Miller Weldmaster T-100 Manual
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Miller Weldmaster T-100 Manual

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  • Page 2: Chapter 1: Machine Overview

    Page 1-1 Chapter 1: Machine Overview Section 1.1: Intended Use The T-500 and T-100 are rotary hot air welders intended to heat seal weldable thermal plastics such as: -Vinyl (PVC) laminated fabrics -Vinyl (PVC) coated fabrics -Vinyl (PVC) films -Polyurethane (PU) coated fabrics...
  • Page 3 Module 1.2.1: Electrical Supply The Miller Weldmaster T-500 and T-100 includes a power cord that is approximately 6 feet in length. Due to the number of different style outlets available, the cord will not include a plug. You may choose to have your power cord hard wired into your power supply.

  • Page 4: Hot Wedge

    Page 1-3 your female quick connect. The Miller Weldmaster T-500 and T-100 require the following shop air requirements: • Minimum of 65 psi at 3 cubic feet per minute. • Not to exceed 125 psi. • An in line water and dirt separator.
  • Page 5 Module 1.4.1: Transporting Within Production Facility Due to the weight of the Miller Weldmaster T-500 and T-100, the manufacturer requires a forklift or tow motor to be used. The forks are to be inserted below the bottom frame along the center of gravity.
  • Page 6 Units in Inches Module 1.4.2: Transporting Outside Production Facility The manufacturer requires the Miller Weldmaster T-500 and T-100 be placed on a pallet using a forklift or tow motor. The forks are to be inserted below the bottom frame along the center of gravity.

  • Page 7: Section 1.5: Explanation Of Symbols

    Heat... Figure 1.7: The Heat decal is placed on the protective guard of the T-100 and T-500. The symbol is to alert the user of the hot air or hot wedge. Section 1.5: Explanation of Symbols...

  • Page 8: About Your Miller Weldmaster

    Page 1-7 About Your Miller Weldmaster Each Miller Weldmaster has this sticker located on the rear of the machine. It identifies the model number and serial number of each welder. It will also state the voltage, amperes, and hertz required for operation.
  • Page 9 Page 1-8 Section 1.6: Controls: Purposes and Functions Figure 1.10: Circuit Breaker Circuit Breaker The purpose of the Circuit Breaker is to protect the machine if a short were to occur somewhere in the system. It is also used to disconnect the machine from the power source if needed.

  • Page 10: Power Switch

    Page 1-9 Figure 1.14: Power Switch Power Switch The purpose of the Power Switch is to turn the machine on and off. When using hot air, if the Power Switch is turned to the on position, the internal air compressor will run if the drive system is ready for operation.

  • Page 11: Heat Swing

    Page 1-10 Figure 1.17: Heat Swing Heat Swing Switch The purpose of the Heat Swing Switch is to control the swing action of the heat swing assembly. When the Heat Swing Switch is turned to the on position, the heat source will automatically swing into position for welding operation when the Drive Foot Switch is depressed.

  • Page 12: Outboard Puller Switch

    Page 1-11 Figure 1.20: Outboard Puller Switch Outboard Puller Switch The purpose of the Outboard Puller Switch is to control the Outboard Puller Assembly, which assists moving material from the welding area, in conjunction with the double roller beam. When the Outboard Puller Switch is turned to the on position, the Outboard Puller Assembly will automatically lower into the pulling position and the puller rollers will rotate when the Drive Foot Switch is engaged.

  • Page 13: Inboard Puller Sync

    Page 1-12 Figure 1.23: By turning the Outboard Puller Sync Control dial Inboard Puller Sync counterclockwise, the Outboard puller will decrease in speed in relation to the weld rollers. The Master Speed Control for the machine determines the overall speed of the weld rollers and puller rollers. The speed ratio between the weld rollers and puller rollers will remain the same whether increasing or decreasing the Master Speed Control.

  • Page 14: Inboard Puller Pressure

    Sync Upper Weld Roller Sync/Vari-Drive Every Miller Weldmaster T-500 and T-100 comes with some type of Upper Weld Roller Sync Control. It may have a digital Upper Weld Roller Sync Control, or it will have a mechanical Vari-Drive Control.
  • Page 15 Page 1-14 Figure 1.29: By decreasing the Upper Weld Roller Sync or the Vari-Drive, the Vari-Drive upper weld roller speed will decrease in relation to the lower weld roller. Section 1.6: Controls: Purposes and Functions Chapter 1: Machine Overview...
  • Page 16 Page 2-1 Chapter 2: Heating System Overview and Adjustments Section 2.1: Hot Air Heating System Nozzle placement is a key component in heat sealing. A properly placed nozzle will be centered on the weld rollers approximately 1/4 - 1/2 inches away and have a slight whistle during the welding process.

  • Page 17: Adjusting Nozzle Angle

    Page 2-2 Adjusting Nozzle Angle The Nozzle angle is the angle at which the Nozzle Tip is blowing air in at the Weld Rollers. This relationship should be parallel so that air flow is directed into the Weld Roller Pinch Point. Having the angle of the Nozzle misaligned will cause the fabric to become overheated leaving the seam under heated and unwelded.

  • Page 18: Preliminary Steps Before Adjusting The Nozzle

    Page 2-3 Preliminary Steps Before Adjusting The Nozzle Below are the steps that need to be taken before adjusting the nozzle NOTE:The Nozzle angle must be adjusted prior to step 1 while the Nozzle is cold to avoid personal injury. (See "Adjusting Nozzle Angle"...

  • Page 19: Nozzle Height

    Page 2-4 Nozzle Height The Nozzle Height is the vertical relationship that the Nozzle Tip has with the Weld Rollers. The ideal height of the Nozzle Tip will be vertically centered between the Weld Rollers so that the Air flow is directed into the pinch point. If the Nozzle is to high or to low, welding speeds will not be as efficient as possible and may cause the fabric to be ascetically overheated.
  • Page 20 Page 2-5 Depth of Nozzle The depth of the Nozzle is the distance that the Nozzle Tip is away from the Weld Roller Pinch Point, which is a very important factor when welding. The optimal distance is 0.25” to 0.50” away from the Weld Roller Pinch Point. Having the Nozzle too close to the Weld Rollers may result in the material contacting the Nozzle and burning the fabric, or cause the nozzle to be dragged into the rollers and cause damage to the nozzle.

  • Page 21: Nozzle Left/Right Alignment

    Page 2-6 Nozzle Left/Right Alignment The left/right alignment is the horizontal relationship the Nozzle has with the Weld Rollers. The center of the Nozzle must be placed directly in the center of the Weld Rollers. Having the Nozzle shifted to one side or the other will result in the weld being shifted to the side that the Nozzle is favoring leaving the opposite side unwelded.

  • Page 22: Adjusting Wedge

    Page 2-7 Section 2.2: Wedge Adjustment The placement of the Wedge is the most important part in Hot Wedge Welding. A properly placed Wedge will be centered on the weld rollers from top to bottom as well as left to right and have the correct angle, tilt and depth.

  • Page 23: Wedge Height

    Page 2-8 Wedge Height The Wedge Height is the vertical relationship that the Wedge Tip has with the Weld Rollers. The ideal height of the Wedge will be vertically centered between the Weld Rollers so that the Wedge Tip is directed into the pinch point. If the Wedge is to high or to low, welding speeds will not be as efficient as possible and may cause the fabric to be aesthetically overheated, or causing materials not to be welded.
  • Page 24 Page 2-9 Wedge Squareness The Wedge squareness is the horizontal angle that the Wedge Tip has with the Weld Rollers. This relationship should be parallel so that the Wedge Tip is aligned with the Weld Rollers. Having the angle of the Wedge misaligned will cause the seam to be less than 100% welded across the seam width.

  • Page 25: Tilt Of Wedge

    Page 2-10 Tilt of Wedge The Tilt of the Wedge is the vertical angle at which the wedge Tip is positioned in relationship with the weld rollers. This relationship must be parallel (or level) with the pinch point of the weld rollers. When the wedge tilt is out of adjustment the seam will be uneven across the width of the weld.

  • Page 26: Wedge Left/Right Alignment

    Page 2-11 Wedge Left/Right Alignment The left/right alignment is the horizontal relationship the Wedge has with the Weld Rollers. The center of the Wedge Tip must be placed directly in the center of the Weld Rollers. The edge of the tips must be placed so that neither side is left exposed on the right or left side of the weld rollers.

  • Page 27: Wedge Pressure Or Depth Adjustment

    Page 2-12 Wedge Pressure or Depth Adjustment Wedge Pressure is the amount of force that the Wedge is applying to both the top and bottom panel at the contact point pressing the fabric against the Weld Rollers. Adequate pressure of the Wedge will allow just enough heat to transfer into the material in order to produce a quality seam.
  • Page 28 Page 3-1 Chapter 3: Changing Heating Systems Section 3.1: Changing from Hot Air to Hot Wedge Figure 3.1: Figure 3.4: Turn the Heat and Power Switch to the off position to activate the cool down cycle and wait for the machine to shut down. Once the cool down cycle is complete and the machine has shut down the Main Power Supply must be disconnected.
  • Page 29 Page 3-2 Disconnect the black Hot Air Supply Line by pushing in the disconnect tab and removing Figure 3.6: Figure 3.11: the line. (Figure3.6) Loosen the two screws on the grey plug located on top of the machine and unplug it. (Figure3.7) (Figure3.8) Carefully remove the Hot Air Heating System by sliding the entire assembly upward until it...
  • Page 30 Page 3-3 Section 3.2: Changing from Hot Wedge to Hot Air Figure 3.15: Figure 3.18: Turn the Heat and Power Switch to the off position to activate the cool down cycle and wait for the machine to shut down. Once the cool down cycle is complete and the machine has shut down the Main Power Supply must be disconnected.
  • Page 31 Page 3-4 Remove the Hot Wedge Heating System by carefully sliding the entire assembly upward Figure 3.21: Figure 3.25: until it is free. (Figure3.21) Install the Hot Air Heating System by placing the Heating System mounting Plate into the slide and sliding the assembly down until the mounting plate is against the Height Adjustment Knob.

  • Page 32: Chapter 4: Operating Procedures

    Page 4-1 Chapter 4: Operating Procedures Section 4.1: Start Up 1. Insure that all cabinet doors are closed and locked. 2. Insure that all safety guards are in place. 3. Plug machine into proper electrical outlet, or turn on junction box if welder is hard wired in.

  • Page 33: Section 4.2: Shut Down

    Page 4-2 Section 4.2: Shut Down 1. Turn the Hot Air or Wedge Switch to the off position. The corresponding Temperature Controller should shut off. 2. Turn the Power Switch to the off position. The machine will not shut off immediately! Hot Air machines will go through a 3 minute cool down cycle to allow the heat elements to cool off.
  • Page 34 Chapter 5: Changing Welding Arms WARNING! Only a qualified technician may change the Welding Arm to this machine. The technician will be someone trained by a Miller Weldmaster representative. 1. Turn the Circuit Breaker to the off 4. Loosen the setscrew on the lower drive position.
  • Page 35 Page 5-2 7. Set the welding arm down in a safe 11. Insert the key and install the lower location. Unlock and open the front drive gear.Tighten the setscrew. Place cabinet door. key with the set screw indentation facing up so key will always fit into keyway ..

  • Page 36: Chapter 6: Welding Tips

    Page 6-1 Chapter 6: Welding Tips Section 6.1: Figure 6.1: Bad Weld Bad Weld This is not a good weld. Although the fabric is somewhat welded, it is not what would be considered 100%. One of two things must happen for this weld to become excepted. Either the speed must be decreased or the heat must be increased.
  • Page 37 Page 6-2 Figure 6.4: Upper Weld Roller going To Fast Upper Weld Roller going To Fast This is an example of the upper weld roller going too fast. The green panel goes through the left side of the welder and the yellow panel goes through the right side.

  • Page 38: Section 7.1: Maintenance

    Module 7.1.1: Cleaning The Air Filter Cartridge The Miller Weldmaster T-500 and T-100 have an internal air compressor that supplies airflow to the heat elements. Periodic cleaning and changing of the Air Filter Cartridge is necessary to maintain sufficient airflow. Insufficient airflow or any impurities in the airflow will shorten the life of the heat elements.
  • Page 39 Air Filter Cartridge every month. Warning! Only a qualified technician may perform maintenance on this machine. This may be a Miller Weldmaster representative or someone trained by a Miller Weldmaster representative. Warning! Machine must be disconnected from power source before any maintenance may begin.
  • Page 40 Page 7-3 1. Turn the Circuit Breaker to the off 5. Remove the Air Filter Cartridge. position. 6. Replace with a new Air Filter Cartridge, part number 30297. 2. Disconnect the power cord from the power supply. If the power cord is wired into the power supply, turn the power off at the junction box.
  • Page 41 Page 7-4 Module 7.1.3: Chains The Miller Weldmaster T-500 and T-100 have several chains that are used to drive weld rollers and puller rollers. Although not a high maintenance item, chains should be inspected once a year to ensure there is not excessive corrosion, rust, or dirt.

  • Page 42: Section 7.2: Replacing Components

    Section 7.2: Replacing Components Warning! Only a qualified technician may perform any maintenance on machine. This may be a Miller Weldmaster representative or someone trained by a Miller Weldmaster representative. Warning! Machine must be disconnected from power source before any maintenance may begin.
  • Page 43 Page 7-6 Module 7.2.1: Heat Elements The Heating Elements used by the Miller Weldmaster T-500 and T-100are rated for 1000 hours of use at 1000 degrees F (537 degrees C). Although longer heat element life is possible with proper maintenance, 1000 hours is the average.
  • Page 44 Page 7-7 7. Remove the 4 leads from the heat 11. Carefully remove the heat elements elements. from the element housing. 8. Loosen the 4 screws securing the NOTE:Inspect each element for any aluminum air divider. broken off fragments of glass or wire.
  • Page 45 #1 to red, wire #2 to yellow.Thermocouple The Miller Weldmaster T-500 and T-100 use a thermocouple to read the air temperature just before it reaches the nozzle, or the ambient heat from the wedge. The typical life expectancy of a thermocouple varies. The...
  • Page 46 Page 7-9 1. Turn the Circuit Breaker to the off 5. Remove thermocouple wire mounts. position. 6. Remove the bottom cover and some of 2. Disconnect the power cord from the the fiberglass insulation from the power supply. If the power cord is element housing.
  • Page 47 Temperature Controller or The Heat Elements are burning out prematurely. Warning! Only a qualified technician may perform any maintenance on machine. This may be a Miller Weldmaster representative or someone trained by a Miller Weldmaster representative. Section 7.2: Replacing Components...
  • Page 48 Page 7-11 Warning! Machine must be disconnected from power source before any maintenance may begin. 1. Turn the Circuit Breaker to the off 5. Remove the plastic cover an disconnect position. the 4 wires connected to the Heater Relay. 2. Disconnect the power cord from the power supply.
  • Page 49 Page 7-12 8. Reconnect the 4 wire leads to the Heater Relay. Yellow #0 to terminal 4, white neutral to terminal 3, red #3 to terminal 1, and red to terminal 2. 9. Close and lock the rear cabinet door. Section 7.2: Replacing Components...

  • Page 50: Chapter 8: Recommended Replacement Parts

    346307 Weld Roller Solenoid; Quantity -1- 350060 Standard Solenoid; Quantity -1- Miller Weldmaster and our distributors can ship parts to within 24 hours of your order. However you will eliminate down time and next day shipping costs by stocking these parts.

  • Page 51: Chapter 9: Accessories

    Page 9-1 Chapter 9: Accessories Section 9.1: Knurled Stainless Steel Weld Rollers Table 9-1: Knurled Stainless Steel Weld Rollers 3.200 inch O.D. 360001 0.500 inch width 360003 0.625 inch width 360005 0.750 inch width 360009 1.000 inch width 360013 1.250 inch width 360017 1.500 inch width 379025...
  • Page 52 Page 9-2 Section 9.2: Silicone Molded Weld Rollers Chapter 9: Accessories Section 9.2: Silicone Molded Weld Rollers...
  • Page 53 Page 9-3 Table 9-2: Table 9-4: Silicone Molded Weld Rollers 3.200 inch O.D. @ Silicone Molded Weld Rollers 3.200 inch O.D. @ Silicone Molded Weld Rollers 3.200 inch O.D Silicone Molded Weld Rollers 3.200 inch O.D 55 Durometer 70 Durometer 70 Durometer 70 Durometer 379451...
  • Page 54 Section 9.3: Rear Tension Rollers Table 9-5: Smooth Steel Rollers 3.200 inch O.D. 360225 2.000 inch width Section 9.4: Nozzles Table 9-6: Standard T-100 & T-500 Right Hand Hot Air Nozzles with Ball End 380701 0.500 inch width 380703 0.625 inch width 380705 0.750 inch width...
  • Page 55 380751 2.000 inch width *Most T-100 & T-500 welders are Right Hand Swing. The Swing is defined by the direction the Hot Air Nozzle swings into the welding position. For example, if the Hot Air Nozzle is normally positioned to the left and swings to the right to begin the welding operation, it is a Right Hand Swing.
  • Page 56 381033 Acrylic Hot Air/ Hot Wedge Universal Overlap Guide • 382001 T-100 & T-500 Adjustable Closing Guide • 382007 T-100 & T-500 Fin Seal Guide Adjustable up to 2 inches • 382009 T-100 & T-500 Adjustable Tape or Webbing Guide •...

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T-500

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