Miller Weldmaster Triad Extreme Manual
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Miller Weldmaster Triad Extreme Manual

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Instruction Manual
This instruction manual is intended to be a guide when operating the Triad Extreme Seam welder. To ensure optimal
performance from your welder, please follow the recommendations and specifications precisely.
For more technical information regarding this machine call our Resolution Center 1-855-888-WELD or email
service@weldmaster.com.
You can also subscribe to Miller Weldmaster Insiders to stay updated on tech tips, machine maintenance updates,
and more at www.weldmaster.com/insiders.
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Summary of Contents for Miller Weldmaster Triad Extreme

  • Page 1 Instruction Manual This instruction manual is intended to be a guide when operating the Triad Extreme Seam welder. To ensure optimal performance from your welder, please follow the recommendations and specifications precisely. For more technical information regarding this machine call our Resolution Center 1-855-888-WELD or email service@weldmaster.com.
  • Page 2 Instruction Manual Page 2...

  • Page 3: Table Of Contents

    Instruction Manual Table of Contents Chapter 1: Introduction Page 4-5 Chapter 2: Material Set-up Page6 Chapter 3: Operating Instructions Page 7 Chapter 4: Material Guides Page 8 Chapter 5: Welding Page 9-10 Chapter 6: General Maintenance Pages 11 Chapter 7: Wedge Cleaning and Honing Pages 12 Chapter 8: Wedge Adjustment Page 13-16...

  • Page 4: Chapter 1: Introduction

    Instruction Manual Introduction The Triad Extreme Seam hot wedge welding machine is designed for in house fabrication of a wide range of flexible membranes. This includes, but is not limited to, PVC, PP , PE, LDPE, Urethane, etc. Thickness of material that can be welded will vary also with product. Normal range is 5-100 mil thick- ness and can be supported or non-supported material.
  • Page 5 Instruction Manual Intended Use The Triad Extreme Seam Welder is a hot wedge welding machine intended to heat-seal weld- able thermal plastics such as: •Vinyl (PVC) laminated and coated fabrics •Vinyl (PVC) and Polyurethane (PU) films •Polyurethane (PU) and Polypropylene (PP) coated fabric •Polyethylene (PE)

  • Page 6: Chapter 2 Material Set-Up

    Instruction Manual Material Setup Material should be laid out as flat as possible, either on the floor or table depending on how you set up your fabrication area. With most material and especially thinner goods, it is prefered to pull out the wrinkles or pull taunt.

  • Page 7: Chapter 3: Operating Instructions

    Instruction Manual Operating Instructions The following procedures should be followed only after you have followed the Wedge Adjustment and Guide adjustment procedures. 1. Pull up on Red Power Switch #3 to turn machine on. The Green Power Light #4 will go on with a one second delay.

  • Page 8: Chapter 4: Material Guides

    Instruction Manual Material Guides All Guides shown below are included with the purchase of the standard machine. Each guide will give you a specific type of weld and more. You can only use one guide system at a time. The Top Guide will be used with all three different welding functions, overlap, hem and prayer welds.

  • Page 9: Chapter 5: Welding

    Instruction Manual Welding Overlap Weld Attach Overlap Guide #1 to base plate with the two screws provided. Loosen screw (A) to adjust bottom side of overlap for proper alignment and re-screw. Hem Weld Slide Hem Guide #2 onto the three stainless rods up to the outer Horn Guide #3 (Diagram #1), leaving enough area between the two so material will slide easily.
  • Page 10 Instruction Manual Prayer or Fin Weld Position the Prayer Guide #5 under the Welding Horn, placing the key way into the slot. Fasten with screw provided once proper alignment is completed. Front Guides Front Guides #6 are adjustable to pre-align material before you reach the welding process. This will help the operator in feeding material into machine properly.

  • Page 11: Chapter 6: General Maintenance Pages

    Instruction Manual General Maintenance General maintenance should be performed annually to your Triad Extreme Welder. Chain tension should be checked to alleviate excessive wear to the chains and sprockets. Using a foaming chain lubricant will cling to the chain and extend chain life.

  • Page 12: Chapter 7: Wedge Cleaning And Honing Pages

    Instruction Manual Wedge Cleaning and Honing For accurate welds and longer wedge life, the wedge should be cleaned and honed on a regular basis. CLEANING: Wedge cleaning should be done daily. There are two ways to clean the wedge. 1. With the Pressure Rollers in the up position and the wedge in the weld position, use the Brass Brush provided and clean wedge top and bottom.

  • Page 13: Chapter 8: Wedge Adjustment

    Instruction Manual Wedge Adjustment Proper wedge alignment is essential to achieve a proper weld. Units are preset at the factory. Sample welds should be made prior to actual use of the machine. If sample welds are good only on one side or the other, or only partially welded, this means the wedge is not aligned or square to the rollers, and alignment adjustment is needed.
  • Page 14 Instruction Manual Wedge Adjustment (Continued) 2. Swing Wedge Handle #2 in this will engage wedge with rollers. The wedge #4 should rest or fit snug into the rollers #3 on both sides and should be centered. CHAPTER 8 WEDGE ADJUSTMENT Page 14...
  • Page 15 Instruction Manual Wedge Adjustment (Continued) 3. To center wedge between rollers, turn screw #5, this will fine tune wedge up and down. Only a 1/8 or 1/4 turn is necessary. Do not overturn. Move Pressure Roller Handle up and down slowly to check centering adjustment.
  • Page 16 Instruction Manual Wedge Adjustment (Continued) 5. Wedge Stop Screw #9 will stop travel of wedge when positioning wedge in weld position. Loosen Locknut #10 , turn Adjustment Screw in or out to proper position. The edge of the wedge should fit snug and square into the rollers on each end. Make a test weld before proceeding with job.

  • Page 17: Chapter 9: Wedge Replacement Pages

    Instruction Manual Wedge Replacement The wedge should be replaced when honing and adjustment is no longer effective. If heater failure occurs after a period of time, the heaters may not be easily removed. The wedge and heater will most likely have to be replaced together.

  • Page 18: Chapter 10: Wedge Installation Pages

    Instruction Manual 10.0 Wedge Installation Install wedge on wedge mount arm along with lead bracket using two screws (note insert photo). Position heater wires properly on lead bracket and gently close tabs to secure. With wedge in engaged position, use zip ties to collect heater wires together.
  • Page 19 Instruction Manual 10.0 Wedge Installation (Continued) Using clip & screw, attach around heater wires and posi- tion to body of Triad. Do not fully tighten. Electrically connect hot wedge to receptacle on body of Triad. When connected, make com- fortable bend of heater wire and position properly in clip.

  • Page 20: Chapter 11: Troubleshooting Pages

    Instruction Manual 11.0 Troubleshooting Condition Possible Cause Corrective Action Wedge doesn’t heat Fuse blown Diagnose wedge Heater failed (220 Volt) Replace fuse Control or relay failure Replace wedge Loose wire Diagnose and replace control Check wiring contacts No drive, motor hums Chain break/binding Find and repair or adjust failed chain Pinch roller bearings...

  • Page 21: Chapter 12: Schematics

    Instruction Manual 12.0 Schematics 12.1 Lower Chassis/Bottom Side Travel System Page 21 CHAPTER 12 SCHEMATICS...
  • Page 22 Instruction Manual 12.0 Schematics 12.1 Lower Chassis/Bottom Side Travel System Drawing 300-M07-3-1 Part # Description 392025 #10 Washer 391050 10-32x.625 818ss SHCS 391060 10-32x.625 818ss FHCS 391051 10-32x.75 818ss SHCS 391072 10-32x.25 818ss SS 392007 Dowel Pin .250 x .625 310125 Idler / Travel Wheel &...
  • Page 23 Instruction Manual 12.2 Lower Chassis/Lower Roller Drive Page 23 CHAPTER 12 SCHEMATICS...
  • Page 24 Instruction Manual 12.2 Lower Chassis/Lower Roller Drive Drawing 300-M07-3-3 Part Description 391031 8-32x.625 818ss SHCS 391033 8-32x1.00 818ss SHCS 391050 10-32x.625 818ss SHCS 391026 8-32x.75 818ss SHCS 392008 Dowel Pin .250x.375 300035 Lower Final Drive Shaft Housing 310128 Needle Brng .687x.500x.625 310126 Pinch Roller 1.50 (std.) 392080...
  • Page 25 Instruction Manual 12.3 Wedge Control System & Upper Drive Pinch Roller Controls Page 25 CHAPTER 12 SCHEMATICS...
  • Page 26 Instruction Manual 12.3 Wedge Control System & Upper Drive Pinch Roller Controls Drawing 300-M07-5-1 Part # Description 391064 10-32x1.50 818ss FHCS 300058 Pinch/Wedge Drive Arm Hub 300056 Pinch Roller Engagement Arm Shaft 391075 Handle Knob 392012 Dowel Pin .125x.500 310160 Brng 1.875x.875x.500 300057 Pinch/Wedge Drive Arm Spindle...
  • Page 27 Instruction Manual 12.4 Wedge Control System & Upper Drive Wedge Controls Page 27 CHAPTER 12 SCHEMATICS...
  • Page 28 Instruction Manual 12.4 Wedge Control System & Upper Drive Wedge Controls Drawing 300-M07-5-2 Part # Description 300085 Wege Pivot Arm Hub 391072 10-32x.25 818ss SS 300084 Wege Pivot Arm Shaft 391075 Handle Knob 300080 Wedge Pivot Shaft 310157 Cam Roller Brng .500x.500x#10 300079 Wedge Height Adjuster 392020...
  • Page 29 Instruction Manual 12.5 Wedge Control System & Upper Drive Upper Roller Drive Page 29 CHAPTER 12 SCHEMATICS...
  • Page 30 Instruction Manual 12.5 Wedge Control System & Upper Drive Upper Roller Drive Drawing 300-M07-5-3 Part # Description 392012 Dowel Pin .125x.500 300072 Upper Roller Arm Lift Mount 391033 8-32x1.00 818ss SHCS 391051 10-32x.75 818ss SHCS 392025 #10 Washer 310126 Pinch Roller 1.50 (std.) 310128 Needle Brng .687x.500x.625 300024...
  • Page 31 Instruction Manual 12.6 Main Chassis Primary Drives Page 31 CHAPTER 12 SCHEMATICS...
  • Page 32 Instruction Manual 12.6 Main Chassis Primary Drives Drawing 300-M07-7-1 Part # Description 391028 8-32x.25 818ss SS 391051 10-32x.75 818ss SHCS 300018 Gear 24p 36t 300019 Gear 24p 36t 300020 Gear 24p 36t 310133 Bushing Aluminum .625 310158 Brng .75x.25x.28 300016 Lower Primary Chain Tensioner 300021 Sprocket Std.
  • Page 33 Instruction Manual 12.7 Main Chassis Motor and Internal Controls Page 33 CHAPTER 12 SCHEMATICS...
  • Page 34 Instruction Manual 12.7 Main Chassis Motor and Internal Controls Drawing 300-M07-7-3 Part # Description 391030 8-32x.500 818ss SHCS 391001 4-40x.500 818ss SHCS 391012 6-32x.500 818ss SHCS 391049 10-32x.500 818ss SHCS 391026 8-32x.75 818ss SHCS 391060 10-32x.500 818ss FHCS 391062 10-32x.875 818ss FHCS 300124 Over-Temp Control Panel 31055(-240) Over-Temperature Contact Relay (120V/240V)
  • Page 35 Instruction Manual 12.8 Main Chassis Assembly Page 35 CHAPTER 12 SCHEMATICS...
  • Page 36 Instruction Manual 12.8 Main Chassis Assembly Drawing 300-M07-7-5 Part # Description 391055 10-32x2.75 818ss SHCS 391050 10-32x.625 818ss SHCS 392006 Dowel Pin .250x.750 391053 10-32x1.00 818ss SHCS 300003 Chassis Motor Housing 300004 Chassis Control Housing 300006 Chassis Primary Drive Cover 300002 Chassis Housing 300089...
  • Page 37 Instruction Manual 12.9 Lap and Fin Weld System Page 37 CHAPTER 12 SCHEMATICS...
  • Page 38 Instruction Manual 12.9 Lap and Fin Weld System Drawing 300-M08-8-1 Part # Description 391054 10-32x1.75 818ss SHCS 391081 1/4-20x1.00 818ss SHCS 310149 Top Cover Handle 310148 Top Cover Handle 310147 Top Cover Handle 320022 Strain Relief 300005 Chassis Control Housing Top Cover 392078 Pinch Roller Tension Knob 300078...
  • Page 39 Instruction Manual 12.10 Hem Weld System Page 39 CHAPTER 12 SCHEMATICS...
  • Page 40 Instruction Manual 12.10 Hem Weld System Drawing 300-M07-9-3 Part # Title 391072 10-32x.25 818ss SS 392060 10-32x.625 303ss Thmb 300111 Hem Weld Outer Guide 300115 Hem Inner/Outer Guide Link 300096 Hem Outer Guide Retainer Rod 391073 10-32x.500 818ss SS CHAPTER 12 SCHEMATICS Page 40...
  • Page 41 Instruction Manual 12.11 Cord/Flat HemWeld System Page 41 CHAPTER 12 SCHEMATICS...
  • Page 42 Instruction Manual 12.11 Cord/Flat HemWeld System Drawing 300-M07-9-4 Part # Title 300352 Cord-Hem .25 Wedge Hsg 1.00 lp 300362 Cord-Hem Out/Top Gd .750x.080 300365 Cord-Hem Front Mat Gd 3/8 300367 Cord-Hem Front Mat Gd 3/8 & Lager 300372 Cord-Hem Out/Btm Gd 1.0x1/8-3/8 300375 Cord-Hem .500 Out/Btm Gd 1.00 lp 300376...
  • Page 43 Instruction Manual 12.12 Tube Guide System Page 43 CHAPTER 12 SCHEMATICS...
  • Page 44 Instruction Manual 12.12 Tube Guide System Drawing 300-M07-9-6 Part # Title 300330 Tube Weld Right Rear Retainer Mount 300331 Tube Weld Left Rear Retainer Mount 300332 Tube Weld Top Edge Guide Mount 300333 Tube Weld Top Edge Guide 300334 Tube Weld Right Front Retainer Mount 300335 Tube Weld Left Edge Guide 4.00 300336...
  • Page 45 Instruction Manual 12.13 Top Cover Hem & Handles Page 45 CHAPTER 12 SCHEMATICS...
  • Page 46 Instruction Manual 12.13 Top Cover Hem & Handles Drawing 300-M08-8-1 Part # Description 391054 10-32x1.75 818ss SHCS 391081 1/4-20x1.00 818ss SHCS 310149 Top Cover Handle 310148 Top Cover Handle 310147 Top Cover Handle 320022 Strain Releif 300005 Chassis Control Housing Top Cover 392078 Pinch Roller Tension Knob 300078...
  • Page 47 Instruction Manual 12.14 Top Cover Controls Page 47 CHAPTER 12 SCHEMATICS...
  • Page 48 Instruction Manual 12.14 Top Cover Controls Drawing 300-M08-8-3 Part # Description 310003 Contact n/o single contact 310002 Selector Switch 2 pos 310004 Selector Switch 3 pos 393050 Fuse Holder 310136 Main Temperature Control 38101(.2) Speed Control Potentiometer (110V/220V) 310111 Speed Control Knob 310006 Indicator Lamp Green Lense 310007(2)

  • Page 49: Chapter 13: Commonly Used Parts

    Instruction Manual 13.0 Commonly Used Parts 300-039A Wedge Heater Lead Bracket 300-130 Chain Rub Bottom/Rear 300-131 Chain Rub - Top/Rear 300-132 Chain Tensioner - Bottom/Front 300-133 Chain Rub - Top/Front 300-220C Lower Primary Chain (10”) 300-221C Lower Final Chain (26”) 300-222C Upper Final Chain (17”) 310-134...
  • Page 50 Instruction Manual NOTES:_________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ NOTES Page 50...

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