Kemppi A5 MIG Rail System 2500 Operating Manual Download Page 4

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A5 MIG Rail System

© Kemppi Oy 2021

R01

OPERA

TING M

ANU

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1.2  About the product

A5 MIG Rail System 2500 is a complete set of welding 

mechanization equipment designed especially for 

horizontal and vertical joints and for all position welding. 

It can be used in medium-heavy industries for MIG/MAG 

welding of long plates and for plasma or oxy-fuel cutters.

The rail is made of extruded aluminum and can be easily 

extended, shortened or stiffened. As the rail does not 

contain any racks, the risk of service interruption due to 

spatter from the weld is minimized. It is flexible and can 

be bent down to a diameter of three meters. 

 Bending the rail to diameters smaller than that will 

deform it permanently. Specially rolled rails are used for 

smaller diameters. 

The rail is attached to the workpiece with magnetic 

brackets or vacuum brackets. For secure attachment each 

vacuum holder consists of one ejector and two vacuum 

suction cups

1.3  Compatibility

A5 MIG Rail System 2500 is compatible with the following 

welding equipment:

•  FastMig M and FastMig X: all wire feeders and 

control panels

•  FastMig Pulse 350/450 power sources

•  Control panel PF 65

•  FastMig KMS 300/400/500 power sources

•  Control panels SF 52W and SF 54

•  SuperSnake mechanization models

•  Other power source brands with limitations

 Some of the functions are available only if the wire 

feeder has the right control panel. For example, changing 

memory channels at the welding carriage is available only 

if the wire feeder has a control panel with the channel 

remote control feature.

Summary of Contents for A5 MIG Rail System 2500

Page 1: ...2500 1920350 R01 A5 MIG Rail System EN OPERATING MANUAL...

Page 2: ...e rail 7 2 6 Selecting a welding gun 7 2 7 Installing the welding gun 7 3 Operation 8 3 1 Carriage functions 8 3 2 Carriage control panel 8 3 2 1 Start menu 8 3 2 2 Menu options 8 3 2 3 Setup menu A 1...

Page 3: ...rized Kemppi dealer or visit the Kemppi website at www kemppi com The specifications presented in this manual are subject to change without prior notice Important notes Items in the manual that requir...

Page 4: ...n that will deform it permanently Specially rolled rails are used for smaller diameters The rail is attached to the workpiece with magnetic brackets or vacuum brackets For secure attachment each vacuu...

Page 5: ...ting to a non FastMig welding machine You need a transformer 1 phase 230 VAC to power the carriage In this setup the start button and the adjustment of welding voltage and wire feed speed are not acce...

Page 6: ...erve a rail of 2 5 meters Released Clamped 2 4 Adjusting the rail 1 Place the rail parallel to the joint at about 200 mm distance from it 2 Fine adjust with a plastic hammer You can adjust distance by...

Page 7: ...ally for root welding in narrow grooves MMT42C Gas cooled straight neck model MT 51MWC Water cooled straight neck model for heavy applications Please see the technical details of the welding guns in t...

Page 8: ...settings 3 2 Carriage control panel 3 2 1 Start menu P1 CH off 8 45 6mm This is the initial view on the carriage display 1 Program number P1 2 Remote memory channels on off CH Off 3 Carriage speed 8 c...

Page 9: ...eed 45mm s Set the weaving speed i e the speed at which the torch moves from one side of the groove to the other during the weaving motion 1 Use and buttons to change the speed 2 Set the weaving speed...

Page 10: ...ng delay 2 Travels during delay stands when weaving square Press MENU to continue Hold out P1 CH on Hold out 0 1s Set outer dwell time the time that the torch holds at the outer side of the weaving mo...

Page 11: ...responding memory channel at the wire feeder CH1 CH2 etc To use the wire feeder s memory channels the CH REMOTE setting must be ON at the wire feeder In this case the fine tuning is disabled at the ca...

Page 12: ...Use and buttons to change the value You need to change these settings only if there is a conflict between the memory channels set by the wire feeder and the welding carriage Adj0 WF A CH on Adj 0 WF 5...

Page 13: ...the button s direction The direction is determined when facing the carriage control panel If you are standing on the other side of the carriage the directions are reversed Increases or decreases the...

Page 14: ...ise up or counterclockwise down 2 1 3 5 Kemppi Wise application software When using Kemppi FastMig welding equipment you can further optimize the quality and productivity of your mechanized welding by...

Page 15: ...neck for mechanized welding W010975 MMT 42C welding gun gas cooled 4 5 m 6254207 MT51MWC welding gun water cooled 4 5 m 6255162 NARROW GAP GAS NOZZLE PMT27 W008123 NARROW GAP CONTACT TIP 1 2 M6 W0081...

Page 16: ...d ON Check the gun control connection and possible Supersnake and separate control cable connections Check that control panels are switched on Dirty poor quality weld Check shielding gas supply Check...

Page 17: ...lyanauthorizedtrainedelectricianshouldcarryoutrepairstoKemppimachines 6 DISPOSAL Do not dispose of electrical equipment with normal waste In observance of European Directive 2002 96 EC on waste electr...

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