welding concept – with savings

In its new range of inverter- based MIG/MAG welding machines with MMA, Migatronic has concentrated all intelligent elements of the machine in one place: in the user-friendly control panel. The result is an increased internal memory with space for even more welding programs and a new possibility of future update of welding programs via downloading of data. For example by means of IGC®, an innovative feature that ensures synergic gas flow and large savings. Sigma2 500 also features a gouging func-tion and PowerArc™ programs that ensure full penetration in fillet welds and butt welds using mild steel and stainless steel.

manufactured to order

No two Sigma machines are necessarily identical. The machines are made to order in precisely the configuration that matches the welding application.

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Sigma2 - the new switch on-press-weld generation for advanced mig/mag

MIG Manager® torch

Migatronic Sigma2 – high welding quality and advanced functions

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You make the demands- we “tailor” the ideal welding machine solution

Some of the Sigma2 family. Note the functional design. The machines shown may be illustrated with extra equipment.

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Four control panels designed for future updates

Advanced featuring DUO Plus™ and sequence spaces for user-defined parameter settings and fine-tuning.

Synergic with built-in DUO Plus™ and full synergy between parameters, for MIG brazing, etc.

Pulse featuring up to 160 welding programs and a user-friendly control panel for advanced pulse machines.

MIG/MAG characteristic

MMA characteristic

Pulse

DUO PlusTM

Two-stroke or four-stroke

Sequence selection 1-9

Tack-welding function

Panel lock

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SYNERGIC

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Control concepts and updatesMigatronic’s software development makes it possible to concentrate the intelligence in Sigma2. The control panels can be locked with an SD lock card and/or mechani-cally by means of a key. An SD port inside the control panel makes it possible to update the machine with new program packages through downloads to an ordinary SD memory card.

Basic for simple and routine welding jobs. With fine adjustment of all secondary parameters.

The number of programs in the respective packages is updated regularly. The above table is intended as a guide.

Program package Standard Standard Plus Special

Material with/without pulse with/without pulse with/without pulseManual MMA-MIG/MAG • • • Arc Gouging • • Fe • • • Fe - PowerArc • ER 316 LSI • • • ER 316 LSI - PowerArc • ER 347 Si • • Duplex • • AIMg / AISi5 • • • AI99,5 / AISi12 • • FCW • • • CuAI8 • • • CuSn • • CuSi3 • • • Inconel • • FE - Seamtrack •approx. no. of programs Standard Standard Plus Special Synergic panel 40 70 100Pulse panel 60 125 160

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Operational comfort in a class by itself - Switch on, press, weld …

Quick changeover between jobs

DUO Plus™ - better finish with increased automatic processThe DUO Plus™ function optimises control of the weld pool and reduces the heat input. DUO Plus™ is an automatic enhancement of traditional MIG/MAG sequence welding.

Powerarc™ for thick-walled platesThe Migatronic PowerArc™ pro-grams ensure full penetration in fillet welds and butt welds using mild steel and stainless steel.

Time-saving sequence optionsSequence welding is a standard function on the ”Advanced”, ”Synergic” and ”Pulse” control panels. Welding parameters for repetitive welding jobs can be stored in the machine’s internal memory which is big enough to hold nine programme settings.

Sequence module for quick change of programMIG Ergo Sequence Mk II is a new control unit for use with and re-installation on all models in the range of MIG Ergo welding hoses. The Sequence Mk II allows the welder to switch between up to seven individual settings at the torch handle (not Basic).

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Set primary parameters: welding current,wire feed speed or thickness of material. The machine puts the finishing touches to the welding result.

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Fine-tuning: welding voltage/trim, arc adjust or seam average log.

Tack-welding function for safe fixation of the workpiece during the welding process.

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DUO Plus™ function – auto-matic changeover between two sequences.

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DUO Plus™ is an automatic sequence func-tion allowing the welder to MIG weld with a ”slow pulse” which is known from many TIG machines. This welding method ensures better control of the weld pool and is the optimal solution for welding root passes in open groove joints etc.

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SYNERGICPress one button and switch between up to nine sequences. Display shows the selected sequence.

Time

Amp DUO Plus™ efficiency rate 0-50% of the set welding current (A) (schematic diagram)

Pause timePulse time

DUO Plus™ – Aluminium

DUO Plus™ – Stainless steel

Set welding current

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green technology is of benefit to the environment and bottom line profitability

Universal outlet for all types of welding hoses

A universal outlet makes it possible to weld using most types of MIG Ergo welding hoses – air-cooled or watercooled.

Lower power consump-tion - less effect on the environment

Sigma2 is green throughout and for ease of use and superb performance, there is no better machine. Its state-of-the-art technology gives a power consumption that is much lower than in machines with traditional technologies.

accessories include: •Programpackages •MIGManager® •Wire-drivespoolsforalltypes

of wire (page 10)•MigaMONITOR™(page11)•RWFMulti(page11)•Robotinterface(page11)•Reliefarm•Dialogandsequencetorch•Flowcontrolforwater•Autotransformer,230-500V

(page 10)•Slidingbracketandsetof

wheels for wire-feed unit•MMAkitforwire-feedunits•Push-pullkit•Remotecontrolunit•CEEmainsplug 2 x MWF 41 with separate relief arms

MIG Ergo Sequence MkII

MIG Manager®

Conditions:

Arc time: 3 hours/day

Standby: 5 hours/day

Welding current: 240 A

Electricity cost: 0.12 € / kWh

Annual power consumption: 858 €*

Annual saving: Up to 245 €

8000

7000

6000

5000

4000

3000

2000

1000

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kWh

*) Thyristor without standby: 220 days x 8 hours = 7,000 kWh x 0.12 = 858 €

Step- regulated

MIG - 500 A

Thyristor without standby

MIG - 500 A

Sigma2

MIG 500 A

Example of power consumption - Sigma2 vs. old technologies(schematic diagram)

Thyristor with standbyMIG - 500 A

intelligent gas Control - Switch on, press, weld ..!

Intelligent Gas Control IGC® is designed specifically for Sigma2 as a configurable option. An efficient gas-saver kit combined with dynamic gas control that monitors consumption and optimises gas protection for the chosen synergic welding program. Under favourable conditions, IGC® may give gas savings in excess of 50% with proportionally fewer replacements of gas cylinder to the benefit of economy, environment and efficiency.

Better welding, better finish

At the start of the welding process, Migatronic IGC® prevents over-consumption of gas and gives a good initial performance with an even lower failure rate. IGC® takes control once the weld pool is established and ensures extensive savings thanks to the controlled gas con- sumption that is always optimised according to current needs.

IGC® automatically calibrates the gas flow according to the widely different densities of the different gas types.

Large-scale reduction of gas consumption

Savings depend on the company’s welding profile, arc time and number of welding machines. In the example below, the calculation is based on a varied usage pattern with short-arc welding and spray-arc welding in equal measure.

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Example of daily savings in Euro(schematic diagram)

Savings during welding

Savings during welding start-up

Basic/Advanced panel

IGC® Synergic/Pulse panel

Long welds Many tack-welds

50

40

30

20

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Gas consumption at the moment of ignition

l/min.

0 1 2 3 4 5

20

15

10

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l/min.

0 50 100 150 200 250 300 350

intelligent gas Control igC®

Synergic gas flow with large-scale reduction of gas consumption

The more ignitions – the larger gas savings

Optimised gas consumption during the welding process

Gas flow using IGC®

Gas waste using traditional valve

Gas consumption using IGC®

*) 220 days x 3 hours x 60 min. x 15 litres = 594 m3 x 5.00 = 3,168 €

Conditions:Arc time: 3 hours/day

Welding profile: Short arc/spray arc

Average gas consumption: 15 l/min.

Welding wire: 1.0 mm FE

Gas cost: 5.00 € / m3

Annual gas costs: 3,168 €*

Annual saving: Up to ≈ 1,600 €

Gas waste using traditional valve

Gas consumption using IGC®

Sec.

Amp

Euro

multi-functional trolley column handles every combination...

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Prizewinning design that can carry a little extra

The unique “backbone” can be used for a double version with two wire-feed units or a triple version combining Sigma2 (MIG/MAG) with Migatronic Pi (TIG) or Zeta (plasma cutter).

Sigma is characterised through-out by Migatronic's new design, which received the iF Product Design Award.

New intelligent Sigma2 advantages:

•IntelligentGasControlIGC®

•Increasedmemorywiththepossibility of more program packages

•SDcardforprogramupdateand/or panel lock against unintended use of control panel

•Bettershort-arc/DUOPlus™properties

•Diffusion-safeweldinghoses

•Mechanicalprotectivecoverwith lock-cylinder and key

•ArcGouging–newgougingprogram for Sigma2 500

•PowerArc™–newprogramsfor welding thick-walled plates

•NewPropan-2-olcoolingliquid

Extra wire-feed unit:

e.g. Pi 200/250 or Zeta 40/60

Power sources:

Sigma2 300Sigma2 400Sigma2 500

Aircooled or watercooled

Special edition - for shipyards and other heavy industries

Two portable yard units, with or without protective brackets, in-crease the operating range of the high-performance Sigma2 400/500 welding inverters: a closed wire-feed unit, MWF 50 Yard, for 5 kg

wire reels or an open model, MWF 55 Yard, for 5 or 15 kg wire reels. There are two optional con-trol panels for both types of wire feed unit: “Synergic” or “Pulse”. See control panels on page 4.

Offshore equipment – robust in every detail

Migatronic has developed a quite new offshore concept consisting of trolley, autotransformer, protective brackets, fittings etc. All in galvanised finish for extra protection of PCBs and plug connections, especially targeted at shipyards and other heavy industries. Safety is in focus which is underlined by a number of solid functions, such as extra large trolley wheels, crane lift eyes, and fork-lift truck side members in addition to a special platform for MWF 50/55 Yard, cable suspension, and a fastening device for gas cylinders … or put simply: Heavy Duty altogether!

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Stable wire-feeding in hard-to-reach locations

MWF 50 yard with galvanised bracket and trolley

MWF 55 yard with galvanised bracket

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Power supply via autotransformer

It is a question of functionality and high performance under all voltage conditions. With an autotransformer incorporated in the “chassis” of the multi-functional column, the Sigma2 is safeguarded against undesirable voltage fluctuations in the 230-500Vrange.

Portable wire-feed unit with industrial wire-feeding

For Sigma2, Migatronic has devel-oped the MWF 41, a compact, portable wire-feed unit (30 m/min. wire-feed speed), that com-bines the limited dimensions of the open type with the good protection of the closed model.

Custom-built solutions - Sigma2 is configurable for any welding application

Migatronic wire-feed unit MWF 41

Four-spool wire-feed system and colour-coding of spools

Example of a special solution: Pivot arm with RWF Multi and wire reel

automated welding with Sigma2 in a complete robot setup

The two largest Sigma2 machines in “automated trim” are designed for integration with robots and automated devices along with RWF Multi.

I/O robotinterface is the commu-nication interface between the CAN-BUS power source and robot or automated device.

RWF Multi is a wire feed unit that feeds wire from a spool or drum through an intermediary cable into the robot torch. RWF Multi can also be used as a sepa-rate wire-feed unit with wire- reel holder for manual welding with Sigma2 compact versions combined with a MIG Manager® torch.

MigaMONITOR™ A simple and user-friendly quality monitoring program for digital collection of welding data and documentation of welds.

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Robot interface

RWF Multi

Robot concept – fully operational with all units

Remote control for Fanuc robot

Sigma2 300 | 400 | 500

COOLiNg UNiT

Output 1 l/min. 1.7 kW

Tank capacity 3.5 l

Pressure, max. 3 bar

Flow 1.2 bar – 60°C 1.75 l/min

maChiNE TYPE Sigma2 300 Sigma2 400 Sigma2 500

Mains voltage +/÷ 15% (50-60Hz) 3x400V(3x230-500V*) 3x400V 3x400V

Fuse 16 A 20 A 32 A

Effective mains current 15.7 A 17.3 A 25.8 A

Mains current, max. 18.1 A 28.0 A 44.9 A

Open circuit power 40 W 40 W 40 W

Efficiency factor 0.90 0.90 0.90

Efficiency rate 0.85 0.85 0.85

Current range 15-300 A 15-400 A 40-500 A

Duty cycle, 20°C (MIG/MAG) 300 A/100% 330 A/100% 475 A/100%

Duty cycle, 20°C (MIG/MAG) - 400 A/70% 500 A/80%

Duty cycle, 40°C (MIG/MAG) 270 A/100% 290 A/100% 420 A/100%

Duty cycle, 40°C (MIG/MAG) 300 A/80% 350 A/60% 450 A/60%

Duty cycle, 40°C (MIG/MAG) - 400 A/40% 500 A/55%

Opencircuitvoltage 69-76V 69-76V 78-95V

Application class CE, S CE, S CE, S

Protection class IP23 IP23 IP23

Norm IEC60974 -1, -2, -5, -10 IEC60974 -1, -2, -5, -10 IEC60974 -1, -2, -5, -10

Dimensions C-L (H x B x L, cm) 90.6 x 52.4 x 92.5 90.6 x 52.4 x 92.5 90.6 x 52.4 x 92.5

Dimensions C-W (H x B x L, cm) 105.1 x 52.4 x 92.5 105.1 x 52.4 x 92.5 105.1 x 52.4 x 92.5

Dimensions S-W (H x B x L, cm) 114.4 x 52.4 x 103.1 114.4 x 52.4 x 103.1 114.4 x 52.4 x 103.1

Weight C-L/C-W/S-W, kg 58/69/85 58/69/85 60/71/87

* Configured with autotransformer

MIGATRONIC WELDING EQUIPMENT LTD.21 Jubilee Drive, Belton Park,

LoughboroughLeicestershire LE11 5XS, England

Tlf. (+44) 01509 267499, www.migatronic.co.uk

WiRE-FEED UNiT mWF 41/internal RWF multifeeder mWF 50 mWF 55

Wire-feed speed, m/min 1-30 1-30 1-30 1-30

Wire-reel diameter, mm 300 - 200 300

Torch connection Euro connection Euro connection Euro connection Euro connection

Duty cycle 40°C 420 A/100% 420 A/100% 420 A/100% 420 A/100%

Duty cycle 40°C 500 A/60% 500 A/60% 500 A/60% 500 A/60%

Protection class IP23 IP23 IP23 IP23

Norm IEC60974 -1, -5, -10 IEC60974 -1, -5, -10 IEC60974 -1, -5, -10 IEC60974 -1, -5, -10

Dimensions H x W x L, cm 44 x 24.5 x 78 27 x 21 x 27 38 x 20 x54 40 x 26 x 62

Weight, kg 19 9 10 12

C = Compact, S = Separate wire-feed unitWe reserve the right to make changes.

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