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Miller Weldmaster 112 Operating Manual

Cross seamer
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Model 112 Cross Seamer
Operating Manual

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Summary of Contents for Miller Weldmaster 112

  • Page 1 Model 112 Cross Seamer Operating Manual...

  • Page 2: Table Of Contents

    Contents Intended Use Explanation of Warnings Electrical and Air Requirements Principles of Heat Sealing Controls: Purposes and Functions Recommended Replacement Parts Guides Weld Rollers Nozzles Carriage Belts Nozzle Adjustments Laser Alignment Micro-Switch Adjustments Maintenance Replacing Heat Elements Replacing Air Filter Cartridge Replacing Thermocouple Replacing Heater Relay Electronics Panel...

  • Page 3: Intended Use

    Intended Use The 112 Cross Seamer is a rotary hot air welder intended to heat seal weldable thermal plastics such as: Vinyl (PVC) laminated fabrics Vinyl (PVC) coated fabrics Vinyl (PVC) films Polyurethane (PU) coated fabrics Polyurethane (PU) films Polypropylene (PP) coated fabrics...

  • Page 4: Explanation Of Warnings

    Explanation of Warnings There are several different warning symbols placed on the Miller Weldmaster Model 112. These symbols are to alert the operator of potentially hazardous areas on the machine. Familiarize yourself with the their placement. Caution, Laser Radiation. Do Not Stare into Beam or View Directly with optical instruments.
  • Page 5 Warning, High Temperature Air. The Warning, High Temperature Air sticker is placed on the Heater Assembly. The Miller Weldmaster 112 is capable of temperatures reaching 1350 degrees F. Caution, Do Not Apply Stress The Caution, Do Not Apply Stress sticker is placed on the Heater Assembly.

  • Page 6: Electrical And Air Requirements

    Electrical Supply The Miller Weldmaster 112 Cross Seamer includes a power cord that is approximately 12 feet in length. Due to the number of different style outlets available, the cord will not include a plug. It is recommended that your electrician install a plug that is comparable to your style power outlet.

  • Page 7: Principles Of Heat Sealing

    Principles of Heat Sealing Heat The heat required for the welding operation is created electrically by two heating elements located inside the heat element housing. The internal air compressor pumps air over the heat elements and carries the heat through the hot air nozzle, applying the heat to the material to be welded.

  • Page 8: Controls: Purposes And Functions

    Controls: Purposes and Functions Circuit Breaker The purpose of the Circuit Breaker is to protect the machine if a short were to occur somewhere in the system. Flipped to the on position, the Circuit Breaker will supply the machine with electricity for operation.
  • Page 9 When flipped to the Weld position, the model 112 will be in the welding mode when the start button is depressed. When flipped to the Cut position, the model 112 will be in the cutting mode when the cutter jog button is depressed.
  • Page 10 The purpose of the Temperature Controller is to control and monitor the Temperature Controller temperature of the air going into the nozzle. The Temperature Controller input is adjusted by using either the up or down arrows to set the desired temperature which is displayed in green. The actual temperature is displayed in red.
  • Page 11 The purpose of the Weld Roller Pressure Regulator is to vary the Weld Roller Pressure amount of pneumatic pressure between the weld roller and the welding track Increasing the Weld Roller Pressure will increase the amount of pressure between the weld roller and welding track. Decreasing the Weld Roller Pressure will decrease the amount of pressure between the weld roller and the welding track.

  • Page 12: Recommended Replacement Parts

    Recommended Replacement Parts Miller Weldmaster recommends keeping the following quantities of spare parts in stock: 2) 330207 Air Filter Cartridge 4) 330305 Heat Elements 1) 330033 Heater Relay 1) 322291 K-Thermocouple Assembly 1) 330093 Micro Switch 1) 330097 Micro Switch Cover...
  • Page 13 1) 350060 Standard Solenoid 1) 376495 Roll of Teflon Tape 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 14: Guides

    Guides Overlap Guide #379139 Pocket Guide #322363 ½ inch Hem Guide #379162 ¾ inch Hem Guide #379164 1 inch Hem Guide #379166 Adjustable Tape Guide #322654 Truck Beading Guide #379248...

  • Page 15: Weld Rollers

    Weld Rollers Stainless Flex Hub Weld Roller 4.00 inch O.D. 362200 0.375 inch Stainless Flex Hub 362201 0.500 inch Stainless Flex Hub 362205 0.750 inch Stainless Flex Hub 362209 1.000 inch Stainless Flex Hub 362213 1,250 inch Stainless Flex Hub 362217 1.500 inch Stainless Flex Hub 362221 1.750 inch Stainless Flex Hub 362225 2.000 inch Stainless Flex Hub...

  • Page 16: Nozzles

    379781 1.500 inch Nozzle 379782 1.750 inch Nozzle * 379783 2.000 inch Nozzle * Left Hand Preheat Hot Air Nozzles for 112 with 3inch Offset Ball Style for Swing 379800 0.750 inch Nozzle 379801 1.000 inch Nozzle 379802 1.250 inch Nozzle 379803 1.500 inch Nozzle...

  • Page 17: Carriage Belts

    Carriage Belts There are a total of 3 belts within the carriage assembly. #379079 Double Sided Drive Belt This belt is located in the upper carriage assembly. #379077 Long Drive Belt This belt is located in the 3.5 X 3.5 square tubing.

  • Page 18: Nozzle Adjustments

    Nozzle Adjustment Nozzle placement is a key component in heat sealing. A properly placed nozzle will be centered on the weld roller approximately ¼ inch away and have a slight whistle during the welding process. When an adjustment is needed, turn the speed control to a low setting. Make the adjustment and check the nozzle placement be engaging the Start Switch.

  • Page 19: Laser Alignment

    Overlap Seam 1. Turn the 112 power switch on. Leave the heat switch and the power switch in the off position. Load some scrap vinyl under the fabric clamp and extend to the end of the machine. Turn the left and right vacuums on.
  • Page 20 5. When finished, the laser lines should line up perfectly with the drawn line. Butt Seam Flip the Laser Switch to the Butt Seam mode. Move the weld roller over so that the edge against the laser. Follow the same procedure as the Overlap Seam.

  • Page 21: Micro-Switch Adjustments

    Micro-Switch Adjustments This page will detail each of the micro-switches on the Miller Weldmaster 112. It will describe the micro-switch function and what the adjustment will change. The first three pictures are shown as sets. All are adjusted by loosening the clamping collar and sliding the set into the desired position, than tighten the collar.
  • Page 22 Forward End Limit Switch - This micro-switch will stop the forward motion of the welding or cutting process when tripped. It can not be adjusted. Pull Cord Stop Limit Switch - This micro-switch will stop the welding or cutting process when activated. The switch itself can not be adjusted. To make an adjustment, do so to the pull cord itself.

  • Page 23: Maintenance

    Machine must be disconnected from power source before any maintenance may begin. Air Filter Cartridge The Miller Weldmaster 112 Cross Seamer has an air compressor that supplies airflow to the heat elements. Periodic cleaning and changing of the Air Filter Cartridge is necessary to maintain sufficient airflow.
  • Page 24 5. Using brake cleaner or a product containing high amounts of Ether, spray the Air Filter Cartridge from the inside out. 6. Dry the Air Filter Cartridge by blowing the Air Filter Cartridge from the inside out with shop air. 7.

  • Page 25: Replacing Components

    Machine must be disconnected from power source before any maintenance may begin. Heat Elements The Heating Elements used by the Miller Weldmaster 112 are 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 26 8. Remove the 4 leads from the heat elements. 5. Unplug the 2 Thermocouple leads. 9. Loosen the 4 screws securing the aluminum 6. Remove the top covering of the element air divider. housing and slide it out of the way. 10.
  • Page 27 14. Install the aluminum air divider. 11. Remove the aluminum air divider. 15. Install the 4 spacers and screws and tighten 12. Carefully remove the heat elements from the down. element housing. 16. Connect the four wire leads to the elements. Warning! Inspect each element for any broken off Make sure wires #1 and #3 plug onto one...
  • Page 28 20. Install the 2 bolts into the top of the heat 17. Insert the 2 pieces of insulation between the element housing and tighten. wires and the aluminum air divider. 21. Connect the thermocouple wire leads, wire 18. Slide the top covering back onto the heat #1 to red, and wire #2 to yellow.
  • Page 29 Replace Air Filter Cartridge Every 2 Months If the surrounding conditions in your production area are not clean, it is recommended that you change the Air Filter Cartridge every month. Otherwise change the Air Filter Cartridge every 6 months. 4. Remove the Air Filter Cartridge. 1.
  • Page 30 Thermocouple The Miller Weldmaster 112 uses a thermocouple to read the air temperature just before it reaches the nozzle. The typical life expectancy of a thermocouple varies. The thermocouple should be replaced if the machine does not maintain a constant temperature of +/- 2 Degrees F (+/- 1 Degree C) or the heat elements burn out prematurely.
  • Page 31 7. Remove the bottom cover and some of the 10. Install the new thermocouple with all the fiberglass insulation from the element spacers in the sequence shown. Make sure the housing. thermocouple is inserted all the way. 8. Using a 7/16 wrench, carefully loosen and 11.
  • Page 32 13. Install the thermocouple wire mount. 16. Install the safety guard, spacers and screws to the bottom element housing. 14. Plug in the thermocouple leads, wire #1 to red, and wire #2 to yellow. 15. Install the nozzle and clamp. Make certain to install the clamp with the ring side up.

  • Page 33: Heater Relay

    Heater Relay The Heater Relay acts as an interpreter between the Thermocouple and the Temperature Controller. Generally the Heater Relay will last several years. The Heater Relay should be replaced id the machine is experiencing erratic temperatures on the Temperature Controller or the Heat Elements are burning out prematurely.
  • Page 34 7. Install the new Heater Relay using the 2 mounting bolts. 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.

  • Page 35: Electronics Panel

    330163 12 Point Euro Strip 330029 Ratchet Relay 379261 5 Hp. Inverter 330751 Digital Display Power Supply 330041 Preheat Relay 379330 112 Relay 330707 Control Relay, 330708 Socket 330009 Brake Relay, 330013 Socket 330021 Cube Relay, 330025 Socket 330099 Fuse Block...
  • Page 36 Fabric/Application Process Control Sheet Material : _______________________________ Created by : ____________________________ Date : ______________________ Weld Weld Roller Torque Drive Roller Vacuum Pressure Temp. Speed Pressure Delay (√ = Steel) (X = Off) Overlap Seal Butt Seal with Tape on One Side Hem with Rope Pole Pocket Webbing Reinforcement...

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