Miller Weldmaster 112 Extreme Manuale utente
Instruction Manual
Page 1
330.833.6739
www.weldmaster.com
This instruction manual is intended to be a guide when operating the 112 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 at 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.
Instruction Manual
Page 2TABLE OF CONTENTS
Chapter 1: Intended Use
Chapter 2: Explanation of Warnings
Chapter 3: Electrical and Air Requirements
Chapter 4: Principles of Heat Sealing
Chapter 5: Definition of Controls
Chapter 6: Recommended Replacement Parts
Chapter 7: Adjustments
Chapter 8: Maintenance
Chapter 9: Transportation Specs and Storage
Chapter 10: Troubleshooting
Page 3
Pages 4-5
Page 6
Page 7
Pages 8-14
Page 15
Pages 16-25
Pages 26-29
Page 30
Page 31-34
Table of Contents
Instruction Manual
Page 3
1.0 Intended Use
CHAPTER 1 INTENDED USE
The 112 is a rotary hot air welding machine intended to heat-seal weldable 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)
•Thermoplastic rubber (TPR) film and fabrics
•Non-woven Polyester and Polypropylene
•Various Fusing Tapes
•Weldable Webbing
•Rigid Extruded Products
The manufacturer does not approve of:
•Any other uses for these machines.
•The removal of any safety guards while in operation.
•Unauthorized modification of the machines.
•Using replacement parts that are not manufacturer-approved.
Only a properly-trained technician may operate and/or perform any routine
maintenance or repairs to the machines.
NOTE: The manufacturer will not be held liable for any damage or injuries occurring
from any inappropriate use of this machine.
Instruction Manual
Page 4CHAPTER 2 EXPLANATION OF WARNINGS
2.0 Explanation of Warnings
There are several different warning symbols placed on the Miller Weldmaster 112. The symbols
are to alert the operator of potentially hazardous areas on the machine. Familiarize yourself with
their placement and meaning.
Danger: Pinch Points
The “Danger: Pinch Points” symbol is placed near any
potential pinch points. Do not place any body parts
near these sections of the machine while the machine
is running.
Caution: Unplug Machine
The “Caution: Unplug Machine” sticker is placed near
the opening of the cabinet and all access panels. To
prevent electrocution, the machine should always have
the power disconnected before the cabinet door is
open.
Caution: Hot
The “Caution: Hot” symbol is placed on a guard near-
hot surfaces.
Caution: Laser Radiation
Do not stare into beam or view directly with optical
instruments. The “Caution: Laser Radiation” symbol
is placed just below all the lasers on the 112 Extreme.
Do not look directly into the laser source. They are for
fabric alignment only. Use caution when calibrating the
lasers.
Instruction Manual
Page 5 CHAPTER 2 EXPLANATION OF WARNINGS
2.0 Explanation of Warnings
Caution: Electricity
The “Caution: Electricity” sticker is placed near areas
that contain electrical.
Warning: Keep Hands Clear
The“Warning: Keep Hands Clear” sticker is placed on
the Heater Assembly. To prevent any pinching or burns,
be aware of the location of your hands at all times.
Warning: High Temperature Air
The “Warning: High Temperature Air” sticker is
placed on the Heater Assembly.
Instruction Manual
Page 6
3.0 Electrical and Air Requirements
CHAPTER 3 ELECTRICAL AND AIR REQUIREMENTS
Warning! Only a qualified electrician may connect the electrical power.
Electrical Supply
Due to the number of different style outlets available, the cord will not be included. It is
recommended that your electrician install a cord and plug that is comparable to your style
power outlet. You may choose to have your power cord hard-wired into your Power Supply.
It is recommended that your electrician use a Junction Box with an ON/OFF switch with
short circuit protection as required by local electrical code to be suitable for the primary
disconnect. The Miller Weldmaster 112 Extreme requires one of the following power
supplies. Please reference the electrical schematic for which power supply your machine
requires.
•80 Amperes - Single phase - 230 Volts
•80 Amperes - 3 phases - 230 Volts
•50 Amperes - 3 phases - 400 Volts
Shop Air Supply
The Miller Weldmaster 112 Extreme includes an In-Shop Air Supply Valve that allows quick
connects and disconnects to your shop air supply. Due to the number of different style
airline connectors, a male quick-connect is not included. You will want to select a male
quick-connect with a ¼ inch NPT (National Pipe Thread) to match your female quick-connect.
The Miller Weldmaster 112 Extreme requires the following shop air requirements:
•Minimum of 12 cfm at 120 psi
•Not to exceed 340 liters/min at 8.2 Bar
•An in-line water and dirt separator
Instruction Manual
Page 7
4.0 Principals of Heat Sealing
CHAPTER 4 PRINCIPALS 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. The hot air temperature ranges from 25 to 730 Degrees Celsius (100 to 1350 Degrees
Fahrenheit).
Speed
The Speed of the Weld Rollers determines the amount of time the heat is applied to the material
being welded. The slower the speed setting, the more the material will be heated. The faster the
speed setting, the less the material will be heated. To achieve the best weld, a minimal amount
of heat should be applied to the material while still achieving a full weld. Too much heat will
cause distortion of the material; while not enough heat will prevent the material from welding.
Pressure
The pressure of the weld roller is the final step when creating a weld. The pressure of the weld
roller compresses the heated material together completing the welding process.
Summary
When heat sealing, the correct combination of heat, speed, and pressure will allow you to
achieve a properly welded seam.
Instruction Manual
Page 8CHAPTER 5 DEFINITION OF CONTROLS
5.0 Definition of Controls
Main Menu
1. Alarms: The alarm button will take the operator to the alarm
screen. This allows a technician to see any alarms the 112
Extreme may have encountered.
2. Maintenance Configuration: The Maintenance Configuration
button will take the operator to the Maintenance Configuration
screen. To enter this screen, the operator will be prompted to
enter a user name and password. User name:____________
Password:___________. This screen will take the
operator to a screen similar to the Operator Configuration
screen. The difference is that the Maintenance Configuration
screen will allow the operator to tune the temperature controller.
3. Help: Will take the operator to a screen to view an assortment
of how to videos and a speed chart to easily convert speed
number to feet or meters per minute.
4. Operator Control: Will take the operator to the screen for
operation of 112.
Help Menu
1. Hem: to see a video demonstration of a Hem.
2. Hem & Rope: to see a video demonstration of a Hem & Rope.
3. Overlap: to see a video demonstration of an Overlap.
4. Speed Chart: to see a graph which tells how fast the 112
Extreme is operating in meters per minute and feet per minute.
5. Previous: to take you back to previous screen.
Speed Conversions
This screen illustrates the speed of the 112 in meters per minute
and feet per minutes. In the right column is the speed of the 112
extreme. This number is represent by the percentage the motor
will drive the head carriage.
Instruction Manual
Page 9
5.0 Definition of Controls
Operator Control
Laser-Overlap: The purpose of this button is when depressed, it will turn
green and turn on the overlap laser and turn off the butt laser.
Laser-Butt: The purpose of this button is when depressed, it will turn green
and turn on the butt laser and turn off the overlap laser.
Weld/Cut: In this box, if weld is showing, the 112 extreme is in the weld
mode. By touching the box it will switch the mode to cut and the 112 will be
in the cut mode.
Seam Select: When this box is selected, a bigger box with all seam selections will pop up and the operator
can choose which seam to select.
Temperature SP: The purpose of this box is to show the set point for the temperature and also allow the
operator to manually change the temperature without going into the recipes.
Temperature PV: The purpose of this box is to show the operator what the actual temperature is reading at
the elements.
Machine Speed: The purpose of Machine Speed is to control the speed of the carriage assembly during the
welding process. The machine speed number is a percentage of how fast the 112 extreme head carriage
will run. Note: To convert to feet per minute or meter per minute, go to help page under Speed Chart.
Clutch Pressure: The purpose of clutch pressure is to vary the amount of clutch pressure on the weld roller.
This helps eliminate any wrinkling of material. Increasing the clutch pressure will allow the weld roller to
spin faster in relation to the head carriage speed. Decreasing the clutch pressure will spin the weld roller
slower than the head carriage.
Return: The purpose of the Return is to give a means of returning the head carriage to the home position.
This can only be depressed at the end of a weld or cut run.
Clear All: The purpose of this is to give a simpler means to turn off all vacuums and fabric clamps by
touching one spot.
Vacuum Left: The purpose of this function is to turn on or off the left vacuum.
Vacuum Right: The purpose of this function is to turn on or off the right vacuum.
Clamp Left: The purpose of this function is to open or close the left clamp.
Clamp Right: The purpose of this function is to open or close the right clamp.
CHAPTER 5 DEFINITION OF CONTROLS
Instruction Manual
Page 10
5.0 Definition of Controls
Weld Roller: The purpose of this function is to lift the weld roller up or down.
Main: The function of this is to take the operator to the Main Menu.
Recipe: The function of this is to take the operator to the recipe page to allow the operator to change
seams or the option to go to the Recipe Management screen.
Configuration: The function of this is to take the operator to the Operator Configuration screen.
Jog: The function of this is to move the head carriage forward or reverse without welding.
Active Recipe
On this screen the operator can change the weld seam for one partic-
ular weld and save.
Recipe Management: By touching Recipe Management the operator
will be taken to a screen to adjust the welding settings for up to 25
Fabrics as well as 10 different welds.
Previous: Will take the operator back to the Operator Controls.
Recipe Management
This screen will allow the operator to set and record settings for 25
fabrics and 10 weld seams per fabrics.
To set a Recipe, first push any box and a word or number pad will
pop up. To start, touch the number the operator would like to set
(0-24). When this number is pressed, a number pad will pop up and
the operator can pick the number. Then to name the recipe, push the
recipe and a word and number pad will pop up and the operator can
set the recipe name. Finally the operator can set the weld settings by
touching the appropriate seam. For example, if the operator would like
to set the settings for an overlap. The operator would touch any box
in the row of overlap to set the settings for weld temp, drive delay,
speed, weld roller psi, and clutch pressure. Once set, the operator
should press Recipe Save to save recipe and Activate to activate
recipe.
CHAPTER 5 DEFINITION OF CONTROLS
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