Kemppi A5 MIG Rail System 2500 User manual

2500
1920350
R01
A5 MIG Rail System
EN
OPERATING MANUAL

2A5 MIG Rail System© Kemppi Oy 2021 R01
OPERATING MANUAL
CONTENTS
1. Introduction..........................................................................................3
1.1 General ......................................................................................................3
1.2 About the product ....................................................................................4
1.3 Compatibility.............................................................................................4
2. Installation .............................................................................................5
2.1 Connecting to a FastMig welding machine .............................................5
2.2 Connecting to a non-FastMig welding machine......................................5
2.3 Installing the rail........................................................................................6
2.4 Adjusting the rail.......................................................................................6
2.5 Mounting the carriage on the 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......................................................................................11
3.3 Remote control unit ................................................................................13
3.3.1 Basic functions.....................................................................................13
3.3.2 Alt functions........................................................................................13
3.4 Fine-adjustment of gun position............................................................14
3.5 Kemppi Wise application software.........................................................14
3.6 Ordering information..............................................................................15
3.7 Technical data..........................................................................................15
4. Troubleshooting................................................................................16
4.1 Operation problems................................................................................16
5. Maintenance.......................................................................................17
5.1 Daily maintenance ..................................................................................17
5.2 Periodic maintenance .............................................................................17
6. Disposal ................................................................................................17

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1. INTRODUCTION
1.1 General
Congratulations on choosing A5 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 authorized 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 permission from
Kemppi.

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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 stiened. As the rail does not
contain any racks, the risk of service interruption due to
spatter from the weld is minimized. It is exible 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.

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2. INSTALLATION
2.1 Connecting to a FastMig welding
machine
To connect the carriage system to the FastMig welding
equipment:
1. Connect welding cable to welding gun connector.
2. Connect control cable to remote control
connection at the wire feeder.
3. Connect control cable to 7-pin connection at the
carriage unit.
4. Connect remote control unit to 7-pin connector on
the carriage front panel.
With Kemppi mechanization welding gun, the control
cable is integrated into the gun cable. The trigger mode
must be set to 2T. With other welding guns, you need to
use a separate control cable. See the ordering codes at the
end of this document.
2.2 Connecting 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 accessible
through the remote control device.
Do the following to connect:
1. Connect welding gun to the wire feeder.
2. Attach welding gun to the carriage gun holder.
3. Connect transformer to the carriage.
4. Start welding by pressing the gun trigger.
When using a manual welding gun, start and stop
the arc with the gun trigger and start the carriage motion
with the remote control as usual. The trigger mode must
be set to 4T. See FastMig operation manual for further
instructions.
When using a Supersnake:
1. Use the mechanization model of Supersnake.
2. Connect as usual to the wire feeder, and connect
the carriage with the welding gun to the
Supersnake. This model includes a bus coupler with
which to connect.

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2.3 Installing the rail
The rail contains powerful neodymium magnets that may cause injuries. Always use
a stopper at the last end of the rail or sequence of rails to avoid dropping the carriage.
Dropping the carriage may break it or cause an injury.
Fasten the xing brackets to the aluminum rail:
• Use two M8 bolts.
• Use either magnetic brackets or suction brackets.
• Quick clamping mechanism.
For safety reasons, use 8 magnets per 2.5 m of aluminum rail.
One magnetic attachment kit contains 8 magnets that serve 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 aligning the displacement of the carriage. Use standard
distance between the rail and the weld in order to minimize the need for adjustment
during welding.
The more accurate the alignment, the less adjustment is needed during welding. When
welding, PC position rail should be mounted above the groove. 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.
200 m
200 m
200 m

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2.6 Selecting a welding gun
Kemppi mechanization guns offer various benefits
compared with manual welding guns. Carriage control
and powering signals are integrated in the gun cable,
so there is only one cable needed between the wire
feeder and the welding carriage. This also enables the
adjustment of carriage functions and welding parameters
at the remote control device.
Kemppi offers three welding gun models designed
especially for mechanized welding:
PMT MN32C (Multi Neck model)
Multiple neck designs. Slightly bent neck available for
mechanized welding. Extra-long gas nozzle and contact
tip are available, suitable especially 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 their documentation.
2.7 Installing the welding gun
2
3
5
4
1
1. Fasten the gun holder on the weaving unit.
2. Fasten the gun on the holder.
3. Connect the control cable.
4. Use adjustment screws and weaving
displacement adjustment to ne-adjust the
position of the gun.
Check that the gun trigger mode is set to 2T.
Create memory channels at the welding machine
and carriage using the desired welding parameters for
your welding jobs.
2.5 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.

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3. OPERATION
3.1 Carriage functions
1. STOP button on top of the carriage is the same as
in the remote control device
2. Display to show menu settings and their values
3. Menu button move from one menu to another
4. Scroll left/right buttons to change values of menu
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/o (CH O )
3. Carriage speed (8 cm/min)
4. Weaving speed (45 mm/s)
5. Weaving width (6 mm)
Press MENU to continue.
3.2.2 Menu options
Program selection
P1 CH on
<8> 45 6mm
The item to be adjusted (P1) is blinking in the display.
Select the program to store the settings:
1. Use + and – buttons to browse programs.
2. Select the program to use: P1…P5.
3. Press MENU to continue.

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Speed Car
P1 CH on
Speed Car 8cm/m
Set the carriage travel speed:
1. Use + and – buttons to change the speed.
2. Set the carriage speed within the range
5–150 cm/min.
3. Press MENU button to continue.
Speed
P1 CH on
Speed <-> 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 within the range
10–50 mm/s.
3. Press MENU to continue.
Width
P1 CH on
Width <-> 6mm
Set the width of the weaving motion:
1. Use + and – buttons to change the width from
center (1 mm = 0.5 mm on each side).
2. Set the weaving width within the range 0–30 mm
3. Press MENU to continue.

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Pattern
P1 CH on
Pattern <-> 0
1 2
0
Determine the pattern used in weaving. Use + and –
buttons to select any of the three patterns:
0. Travels constantly while weaving (triangular).
1. Travels when weaving, stands during 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 motion):
1. Use + and – buttons to change the time.
2. Press MENU to continue.
Hold in
P1 CH on
Hold in 0.1s
Set inner dwell time (the time that the torch holds
at the inner side of the weaving motion):
1. Use + and – buttons to change the time in
seconds.
2. Press MENU to continue.

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3.2.3 Setup menu A
P1 CH off
<8> 45 6mm
Long press of the MENU button activates Setup menu A,
which contains 3 options:
• CH remote
• WF+V fac
• Delay car
Brief press of the MENU button toggles the menu items.
No buttons pressed in 3 seconds or a new long press on
MENU button exits the Setup Menu A.
CH remote
A CH off
CH remote: 0
Use + and – buttons to set the remote memory channels
function on or o:
• If CH setting is OFF, the selected P setting only
enables the corresponding carriage program
(P1, P2 etc.).
• If CH setting is ON, the selected P setting also
activates the corresponding 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 ne tuning is disabled at the carriage remote
control unit.
WF+V fac
A CH off
WF 0 V 0
Set the factor that is used for determining the roughness
of ne tuning and aects the adjustment of WFS and arc
voltage:
1. Use + button to select value 0, 1, 2, 3 or 4
(default = 2).
• Higher setting = wider steps
• Lower setting = narrower steps
2. Press MENU to continue.
The wire feeder scale varies according to the min/
max limits set in the power source. If the power source
holds narrow limits, the carriage may require a rough
scale. If limits have not been set in the power source,
the carriage requires a ner scale. Dierent applications
may benet from dierent scaling.

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Delay Car
A CH off
Delay Car: 600 ms
Set the start delay (the time that the carriage stands still
after welding has started):
1. Use + and – buttons to change the time.
2. Range: 100–3000 milliseconds
3. Press MENU to continue
Value CH2-CH5
A CH on
Value CH2: 4
Fine adjust the signal level of the memory channels at
the welding carriage for channels 2 to 5.
• Use + and – buttons to change the value.
You need to change these settings only if there is a
conict between the memory channels set by the wire
feeder and the welding carriage.
Adj0 WF
A CH on
Adj. 0 WF: 5
With this parameter you can ne-tune the signal zero
level for setting the wire feed speed value.
• Use + and – buttons to change the value.
In normal use, you never need to change the value
of this parameter.
Adj0 V
With this parameter you can ne-tune the signal zero
level for setting the voltage value.
• Use + and – buttons to change the value.
In normal use, you never need to change the value
of this parameter.

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3.3 Remote control unit
3.3.1 Basic functions
1. Press Stop to extinguish the arc and stop the
carriage.
2. Hold down ALT to activate the orange marked
secondary functions of the buttons.
3. CH rst press: Start test run (arc o) with
programmed speed and weaving.
4. CH second press during welding/running:
Carriage speed increases (up), or decreases
(down).
5. CH long press: High-speed transportation (arc
o).
Moves the centerline of weaving or welding to 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 weaving width by 1 mm per
press of button (0.5 mm on both sides).
3.3.2 Alt functions
Starts welding to the button’s direction. If on test run,
the arc ignites.
Activate the next (up) or previous (down) program,
including memory channel, if CH REMOTE is ON at the
wire feeder.
Increase (+) or decrease (-) the arc voltage
Increase (+) or decrease (-) the wire feed speed
Fine-adjustment of voltage and wire feed only works
when CH REMOTE is OFF at the wire feeder.
Stop terminates the operation of the carriage and stops
welding.

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3.4 Fine-adjustment of gun position
When the welding gun is xed in position and connected,
adjust its position vertically by turning the wheel on the
vertical slide clockwise (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 using Wise application software.
There are several Wise processes and functions available
for dierent welding applications. For more information
about Wise, please refer to FastMig documentation or
Kemppi website at www.kemppi.com.

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3.6 Ordering information
Product name Product code
A5 MIG RAIL CARRIAGE 2500 6190700
RAIL QUICK EXTENSION BRACKET 6190702
RAIL MAGNETIC BRACKET 6190703
RAIL VACUUM BRACKET 6190704
WEAVING TILT BRACKET 6190708
WEAVING TURN BRACKET 6190709
RAIL 2500 6190710
TORCH FLOATING HEAD 6190711
MACHINE CUTTING TORCH SP800679
CARRIAGE TRANSFORMER 6190714
CARRIAGE CONTROL CABLE 6190716
STORAGE BOX 6190717
MMT MN 32C welding gun (gas-cooled, multi-neck, 5 m, 320 A) 6250405
Neck 30°, 198 mm, RP (30° bent 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 W008124
NARROW GAP CONTACT TIP 1.0 M6 W008333
SUPERSNAKE GT 02SWC 15M 61541501
SUPERSNAKE GT 02SWC 25M 61542501C1
SUPERSNAKE GT 02SWC-70 20M 61542001
SUPERSNAKE GT 02SC 15 M 61531501
3.7 Technical data
Input Power 30 – 55 V DC or 24 – 50 V AC
Carriage Speed 5 – 150 cm/min
Transport Speed 200 cm/min
Weaving speed 10 – 50 mm/s
Weaving width 0 – 30 mm
Weaving displacement ± 40 mm
Dwell time
(Adjustable on both sides separately)
0 – 2.0 s
Weaving patterns 3
Torch horizontal adjustment (manual) ± 40 mm
External dimensions (L x W x H) 365 x 217 x 255 mm
Weight 7.3 kg

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4. TROUBLESHOOTING
4.1 Operation problems
Should you experience a malfunction from your machine,
please consult the troubleshooting sections below rst,
and complete some basic checks.
If the machine malfunction cannot be corrected with
these measures, contact your Kemppi maintenance
service workshop.
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 A5 MIG Rail System 2500.
Below instructions only apply to possible problems with
the carriage. Always ensure that the related welding
system is functional and ready for welding.
Problem: Check the following:
Carriage won’t work • Check that power reaches carriage (display is ON).
• Check that the welding power source is switched 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 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?
Arc is not ignited or welding
starts or stops strangely
• Check gun logic. 2T should be selected.
• Check torch connection.
Carriage moves but arc does
not start
Check that remote control buttons have been pressed
correctly:
• Stop+Up/Down ignites the arc and starts the carriage.
• If carriage is moving fast but arc is o, you may have
pressed Start button for too long.
The magnets do no longer hold • Magnets may be weakened. Replace the magnets.
• Material to fasten is not magnetic. Use vacuum or other
additional fastening method.
The vacuum cups do no longer
hold
• If they use compressed air, check compressed air supply.
• Clean surfaces and vacuum cups. Even small leakage can
greatly decrease suction.

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5. 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.
Make sure that the carriage does not start accidentally when your ngers are in
the wheel area.
5.1 Daily maintenance
• Check that all cables and plugs are intact.
• Keep the carriage and the torch holder clean.
• Check that all parts slide smoothly. Add grease or clean spatters if necessary.
• Check the gun’s condition.
5.2 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.
• Condition of the drive and support wheels. If worn, change.
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.
6. 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.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.