AIM HPM-350-HD Hybrid Pulse MIG Welder Owner’s Manual

HPM-350-HD Hybrid Pulse MIG Welder

AIM Hybrid Pulse MIG Welder -HPM-350-HD

The AIM Hybrid Pulse MIG Welder -HPM-350-HD is a battery-operated unit that comes with a specially designed charger to ensure the power needed to operate the machine. This manual contains valuable information concerning how to operate and maintain your new equipment properly and safely.

Standard Equipment

The standard equipment for the HPM-350-HD includes:

• Welder
• MIG Torch-Steel
• Torch/Cable Rack
• Ground Cable with Clamp

First Time Use

Before using the unit, it is important to charge it. The Battery Charge Status reading must be between 25.0 and 28.5 Volts. Follow these steps to charge the unit:

1. If batteries have not been provided from the factory, proper batteries must be installed (see battery specification). See Figure #1 for proper battery position.
2. The HPM 350-HD requires AGM/Spill proof batteries. Do not use flooded wet batteries.
3. Carefully connect battery terminals as shown.
4. Connect the Battery Charger-Battery twist lock plugs.
5. Check/Connect the Charger Power plug.
6. Connect the Welder/Charger System to a 110V-15Amp AC power supply.

Battery Specification: Replacement batteries must meet the following requirements. 12V Group 31 or Group 65 AGM Batteries with 950 Cold Cranking Amp Rating or Better. Two (2) Batteries are required, when batteries need replacing, both batteries should be replaced at the same time with matching batteries.

Important Safety Instructions

Please read the important safety instructions carefully before operating the HPM-350-HD. Safety instructions can be found on page 4 of the owner’s manual.

Warranty Information

Don’t forget to complete and mail the enclosed warranty registration card within 30 days of purchase. For factory assistance or service, call toll-free 1-800-644-2730 within the USA and Canada.

THANK YOU for purchasing an A.I.M. product. This Manual has been prepared to ensure that you experience years of trouble-free use of your new welder. Please read this manual and share it with any personnel that will be involved with the use and care of this equipment. Your Local Dealer will be able to provide product orientation and operating instructions. We at American Innovative Manufacturing believe this equipment and our other products will help you to be successful. It is our goal to help you make that happen. This manual contains valuable information concerning how to operate and maintain your new equipment properly and safely. Please read it carefully. Also, please complete and mail the enclosed warranty registration card. You must send in your warranty registration card within 30 days or your warranty may be void.

For factory assistance or service please call;
Inside the USA and Canada call toll free 1-800-644-2730

If you need assistance or service, first see the “Troubleshooting” section of this book. When calling – you will need your model and serial numbers. This information can be found on the back of the main unit.

Model:
HPM-350-HD
(Record the following information for easy reference)

Serial Number: ___

Purchase Date: ___

Local Representative: ____

IMPORTANT SAFETY INSTRUCTIONS:

WARNING – When operating this equipment, please follow basic precautions, including the following :

• Read all instructions before using this machine and its attachments.
• Use this equipment only for its intended use.
• All electrical service connections must be made by a qualified electrician. Risk of electrical shock.
• IMPORTANT! The welder may only be used by qualified personnel.
• Do not touch the work piece or welding tips during or immediately after use. Electrodes become hot and may cause severe burns.
• Make sure to use appropriate eye protection and other PPE when welding. The sparks and bright arc can injure eyes and unprotected skin.
• Do not weld near flammable materials. Sparks from welding could start a fire.
• Do not operate equipment unless all enclosure panels are properly installed, and electrical cords are in good condition. Risk of Electrical Shock and Pinch Points.
• Always wear protective face shield and other PPE when working with batteries. Risk of chemical burns
• Before using any welder, consult your physician if you have a pacemaker or any other medical conditions. Risk of death or personal injury.
• Failure to take basic safety precautions can result in serious injury and/or property damage
• Provide covers or other protection for items near the work area to prevent damage from sparks, welding arc or accidental contact.
• Batteries must be properly maintained; improperly maintained batteries may short out or explode.
• Contact Factory Service or your local dealer for all repairs or service to unit.

WARNING – Machine must always remain in upright position!

• Shut down unit, and disconnect input power before inspecting, maintaining or servicing the welder.
• Unplug the welder from the wall outlet before servicing, cleaning, or maintenance. Risk of electrical shock.
• Cigarettes, sparks or other ignition sources could cause battery to explode. Always shield eyes and face from battery. Do not charge, use booster cables or adjust post connections without proper instructions and training. Keep vent caps tight and batteries level.
• Do not place the welder on unstable or uneven ground. The welder might tip causing personal injury or serious damage to the welder and other property.
• Do not operate this equipment unless the user is fully trained in the safe use of welders and related accessories.

HPM-350-HD Standard Equipment and General Assembly

• Welder
• MIG Torch-Steel
• Torch/Cable Rack
• Ground Cable with Clamp

Items to be provided by others (not included with the basic welder)

• Compressed Gas Cylinder
• Compressed gas meters and gauges (available as an option)
• Compressed gas hoses and connection to the female fitting on back of welder
• Welding wire
• Consumable welding contact tips and other normal wear parts.

FIRST TIME USE

IMPORTANT—BEFORE YOU USE THE UNIT—CHARGE IT!
The Battery Charge Status reading must be between 25.0 and 28.5 Volts

CHARGING THE UNIT

Upon receiving you’re A.I.M. equipment, you must charge the unit before operating.

1. If batteries have not been provided from the factory, proper batteries must be installed (see battery specification). See Figure #1 for proper battery position
2. The HPM 350-HD requires AGM/Spill proof batteries. Do not use flooded wet batteries
3. Carefully connect battery terminals as shown.
4. Connect the Battery Charger-Battery twist lock plugs
5. Check/Connect the Charger Power plug
6. Connect the Welder/Charger System to a 110V-15Amp AC power supply

The HPM-350-HD is a battery-operated unit that comes with a specially designed charger to ensure the power needed to operate the machine. The A.I.M. charger is designed to automatically regulate the battery voltage level and should be charging when the machine is not in use. However, you may unplug the charger unit for an extended period as long as you plug the unit in at least one hour before operation. Periodic maintenance charging is required to maintain the batteries and extend battery life. Batteries need to be brought to full charge at least once per week. Refer to battery manufacturer recommendations if storing the machine for extended periods.

Battery Specification; Replacement batteries must meet the following requirements. 12V Group 31 or Group 65 AGM Batteries with 950 Cold Cranking Amp Rating or Better
Two (2) Batteries are required, when batteries need replacing, both batteries should be replaced at the same time with matching batteries.

Extended Storage:

• Consult battery manufacturer recommendation for extended storage of the batteries.
• For extended storage disconnect the batteries and/or remove them from the welder

Figure #2- Battery Locations and Orientation

Figure #3 Battery Charger Face

INDICATOR LIGHTS

There are two sets of three indicator lights displayed on the front panel of the machine; a set for each of the two batteries.

• The RED light indicates there is power to the charger.
• The YELLOW light indicates the charger is connected to the battery and charging when plugged into the 110V-15-amp power source.
• The GREEN light indicates high voltage level of the battery – full charge.

When the GREEN light flashes with the YELLOW charge light – this signals the battery is approaching a full charge.
When the GREEN light is on almost continuously – this indicates maximum charge.

• Green light should always alternate with yellow light.
• The alternating GREEN/YELLOW mode is signaling that the charger is in maintenance mode and maintaining the battery(s) at peak voltage
• It is recommended that units in daily use be kept plugged in to the power source to maintain the batteries
• If storing the unit for long periods, please refer to the battery manufacturer’s guidelines for battery storage

The voltage required for your charger’s power source is indicated on the back label of the charger.

Voltages Available

• 110 / 120 Volt 60 HZ
  Other voltages are available on special order contact A.I.M. for information.

WELD PREPARATION

Carefully examine the surface, looking for defects; cracks, contamination and rust. Properly prepare the work piece for welding. When the workpieces are treated with transport coatings applied, initially clean all sides. The work pieces need to be free of all coatings as required for proper weld technique

Special Note: Preparation is very important. It could be the difference in a successful weld and an unsuccessful weld. Take the extra time necessary to prepare the panel properly. Consult Welding and Preparation Specifications

WELDER SETTING GUIDLINES

Note: The tables below our general guidelines for setting the welder prior to welding; Actual setting may vary based on many factors, such as; Ambient temperature and humidity, battery condition, work piece preparation and position, operator preference and technique etc.

Figure #5 WELDER SETTING TABLES-STEEL/ALUMINUM/SILICON BRONZE

OPERATIONS & CARE INSTRUCTIONS

CHARGING

It is recommended that the machine be plugged into a 110V circuit when not in use, in order to keep the batteries charged, for optimum power. The charging system will not overcharge and will prolong the life of your batteries. It is preferred that this machine be plugged into an 110V circuit during any welding procedure.

BATTERY ONLY OPERATION

An important feature of the AIM MIG Welding Station is the ability to produce high quality welds on battery power alone. The duty cycle for battery welding will vary over a large range based on work piece thickness, metal alloy, battery condition. For the best result, start with the battery at or near full charge.

BATTERY CONDITION

The batteries, when provided from the factory are high quality commercial grade automotive style batteries. See charging instructions above for maintaining the battery charge state. The batteries should also be inspected periodically (monthly) for tightness of connections, swelling of the case and leakage. Batteries that show any signs of distress should be replaced or serviced by a qualified technician. Eye protection, rubber gloves and other personal protective equipment must be used when servicing the batteries. The battery MSDS is included with this manual and should be reviewed with all personnel to be using the welder.

CLEANING

The welder should be kept clean by wiping with a dust cloth. Internal components can be blown off with low pressure (inert) compressed air. Do Not Pressure Wash the AIM MIG Welding Station! Damage to the machine will occur and there is a potential for electrical shock injury to nearby personnel.

CHANGING WELDING WIRE SPOOL

Caution

• The gear drive can injure or crush fingers in open rolls, Keep Guards in Place
• Eye protection must be worn, weld wire can spring off reels when unrestrained; causing personal injury.
  • Open Hinged door (on right side of welder when facing the front)
  • Choose the correct wire size and alloy for the item to be welded
  • To remove a previously used wire spool that is still connected to the drive motor.
  • Use wire cutters to cut the wire where it enters the feed drive
  • Secure the wire to the feed spool
  • Open the torch nozzle and remove the contact tip.
  • Pull old wire through the torch cable and liner
  • Properly dispose of old wire scraps.
  • Remove spool holder nut and remove the old wire spool, and properly store
  • Install the new wire spool on the spool holder.
  • Wire must feed off the bottom of the spool
  • Check wire feed rollers to ensure that the proper rolls with the correct groove size and style (U or V) are installed for the wire size and alloy you have selected.
  • The wire is fed by the inboard roll groove. The wire diameter that the groove is made for is marked on the corresponding side of the feed roll.
  • Flip drive rollers or install the correct ones to get the right grove aligned with the wire axis.
  • Feed the wire from the new spool into the feed rolls
  • For ease of installation the first few inches of the new wire need to be strait and any burrs or sharp protrusion removed.
  • Keep the torch cable as straight as possible when feeding a new wire through the cable.
  • When the wire is through the torch cable the proper size contact tip is installed and the diffuser cover reinstalled

GENERAL INSTRUCTIONS

Do not try to weld with low batteries. This will cause a substandard weld and rapid heat build-up in cables. The charge indicator lights and/or analog voltage meters provide an indication of the battery charge condition. Monitor those indicators regularly to ensure proper weld performance.

Do not overheat the machine. Periodic cooling is suggested. Use “00” Steel Wool to clean the copper surfaces. Oils or contamination could interfere with the welding process.
Warning: Always turn the welder off and disconnect the power before conducting maintenance or changing wire spools

BATTERY CARE AND MAINTENANCE

Note: This machine is equipped with maintenance free batteries.

Equipment needed

• Gloves and Goggles
• Insulated wrench
• Baking soda
• Terminal protector spray
• Voltmeter
• Discharge tester (if available)

Safety

• Always wear protective clothing, goggles and gloves when handling batteries
• Do not smoke or allow open flames near batteries
• Avoid skin contact with battery electrolyte
• Use insulated wrenches and tool to avoid shorting batteries
• In case of contact with electrolyte flush with water immediately, seek medical treatment
• Charge batteries in ventilated area
• Always keep your machine and battery upright.
• Do not allow a battery to freeze, do not attempt to charge a frozen battery
• Avoid charging at temperatures over 120 degrees F.

Battery Connections
Faulty connections can lead to poor performance and property damage, meltdown or fire. Do not change the cable size that your machine was equipped with at the factory. Tighten battery connections properly using an insulated wrench. Use terminal protection to prevent corrosion.

Battery Ventilation
Do not block or cover ventilation panels. Always charge your machines battery in a properly vented area away from open flame or other ignition source.

Inspection
Periodically inspect your battery. The battery case must not be swollen or damage, replace the battery if physical damage is evident. Clean battery top and terminal connections if needed. Check batter connections and cables; tighten connections if necessary and replace any worn or damaged cables.

Cleaning

Clean the top of your battery with a cloth or brush and a solution of baking soda and water. Do not allow cleaning solution to get inside the battery. Keep the battery cabinet clean and dry.

Charging

Use the charger attached to the machine, this charger is designed to not over charge the battery. If other charging equipment is used please refer to the charger and battery manufactures’ recommendations to ensure compatibility. Fully charge your battery after each use.

Storage

• Fully charge battery before storing
• Store in a cool dry location, indoors or under cover
• If storing for long periods (greater than one month) disconnect battery from machine
• Batteries will self-discharge and should be fully charged every 4-6 weeks
• Fully charge battery when removed from storage before using
• Avoid direct exposure to heat sources, batteries self-discharge faster in hot weather.
• Do not allow battery to freeze. Batteries that are not fully charged can freeze during cold weather.

Battery Recycling

97% of a lead acid battery can be recycled. When it is time to replace your battery properly dispose of the old one at a licensed battery recycler and help keep the environment clean.

Material Safety Data Sheet

The MSDS sheet for your battery is attached to this manual.

Hybrid Pulse MIG HPM-350 PERIODIC MAINTENANCE

Note: Follow safety instructions before performing maintenance

• DAILY
  • Inspect for damage to the machine, torches and gas system. Make any repairs or adjustments. Check for leakage or unusual odors from the battery compartment
• MONTHLY
  • Inspect cables for cuts or damage.
  • Use fine steel wool on copper connections.
• EVERY 6 MONTHS
  • Check and inspect batteries
  • Check and tighten all electrical connections
• ANNUALLY
  • Remove dust from charging unit. Use low pressure dry compressed air to blow out dust

USEFUL OPERATING INFORMATION

Keeping your battery fully charged after use will increase the life of your battery. Keep welding tips cool. A low battery will cause excessive cable heat. Gases from battery vent out of the machine. Baking soda should be used to neutralize battery acid in the event of a spill. Refer to MSDS from battery manufacturer for additional information

TROUBLE SHOOTING

LIMITED WARRANTY

American Innovative Manufacturing LLC (AIM) of Spokane, WA, subject to the terms and conditions described below, warrants to its original retail purchaser that new AIM equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by AIM. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. AIM PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF THE EQUIPMENT. AIM shall honor valid warranty claims on warranted equipment for a period of ONE YEAR in the event of such a failure within the warranty time period. All warranty time periods start on the date manufacture of the equipment and not to exceed one year after the equipment is shipped to a distributor or retail customer. Within the applicable warranty period AIM will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. AIM must be notified in writing within thirty (30) days of such defect or failure, at which time AIM will provide instructions on the warranty claim procedures to be followed.

AIM’s Limited Warranty shall NOT apply to:

1. Consumable components or parts that fail due to normal wear.
2. Items furnished by AIM but manufactured by others. These items are covered by the  manufacturer’s warranty, if any.
3. Equipment that has been modified by any party other than AIM, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at AIM’s option:

1. Repair,
2. Replacement,
3. The reasonable cost of repair or replacement by an authorized AIM service representative (where authorized in writing by AIM in appropriate cases), or
4. Payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. AIM’s option of repair or replacement will be F.O.B., Factory at Spokane, WA, or F.O.B. at an AIM authorized service representative as determined by AIM. Therefore, no compensation or reimbursement for transportation costs of any kind will be allowed.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL AIM BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY AIM IS EXCLUDED AND DISCLAIMED BY AIM.

WARRANTY QUESTIONS?
Call Customer Service 1-800-644-2730

The Panel Beater is a Registered Trademark of American Innovative US Patent Nos. 5,516,997 / 5,917,394 & Other Patents Pending

REPLACEMENT PARTS & ACCESSORIES

(Available through your dealer or at www.ai-mfg.com)

Parts and accessories available please visit our website: www.ai- mfg.com

SHIPPING & HANDLING PROCEDURES

HYBRID PULSE MIG HPM-350-HD

This machine contains AGM batteries. Each battery is liquid tight when battery manufacture instructions are followed. However, in the event the battery is tipped over and some acid spillage does occur, neutralize the acid with baking soda. Refer to the battery manufacturer MSDS sheet for additional information Should acid get on your skin, immediately flush the area with a large quantity of water. This machine is designed for indoor environments protected from weather, dust and high temperatures. The machine should be properly packaged and protected from damage during shipping. Hazardous material notifications may be required when shipping this machine. Follow all A.I.M. guidelines and use proper safety procedures when handling this machine.

WARRANTY REGISTRATION INFORMATION

Please Record the Following Information

Owner: _____ Location: __ Owner Address: ____ Owner Telephone: _ Fax: ____ Owner E-Mail: _____
Dealer: ____ Dealer Telephone: __ Dealer E-Mail:

Serial Number: ___ Date of Manufacture: ____ Date Placed in Service: _

AIM MIG OWNER’S MANUAL Rev. 2019:
SHIPPING & HANDLING PROCEDURES 31

References

• AIM | American Innovative Manufacturing - Panel Beater Battery-Powered Dent Puller, MIG and Spot Welders
• AIM | American Innovative Manufacturing - Panel Beater Battery-Powered Dent Puller, MIG and Spot Welders

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