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A5 MIG Rail System 2500

Weld faster,

A compact, battery-driven mechanization solution for MIG welding

 





More details

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. 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.

 

 

 

Kemppi A5 MIG Rail System 2500

Key benefits

SAVINGS IN TIME

Additional increases in welding speed with the Kemppi WiseFusion process.

 

 

 

 

 

 

 

 

FILLER SAVINGS

With combined use of WiseFusion and WisePenetration processes



 

Key applications

 

 

Shipbuilding

Oil rigs

Machines

 

 

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
  • 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

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.

 

What's in the system ?

Equipments

 


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 applications. This unit is made for those who are looking to optimize welding productivity and quality.

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 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 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 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 A3 MIG Rail Welding Carriage product image

A3 MIG Rail Welding Carriage

Battery operated welding carriage driven by a robust electronic motor and equipped with welding gun holder. Battery has 8 hours of operating time and is commonly available, being an industry standard version. Lightweight carriage is easy to lift and move around.

Kemppi Rail 2500 with magnets product image

Rail 2500 with magnets

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 MMT 42C  product image

MMT 42C

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.