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AGM PA-15 Instruction Manual

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AGM Pin Welder
Instruction Manual
Model PA-15
AGM Industries, Inc.
16 Jonathan Drive, Brockton, MA 02301
TEL: 800 225-9990/ 508-587-3900 FAX: 800 342-5246
www.agmind.com
Read equipment manufacturer's manual before using this product. Failure
to do so can result in serious injury or death.

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  • Page 1 AGM Pin Welder Instruction Manual Model PA-15 AGM Industries, Inc. 16 Jonathan Drive, Brockton, MA 02301 TEL: 800 225-9990/ 508-587-3900 FAX: 800 342-5246 www.agmind.com Read equipment manufacturer’s manual before using this product. Failure to do so can result in serious injury or death.
  • Page 2 As is true for all types of welding equipment, serious injury may result if not properly used and maintained. Though numerous safety features are built into this welder, the users must familiarize themselves with the proper installation, usage and maintenance of the welder as outlined in this instruction manual.
  • Page 3 TABLE OF CONTENTS – MODEL PA-15 WELDER PAGE  Foreword and Warranty  Description of Welding System  System Operating Instructions  Model 250-C Weld Gun  Description of Accessories  Installing and Removing Collets, Stops, etc.  Installing 437G- & 250C-G Type Stops ...
  • Page 4 FOREWORD The AGM Model PA-15 is the most up to date welding system in the pin and stud welding industry. This welding system has been carefully constructed from the finest and most reliable parts available, with all components being rigidly inspected and tested to assure long and trouble free performance.

  • Page 5: Description Of Welding System

    The weld gun has a contoured, pistol shaped handle with a trigger button. As a safety feature, all AGM welding systems are designed so that the stud or pin must be in contact with the work piece before the weld cycle can be actuated.
  • Page 6 DESCRIPTION OF WELDING SYSTEM SYSTEM SPECIFICATIONS Model PA-15 Power Pack Model 250C Weld Gun Construction 16 Ga. Fabricated Steel Type Pistol Grip Mode Contact Dimensions 18” 9-1/2” W Weight 2lbs. 9-1/2” H Dim. 8 1/2” L x 2” D Weight 51 lbs.
  • Page 7 WELDING OPERATION WELDER SET UP Set up the weld gun as described on pages 8-15 (refer to the Gun Set-Up sheets for specific details). Next, install the cables as shown below. Note that the illustration shows the gun set up for “reverse” polarity. This polarity is used for welding tipped CD pins or studs to galvanized steel.
  • Page 8 WELDING OPERATION Adjust the voltage control to the desired setting for your application. Turn the AC line switch “on”. The green Weld Ready Light will glow within three seconds, indicating that the weld capacitors are charged and the unit is ready to weld.

  • Page 9: Model 250-C Weld Gun

    MODEL 250-C WELD GUN The AGM Model 250-C weld gun is a semi-automatic, contact welding tool that has been carefully engineered and designed for use with a wide variety of AGM accessories. Given normal care and use, this weld gun will require very little maintenance. When repairs are required, the complete disassembly of the weld gun can be accomplished in a matter of minutes.
  • Page 10 ADAPTER RING – This is used to extend the three legs in certain applications, such as when a longer collet protector is used to weld aluminum pins. ADJUSTABLE FOOT ASSEMBLY – This is necessary when welding very long CD pins and studs. It is used in conjunction with a stop and spark shield to stabilize the pin or stud.
  • Page 11 MODEL 250-C WELD GUN INSTALLATION AND REMOVAL PROCEDURES INSTALLING COLLET AND COLLET PROTECTOR A. Examine the inside of the collet adapter assembly for pitted areas or splatter. Clean by scraping with sharp object or replace if necessary. B. Insert the collet into the collet adapter assembly, making sure that it seats against the inside shoulder.
  • Page 12 MODEL 250-C WELD GUN INSTALLING TYPE 437G STOP A. Place stop inside the rear of the collet. B. Insert the collet, with stop, into the collet adapter assembly. C. Locate and tighten the collet holding set screws, as previously described. D.
  • Page 13 250C-G TYPE STOPS STUD LENGTH CATALOG NUMBER STOP LENGTH 1/4” - 5/16” 250C-G-*-0250 7” 3/8” – 7/16” -0375 6.875” 1/2” – 9/16” -0500 6.750” 5/8” -0625 6.625” 3/4” -0750 6.500” 7/8” -0875 6.375” 1” -1000 6.250” 1-1/4” -1250 6.000” 1-1/2” -1500 5.750”...
  • Page 14 MODEL 250-C WELD GUN INSTALLATION OF COLLET ADAPTER ASSEMBLY This procedure can be accomplished with a collet and stop or collet protector already installed. A. Before installing, be sure that the tapered surfaces of the collet adapter and shaft assembly are clean. Wipe with a clean cloth if necessary. B.

  • Page 15: Installing Or Changing Springs

    MODEL 250-C WELD GUN INSTALLING OR CHANGING SPRING A. Unscrew the end cap from the gun housing. B. Unscrew stop nut from the end of gun shaft. C. Unscrew the spring retainer and remove the washer from the housing. D. Remove the spring from the shaft. E.

  • Page 16: Illustration No. 1

    MODEL 250C WELD GUN DISASSEMBLY OF THE WELD GUN (Refer to Illustration No. 1, page 17) A. Remove handle cover screws (items 28, 29, & 45). B. Lift off the handle cover (item 38). C. Remove the nut, washer, and cap screw (items 34, 35, & 36) from the welding lead (item 40).
  • Page 17 ILLUSTRATION 1 (Not Shown) 2615-M ADAPTER ASSEMBLY INCLUDES ITEMS # 25, 13, 14 &24...

  • Page 18: Operating Suggestions

    Pull welder by cables. Leave weld cables coiled up while welding. Use wrong ground polarity for the application. Use pins or studs not designed for use with the AGM PA-15 Welding System. Care must be taken to operate this welder on the rated AC line voltage range (95-130 VACS) only.

  • Page 19: Maintenance

    PREVENTATIVE MAINTENANCE (see note at bottom of page) The Model PA-15 welding system has been designed to give maximum service with little maintenance. Like most equipment, however, a small amount of care and preventative maintenance is a wise investment. To minimize down time when repairs are required, AGM recommends you always have a spare gun and cables available and in good working order.
  • Page 20 SET-UP FOR WELDING STEEL/STAINLESS STEEL WELD PINS GUN SET UP WITH HEAVY (3”) SPRING 1. 12 & 10 gauge pins to galvanized steel 26 Gauge (.0217) and thicker. A. Set up the gun as described on page 8-15 of this manual. Refer to the chart below for collet and collet protector part numbers.
  • Page 21 SET-UP FOR WELDING ALUMINUM WELD PINS GUN SET UP WITH HEAVY 3” SPRING & 2367-M ADAPTER ASSEMBLY A. If previously installed, remove the legs (2) from gun. B. Install proper collet (5) and protector (4) make sure collet holding set screws are tightened securely.

  • Page 22: Welding Pins Over 7" Long

    SET-UP FOR WELDING PINS OVER 7” LONG GUN SET UP WITH HEAVY 3” SPRING & 2318-M FOOT PIECE ASSEMBLY A. Install proper collet (2); stop (1) and protector (3). Make sure collet holding set screws are tightened securely. See page 20 or 21 for part numbers. B.
  • Page 23 SET-UP FOR WELDING FLANGED STEEL & STAINLESS STEEL STUDS UP TO AND INCLUDING 1/4-20 DIAMETER UP TO 7” LONG GUN SET UP WITH HEAVY 3” SPRING A. Set up the gun as described on pages 8-15 of this manual, using the proper collet and collet protector.

  • Page 24: Welding To Curved Surfaces

    SET-UP FOR WELDING TO CURVED SURFACES GUN SET UP A. Set up the gun as described on pages 11-15 of this manual, using the proper collet and collet protector or stop (if required). Tighten the collet holding set screws securely. B.

  • Page 25: Typical Template

    TYPICAL TEMPLATE SPECIFICATIONS Material: Phenolic sheet Thickness: .0125” min., .0250” max The above drawing shows the spacing and diameter of the leg location holes. The two standard 1151-M legs are inserted into these holes. To ensure that the welded stud is perpendicular to the work surface, a third leg, shortened by an amount equal to the template thickness, may be used in the weld gun.

  • Page 26: Welding Through A Template

    SET-UP FOR WELDING THROUGH A TEMPLATE GUN SET UP A. Make a template as described on page 25. B. Set up the gun as described on pages 11-15 of this manual, using the proper collet and collet protector or stop (if required). Be sure the collet holding set screws are tightened securely.
  • Page 27 SET-UP FOR WELDING 5/16-18, 5/16 SHOULDER & 3/8-16 STUDS GUN SET-UP WITH HEAVY 3” SPRING AND 2318-M FOOT PIECE ASSEMBLY Install proper stop (1) and collet (2). Be sure the collet holding set screws are tightened securely. If previously installed, remove 1151-M legs from the face plate. Insert adjustable legs of foot piece into the holes in the face plate.
  • Page 28 CONTINUED SET-UP FOR WELDING 5/16-18, 5/16 SHOULDER & 3/8-16 STUDS CONTINUED WELDER SET-UP Weld Stud Size & Ground Approximate Collet Base Material Material Polarity Welding Voltage Steel/Stainless Non- Unplated Steel Standard 437-S-307 Flanged 5/16-18(M8) Galvanized Steel Reverse Aluminum Non- Flanged 5/16-18 437-S-307 Aluminum Standard...
  • Page 29 SET-UP FOR WELDING FLANGED & NON-FLANGED ALUMINUM & NON- FLANGED STEEL / STAINLESS STEEL STUDS THROUGH 1/4-20 DIAMETER GUN-SET UP WITH HEAVY 3” SPRING A. Set up the gun as described on page 11-15 of this manual, using the proper collet and stop.
  • Page 30 ALTERNATE GUN SET-UP FOR STUDS OVER 1-3/8” LONG GUN SET-UP WITH HEAVY 3” SPRING & 2318-M FOOT PIECE ASSEMBLY A. Install proper stop (1), collet (2) and protector (3). Make sure the collet holding set screws are tightened securely. See the chart below and on previous page for part numbers.
  • Page 31 SET-UP FOR WELDING CUPPED PINS IN THE FIELD GUN SET-UP WITH LIGHT 1-1/4” SPRING A. If previously installed, remove the three 1151-M legs, as they will interfere with the proper gun shaft movement. B. Install the 2506-M-125 light spring as instructed on page 15 of this manual. THIS SET UP IS FOR WELDING TO 22 GA.
  • Page 32 AGM insulated cupped pins are furnished with an insulator disc adhered to the underside of the washer. Be sure to specify “insulated”...
  • Page 33 437-PM MAGNETIC COLLET INSTRUCTIONS FOR REPLACEMENT OF WORN OUT COLLET PARTS The 437-PM-RK Repair Kit should be used to rebuild the 437-PM Magnetic Collet. It includes the following: 437-PM-1 Collet Insert, 437-PM-2 Cap Screw, 437-PM-7 Insulator Disc, 437-PM-4 Screw Sleeve Insulator, as well as the proper size Allen Wrench.

  • Page 34: Welding Powerbase And Double Pointed Pins

    SET-UP FOR WELDING POWERBASE AND DOUBLE POINTED PINS GUN SET UP WITH LIGHT SPRING (1-1/4”) AND 2318-M FOOT PIECE ASSEMBLY The set up listed below is for pins 2-1/2” and longer. For pins less than 2-1/2” see note on next page. A.
  • Page 35 SET-UP FOR WELDING POWERBASE PINS AND DOUBLE POINTED PINS Steel/ Stainless Collet Polarity Voltage Powerbase Pin Protector 437-106 12 Gauge (2.69mm) Standard 437-P-106 437-135 10 Gauge( 3.42mm) Standard 437-P-135 CAUTION: DO NOT USE POWERBASE PINS ON METAL LESS THAN 1/16” THICK. WELDING PROCEDURE Insert the weld pin and place it against the welding surface.
  • Page 36 WIRING DIAGRAM PA-15...
  • Page 37 WIRING DIAGRAM LEGEND – MODEL PA-15 SYMBOL PART NUMBER DESCRIPTION 3087-E Capacitor, Welding 2475-E Line Switch/Circuit Breaker CB1-A&B Part of 2475-E Switch only CB1-C “ “ “ SCR Voltage Sensor 3081-E Circuit Breaker, 20 Amp 2267-E Capacitor 3074-E Relay, Discharge...

  • Page 38: Illustration No. 3

    Illustration No. 2...

  • Page 39: Illustration No. 4

    Illustration No. 3...
  • Page 40 Illustration No. 4...

  • Page 41: Power Pack Parts List

    PA-15 POWER PACK PARTS LIST PART NO. QUANTITY DESCRIPTION 1046-E Receptacle, Weld 1086-M Name Plate 1107-E Receptacle, AC Control 1255-E 1434-E-6 Terminal Strip 2079-M-0375 Screw, Cover 2148-E Line Cord 2253-E 2295-E Light Weld Ready 2300-M Handle 2312-M Fan Guard 2394-M-JS1...
  • Page 42 NOTES Welder Serial Number ________________ Gun Serial Number ________________ AGM Industries, Inc. 16 Jonathan Drive, Brockton, MA 02301 Telephone: 1 (800) 225-9990 FAX: 1 (800) 342-5246 www.agmfasteners.com...

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