A5 MIG Rail System 2500

Weld faster

Mechanized MIG welding made extremely efficient and easy

Kemppi K5 Welding equipment Read more


A5 MIG Rail System 2500 is the most cost efficient way to improve productivity in mechanized MIG/MAG welding. The system has an inbuilt weaving and rail fastening mechanism with magnets or with vacuum suction cups. With the system you can achieve significant savings for all applications where the weld lengths exceed 2 m or in case of multi-layer welds. In mechanized welding, the welding carriage carries the gun (instead of being held in the operator's hand), making the arc movement accurate and steady. The setup includes the FastMig M 420, a top of the line welder with unique WISE welding application software. The smart WISE processes provide significant improvements in welding production efficiency.

Key benefits

SAVINGS IN TIME

SAVINGS IN TIME

Additional increases in welding speed with the Kemppi WiseFusion process.

FILLER SAVINGS

FILLER SAVINGS

With combined use of WiseFusion and WisePenetration processes

Key applications

Shipbuilding

Shipbuilding

Oil rigs

Oil rigs

Machines

Machines

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Benefits

  • Fewer human errors affecting the arc movement
  • Increased welding productivity
  • Light and durable Remote Control Unit makes operation simple and fast
  • Easy to use and quick to set up. Save time, costs, and repair work with the easy-to-use user interface and integrated power supply.
  • Fast setup time with light, strong, and flexible 2.5 m aluminum rails that can be bent to any curved surfaces, including pipes.
  • Magnetic fixing of rails significantly saves set up and reinstallation time Vacuum suction cups available for non-magnetic materials.
  • Multiple weaving patterns possible with integrated Weaving Unit
  • Can be used in any welding position.
  • Flexible adjustment of the tilt and push/pull angle enabled by the welding gun holder
  • Significant savings with Kemppi Reduced Gap Technology (RGT), more information www.kemppi.com

Weld 25% more per year

WiseFusion makes it possible to weld at a significantly higher speed, providing the same quality level and throat thickness as with a conventional spray and pulse arc. Synergic fusion is 20% faster than 1-MIG and pulsed fusion, and even 38% faster than conventional pulse welding. Welding speed increases from 60 cm/min to 72 cm/min, and arc-on time is 4% higher as there is no need for arc length adjustments (50-52% duty cycle). One of our use cases actually proved that you can weld 161 km (25%) more during the year with WiseFusion!

30 % SAVINGS ON LABOR AND FILLER COSTS BY USING WISEFUSION AND WISEPENETRATION SIMULTANEOUSLY

When combined, the WiseFusion and WisePenetration processes can save up to 30 % in filler material and welding time because a narrower groove angle can be used for butt joints up to 25 mm plate thickness from one side. A study made in the Lappeenranta University of Technology in Finland shows that fewer welding runs were needed to complete the joint when a 30° groove angle was used instead of the traditional 45°. In the example case, the consumption for filler material was reduced from 3.1 kg/m to 2.3 kg/m.

See it in action

Videos

A5 MIG Rail System 2500

Kemppi A5 MIG Rail System 2500 is the most cost efficient way to improve productivity in mechanized MIG/MAG welding.

How to setup A5 MIG rail system 2500

Kemppi A5 MIG rail system 2500 consists of power source, remote control unit, welding carriage, wire feeder, rail and welding gun.

Kemppi Reduced Gap Technology

Reducing the groove angle can add significantly to efficiency and productivity of welding of heavy metal structures.

What's in the system

Equipment

Kemppi A5 MIG Rail Welding Carriage product image

A5 MIG Rail Welding Carriage

Welding carriage driven by a robust electronic motor and equipped with welding gun ho...

Welding carriage driven by a robust electronic motor and equipped with welding gun holder and integrated gun weaving unit, with several optional weaving patterns. Gun weaving unit allows flexible adjustment of the tilt and push/pull angles. Two models - ES-model equipped with electric gun height control, DD-model equipped with double display to alloy viewing at any direction.

Kemppi A5 MIG Remote Control Unit product image

A5 MIG Remote Control Unit

Light and durable remote controller for welding parameter control and immediate chang...

Light and durable remote controller for welding parameter control and immediate change of program. Seamlessly integrated with Kemppi power sources. Starting, stopping, and changing the welding parameters is very quick and simple. Easy to learn and use.

Kemppi Rail 2500 product image

Rail 2500

Flexible high quality aluminum rails with extra strong magnets. Flexible 2.5 m long r...

Flexible high quality aluminum rails with extra strong magnets. Flexible 2.5 m long rails can used on different kind of surfaces from flat, curved to round up from 1500 OD onwards.

Kemppi FastMig M 420 Power source product image

FastMig M 420 Power source

The FastMig M 420 is a top performance multi-purpose power source, suitable for many ...

The FastMig M 420 is a top performance multi-purpose power source, suitable for many applications. This unit is made for those who are looking to optimize welding productivity and quality.

Kemppi FastMig MS 300 control panel product image

FastMig MS 300 control panel

MS control panel, which includes easy-to-use synergic functionality and a rich select...

MS control panel, which includes easy-to-use synergic functionality and a rich selection of additional features for optimizing your welding work. These packages are suitable for professional use in more demanding industrial applications. This panel is for for MXF 65 EL and MXF 67 EL wire feeders.

Kemppi MXF 65 EL Wire feeder product image

MXF 65 EL Wire feeder

EL wire feeder versions are suitable for synergic MS control panels. Flexibility and ...

EL wire feeder versions are suitable for synergic MS control panels. Flexibility and performance for all welding applications in today’s medium and heavy industries. This unit is compatible with 300 mm spool and is covered in an aluminum casing.

Kemppi MMT 42C product image

MMT 42C

MMT 42C is a welding gun for mechanized welding. This gun is available in 3 m (625420...

MMT 42C is a welding gun for mechanized welding. This gun is available in 3 m (6254205) and 4 m (6254207). Gas cooled, 420 A.

Application software and welding programs


WiseFusion

Ensures excellent weld quality, efficiency and ease of use. Keeps the welding arc foc...

Ensures excellent weld quality, efficiency and ease of use. Keeps the welding arc focused and guarantees the optimal arc length in any welding position in pulse and synergic MIG/MAG welding. Also available for automated welding.


WisePenetration

A welding function for ensured penetration in synergic MIG/MAG welding. Delivers cons...

A welding function for ensured penetration in synergic MIG/MAG welding. Delivers constant power to the weld pool regardless of changes in welding gun orientation or distance between the welding gun and work piece. Also available for automated welding.

Alternative

Equipment and software


FastMig X Intelligent

High-class multi-process solution for diverse demanding welding applications.

High-class multi-process solution for diverse demanding welding applications.


FastMig X Pipe

A multi-process welding solution specially designed for pipelines and pressure vessel...

A multi-process welding solution specially designed for pipelines and pressure vessels.


FastMig X Regular

High-end multi-process welding equipment for demanding industrial and manufacturing c...

High-end multi-process welding equipment for demanding industrial and manufacturing conditions.


SuperSnake GT02S/GT02SW subfeeder - subfeeder

If distance and access are your problem, then take a look at SuperSnake GT02S and GT0...

If distance and access are your problem, then take a look at SuperSnake GT02S and GT02SW. SuperSnake extends the reach of standard Euro MIG welding guns, providing simple distance wire feeding for a variety of filler wires up to 25m from the wire feed unit.

Kemppi FastCool 10 product image

FastCool 10

The FastCool 10 is a cooling unit designed for FastMig M welding equipment and is use...

The FastCool 10 is a cooling unit designed for FastMig M welding equipment and is used for cooling the welding gun.

Kemppi MT51MWC product image

MT51MWC

MT51MWC is a 500A water cooled welding gun for mechanized welding. Two lenght options...

MT51MWC is a 500A water cooled welding gun for mechanized welding. Two lenght options 4,5 m ( 6255162) or 6,0 m (6255163).

Kemppi MMT MN 32C product image

MMT MN 32C

MMT MN 32C is a 5 m gas-cooled multi-neck, 320A welding gun for mechanized welding.

MMT MN 32C is a 5 m gas-cooled multi-neck, 320A welding gun for mechanized welding.

Kemppi Rail 2500 with vacuum suction cups product image

Rail 2500 with vacuum suction cups

Flexible high quality aluminum rails with vacuum suction cups. Flexible 2.5 m long ra...

Flexible high quality aluminum rails with vacuum suction cups. Flexible 2.5 m long rails can used on different kind of surfaces from flat, curved to round up from 1500 OD onwards.

Extras and accessories

Technical specifications

Technical specifications

A5 MIG Rail Welding Carriage
Product code6190700
6190730 (-ES Model)
6190732 (-ES DD Model)
Carriage speed5 – 150 cm/min
Input power30 – 55 V DC or 24 – 50 V AC
Transport speed200 cm/min
Weaving speed10 – 50 mm/s
Weaving width0 - 30 mm
Weaving displacement± 40 mm
Dwell time (Adjustable on both sides separately)0 - 2.0 s
Weaving patterns3
Torch horizontal adjustment (manual)± 40 mm
External dimensions LxWxH365 x 217 x 255 mm
Weight7.3 kg
Rail 2500
Product code6190710
FastMig M 420 Power source
Product code6132420
Connection voltage 3~ 50/60 Hz400 V -15...+20%
Fuse (delayed)35A
Minimum generator power20kVA (60%)
18kVA (100%)
Welding rangeU0 = 50 - 58 V
Output 60% ED420 A
Output 100% ED380 A
Rated power 60% ED20 KVA
Rated power 100% ED18 kVA
Max. welding voltage45 V
Open circuit voltage MMAU0 = 48 – 53 V, Uav = 50 V
Open circuit voltage MIG/MAGU0 = 50 – 58 V
Welding current and voltage range, Stick (MMA)15 A/20 V – 420 A/44 V
Idle power25 W
Efficiency at max. current89 %
Power factor at max. current0.87
Welding current and voltage range, MIG20 A/12 V – 420 A/44 V
Operating temperature range-20 ... +40 °C
External dimensions LxWxH590 × 230 × 430 mm
Weight (no accessories)35 kg
Degree of protectionIP23S
StandardsIEC 60974-1, IEC 60974-5, IEC 60974-10
Storage temperature range-40 ... +60 °C
FastMig MS 300 control panel
Product code6136400
MXF 65 EL Wire feeder
Product code6152100EL
Output 60% ED520 A
Output 100% ED440 A
Wire feed mechanism4-roll
Filler wires, Ss0.6 – 1.6 mm
Filler wires, Al1.0 – 2.4 mm
Filler wires, Fe0.6 – 1.6 mm
Wire feed speed0 – 25 m/min
Diameter of feed rolls32 mm
Filler wires, Cored wire0.8 – 2.0 mm
Wire spool weight, max.20 kg
Wire spool diameter, max.300 mm
External dimensions620 × 210 × 445 mm
Weight11.1 kg
MMT 42C
Product code3 m - 6254205
4,5 m - 6254207
CoolingGas
Filler wires0.8…1.6 mm
Load capacity, Ar + CO2 (100%)350A

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Technical specifications