Kemppi A3 MIG Rail System 2500 User manual

2500
1920340
R01
A3 MIG Rail System
EN
OPERATING MANUAL

2A3 MIG Rail System© Kemppi Oy 2020 R01
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OPERATING MANUAL
CONTENTS
1. Introduction..........................................................................................3
1.1 General ......................................................................................................3
1.2 About the product ....................................................................................3
1.3 Compatibility.............................................................................................3
2. Installation .............................................................................................4
2.1 Battery .......................................................................................................4
2.2 Rail .............................................................................................................5
2.3 Mounting the carriage on the rail.............................................................6
2.4 Welding gun ..............................................................................................6
3. Operation...............................................................................................7
3.1 Carriage control panel...............................................................................7
3.2 Welding .....................................................................................................9
3.3 Cutting.......................................................................................................9
4. Additional details..............................................................................10
4.1 Technical data..........................................................................................10
4.2 Ordering information..............................................................................10
5. Troubleshooting................................................................................11
5.1 Operation problems................................................................................11
6. Maintenance.......................................................................................11
6.1 Daily maintenance ..................................................................................11
6.2 Periodic maintenance .............................................................................11
6.3 Service Workshop maintenance .............................................................12
7. Disposal ................................................................................................12

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OPERATING MANUAL
1. INTRODUCTION
1.1 General
Congratulations on choosing A3 MIG Rail System 2500
welding equipment. Used correctly, Kemppi products
can signicantly increase the productivity of your
welding and provide years of economical service.
This operating manual contains important information
on the use, maintenance and safety of your Kemppi
product. The technical specications of the equipment
can be found at the end of the manual.
Please read the operating manual and the safety
instructions booklet carefully before using the
equipment for the rst time. For your own safety and
that of your working environment, pay particular
attention to the safety instructions in the manual.
For more information on Kemppi products, contact
Kemppi Oy, consult an authorised Kemppi dealer, or
visit the Kemppi website at www.kemppi.com.
The specications presented in this manual are subject
to change without prior notice.
Important notes
Items in the manual that require particular attention in
order to minimise damage and harm are indicated with
below symbols. Read these sections carefully and follow
their instructions.
Note:
Gives the user a useful piece of information.
Caution:
Describes a situation that may result in damage to
the equipment or system.
Warning:
Describes a potentially dangerous situation. If not
avoided, it will result in personal damage or fatal
injury.
Disclaimer
While every eort has been made to ensure that the
information contained in this guide is accurate and
complete, no liability can be accepted for any errors
or omissions. Kemppi reserves the right to change
the specication of the product described at any time
without prior notice. Do not copy, record, reproduce
or transmit the contents of this guide without prior
written permission from Kemppi.
1.2 About the product
A3 MIG Rail System 2500 is a simple battery-powered
welding mechanization equipment for applications
where weaving is not needed. It has been designed for
MIG/MAG welding in at position and for ame cutting.
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1.3 Compatibility
A3 MIG Rail System 2500 is compatible with the
following welding equipment:
• All MIG/MAG welding machines, any brand.
• Any manual welding gun with 4T trigger mode.
• Flame and plasma cutters equipped with ON/
OFF switch and 4T trigger mode.

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2. INSTALLATION
2.1 Battery
This carriage is battery-operated. Battery and charger
are included in the product delivery package. Battery’s
operation is about 8 hours. Complete technical data of
the battery and the charger can be found at the end of
this document.
To mount the battery, push it rmly into its slot in front
of the carriage.
To unmount the battery, press button 1 while pulling
the battery out.
To recharge the battery, connect it to the battery
charger.
Always use the original battery charger to avoid
damage to the battery.
A3 MIG Rail System 2500 uses Makita batteries
and chargers. Dierent charger models are available
for dierent mains plugs. Please follow the original
manufacturer’s instructions on use and storage.

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2.2 Rail
Released
Clamped
Use two M6 bolts to fasten the magnetic or suction cup
brackets on the aluminum rail.
With the quick realease mechanism you can easily
mount and unmount the rail to enable quick and easy
ne adjustment of the rail’s position.
Adjusting the rail into position
200 m
200 m
200 m
Adjust the rail by positioning it parallel to the joint at
about 200 mm distance.
1. Fine-adjust with a plastic hammer. The more
accurate the alignment, the less adjustment is
needed during welding.
2. The rail bends around items with minimum outer
diameter of about 1.5 m.
If the diameter is smaller than 2500 mm, the rail
must be rolled to shape. If the diameter is more than
2500 mm, a straight rail can be used and magnets can
make the bending.
Use the quick extension brackets to connect rails
together.
For safety reasons, use 8 magnets or 4 suction
brackets per one aluminum rail with 2.5 m of length.

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2.3 Mounting the carriage on the rail
2
1
3
1. Mount the carriage on the rail with drive wheels
facing the rail.
2. Check that the drive wheels are levelled with the
rail.
3. Tighten the pressure screw so that the drive
wheels grip tightly to the rail.
2.4 Welding gun
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2
2
2
2
1
1. Fasten the gun on the holder.
2. Use cross slides to ne-adjust the position of the
gun.
When using a manual welding gun, ensure that the
gun is set to use 4T trigger mode. Change the mode at
the wire feeder if necessary.

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OPERATING MANUAL
3. OPERATION
3.1 Carriage control panel
The following is the initial view of the carriage control
panel:
1
2
1. Battery level.
2. The speed at which the carriage travels.
Carriage control panel buttons
Buttons
• Decrease (–) and increase (+) the speed and
length values. In this mode the buttons are
referred to as – / + buttons.
• Start the carriage travel to the left / right. In
this mode the buttons are referred to as Start
left / Start right buttons. Long press starts rapid
speed.
Button
• Stops the carriage.
• Moves between and saves speed and length
values.
• Resets the length counter to the previous value
(long press).
Speed
Set the carriage travel speed:
1. Press the STOP/MENU button to have speed
shown on the display.
2. Press the – / + buttons to change the speed in
the range of 7-160 cm/min.
3. Press the STOP/MENU button to save the setting.
TIP: You can change the speed also when the
carriage is moving.
Length
Length determines the distance the carriage travels. Set
the length:
1. Press the STOP/MENU button to have Length
shown on the display.
2. Press the – / + buttons to change the length in
the range of 0-250 cm.
• When the length is other than 0 cm, the
carriage stops automatically when it reaches
the end.
• When the length is 0 cm, the carriage travels
until you stop it manually.

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Start carriage
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To start the carriage, press the Start left / Start right button.
TIP: When the carriage travels, the length
countdown is displayed at the bottom left corner
of the carriage control panel.
Rapid speed
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2s
180 cm/min 180 cm/min
2s
When not welding/cutting the carriage can travel at a
rapid speed of 180 cm/min.
To start the carriage in rapid speed, long press (2 sec.)
the Start left / Start right button.
• When the length is 0 cm, the carriage travels in
rapid speed until you stop it manually.
• When the length is other than 0 cm, the Start
left button returns the carriage to the start and
the Start right button moves the carriage to the
end.
Length counter reset
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3s
To reset the length counter to the previously set length,
long press (3 sec.) the STOP/MENU button.
Stop carriage
To stop the carriage, press the STOP/MENU button.

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3.2 Welding
Position the welding gun:
1. Adjust the gun angle to pushing or pulling.
2. Focus the aiming point.
3. Adjust vertical and horizontal position of the gun.
Select the travel speed:
• Use the - / + buttons to set the desired travel speed in cm/min.
Start welding:
1. Ensure that the gun is set to 4T trigger mode.
2. Press the gun trigger to ignite the arc
3. At the same time, press the Start left / Start right button to start the carriage
movement to that direction.
4. Make ne adjustments if necessary:
• Adjust the travel speed with the - / + buttons.
• Change welding parameters at the wire feeder.
3.3 Cutting
Set the cutting speed according to:
• material thickness
• groove angle
• cutting tip.
Ignite the ame cutter:
1. Adjust the height and the ame.
2. Preheat the steel.
3. Turn on the cutting oxygen.
4. Start the carriage.
5. Use the - / + buttons to ne-adjust the travel speed.

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4. ADDITIONAL DETAILS
4.1 Technical data
Power 18 VDC (battery)
Battery type BL1840
Battery operation time 8 h
Carriage speed 7-160 cm/min
Carriage travel length 0-250 cm
Rail length 2500 mm
External dimensions* 330 x 290 x 250 mm
Weight** 6.1 kg
*) Height from plate surface
**) Weight Including battery
4.2 Ordering information
Product name Product code
A3 MIG RAIL CARRIAGE 6190725
A5 MIG RAIL QUICK EXTENSION BRACKET 6190702
A5 MIG RAIL MAGNET ATTACHMENT 6190703
A5 MIG RAIL VACUUM ATTACHMENT 6190704
A5 MIG RAIL 2500 6190710
A5 TORCH FLOATING HEAD 6190711
Flame cutting torch SP800679
Battery 9755706
Battery charger Euro plug (Schuko) 9777582
Battery charger UK Plug 9777583
Battery charger AU plug 9777584
Battery charger DK plug 9777585
Battery charger CN plug 9777586
Storage box (plywood) 6190717
Normal Kemppi guns are supported. No mechanization options.
Normal SuperSnake models are supported

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5. TROUBLESHOOTING
5.1 Operation problems
The problems listed and the possible causes are not denitive but serve to suggest
some standard and typical situations that may present during normal environmental
use when using the A3 MIG Rail System 2500.
Problem: Check the following:
Carriage won’t work • Check that the battery is properly connected.
Carriage moves, but arc does not
ignite
• Ensure that the gun trigger mode is set to 4T.
• Check welding parameter settings.
Dirty, poor quality weld • Check shielding gas supply.
• Check and set gas ow rate.
• Check gas type for application.
• Check that correct welding program is selected.
• Check correct selection on the control panel.
• Check power supply – phase down?
Variable welding performance • Check welding parameter settings.
Magnets do not hold • Clean metal dust from magnets.
• Replace weakened magnets.
The vacuum cups no longer hold • Check compressed air supply.
• Chech compressed air hoses.
• Clean vacuum surfaces.
• Check welding parameter settings.
6. MAINTENANCE
When considering and planning routine maintenance, please consider the frequency
of machine use and the working environment.
Correct operation of the machine and regular maintenance will help you avoid
unnecessary downtime and equipment failure.
6.1 Daily maintenance
• Check that all cables and plugs are intact.
• Clean the magnets, vacuum cups and air hoses and check for damage.
• Keep carriage and torch holder clean.
6.2 Periodic maintenance
Periodic maintenance should only be carried out by a suitably qualied person.
Check at least every half year:
• Electric connectors of the machine – clean any oxidized parts and tighten
loose connections.
• Battery condition – replace if needed.
Do not use compressed air for cleaning as there is a risk that the dirt will compact
even more tightly into gaps of cooling proles.
Do not use pressure washing devices.
Only an authorized trained electrician should carry out repairs to Kemppi
machines.

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6.3 Service Workshop maintenance
Kemppi Service Workshops complete maintenance according to their Kemppi service
agreement.
The major points in the maintenance procedure are listed as follows:
• Cleaning of the machine
• Checking and maintenance of the welding tools
• Checking of connectors, switches and potentiometers
• Checking of electric connections
• Checking of mains cable and plug
• Damaged parts or parts in bad condition are replaced by new ones
• Maintenance testing.
• Operation and performance values of the machine are checked, and when
necessary adjusted by means of software and test equipment.
7. DISPOSAL
Do not dispose of electrical equipment with normal waste!
In observance of European Directive 2002/96/EC on waste electrical and electronic
equipment, and its implementation in accordance with national law, electrical
equipment that has reached the end of its life must be collected separately and taken
to an appropriate environmentally responsible recycling facility.
The owner of the equipment is obliged to deliver a decommissioned unit to a
regional collection centre, as per the instructions of local authorities or a Kemppi
representative. By applying this European Directive you will improve the environment
and human health.

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And you know.