Miller Weldmaster T-100 Manuale utente
Page 1-1
Chapter 1: Machine Overview | Section 1.1: Intended Use
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
-Polyurethane (PU) films
-Polypropylene (PP) coated fabrics
-Polyethylene (PE)
-Thermoplastic Rubber (TPR) film
-Thermoplastic Rubber (TPR) fabrics
-Non-woven Polyester
-Non-woven Polypropylene
-Various Fusing Tapes
-Weldable Webbing
-Rigid Extruded Products
• The manufacturer does not approve of any other uses for these
machines.
• The manufacturer does not approve of the removal of any safety
guards while in operation.
• The manufacturer does not approve of any unauthorized modifica-
tion of the machines.
• Only a properly trained technician may operate the T-500 and T-
100.
• Only a properly trained technician may perform any routine main-
tenance to the T-500 and T-100.
Page 1-2
Chapter 1: Machine Overview | Section 1.2: Electrical and Air Requirements
•Only a properly trained technician may perform any repairs to the T-
500 and T-100.
• Only manufacturer approved replacement parts are to be used for
the T-500 and T-100.
NOTE:The manufacturer will not be held liable for any damage or injuries occurring
from any inappropriate use of this machine.
Section 1.2: Electrical and Air Requirements
Warning! Only a qualified electrician may connect the
electrical power.
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. It
is recommended that your electrician use a junction box with an on/
off switch.
The Miller Weldmaster T-500 and T-100 are available in both single
phase and three phase power, refer to your quotation for this
specification.
The Miller Weldmaster T-500 and T-100 require the following
electrical requirements:
• 208/240 volts
• 50Hz or 60Hz
• 40 amperes
If using the Miller Weldmaster T-500 and T-100 with a carriage,
this requires the following electrical requirements:
• 208/240 volts
• 50Hz or 60Hz
• 60 amperes
Module 1.2.2: Shop Air Supply
The Miller Weldmaster T-500 and T-100 include 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
Page 1-3
Chapter 1: Machine Overview | Section 1.3: Principles of Heat Sealing
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.
• It is not recommended to use an oiler for the air supply.
Section 1.3: Principles of Heat Sealing
Module 1.3.1: Heat
Hot Air
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 100 to 1350 Degrees Fahrenheit or 25 to 730 Degrees
Celsius.
Hot Wedge
The heat required for the welding operation is created
electrically by heating elements located inside the wedge. Heat
dissipates through the aluminum core of the wedge, to the contact
area, applying heat to the material to be welded. The temperature
ranges from 100 to 900 Degrees Fahrenheit or 25 to 490 Degrees
Celsius.
Module 1.3.2: 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 less heat needed to be applied to the material. The
faster the speed setting, the more heat will have to be applied to the
material. 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.
Module 1.3.3: Pressure
The pressure of the weld rollers is the final step when creating a
weld. The pressure of the weld rollers compresses the heated
Page 1-4
Chapter 1: Machine Overview | Section 1.4: Transportation, Specifications, and Storage
material together completing the welding process.
Module 1.3.4: Summary
When heat sealing, the correct combination of heat, speed, and
roller pressure will allow you to achieve a properly welded seam.
Section 1.4: Transportation, Specifications, and Storage
Warning! It is recommended to use a forklift when moving a
crated machine or removing crated machine from pallet.
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. Lift slowly to insure proper placement of forks.
Figure 1.1: T-100
36.625
72.843
22.00020.750
32.500
63.603
24.000 1.000
49.750
Center of Gravity
Units in Inches
MILLER
WELDMASTER
CORPORATION
T-100
Page 1-5
Chapter 1: Machine Overview | Section 1.4: Transportation, Specifications, and Storage
Figure 1.2: T-500
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.
Secure the machine to the pallet. To protect the various controls and
features, crate the machine. When loading into a truck for
transportation, use a forklift or tow motor.
Module 1.4.3: Storage
The manufacturer recommends that any time the machine is not
in use, it must be protected from excess dust and moisture.
MILLER
WELDMASTER
CORPORATION
T-500
24.000 1.000
49.750
117.843
108.603
81.625
32.500
46.25041.500
Center of Gravity
Units in Inches
ForkFork
Table 1-1:
Specifications T-100 T-500
Approximate Weight 510 lbs 780 lbs
Approximate Crated Weight 800 lbs 1090 lbs
Crated Width 32 in 32 in
Crated Length 75 in 120 in
Crated Height 65 in 65 in
Noise level during operation 90 dB(A) 90 dB(A)
Page 1-6
Chapter 1: Machine Overview | Section 1.5: Explanation of Symbols
Section 1.5: Explanation of Symbols
There are several different warning symbols placed on the Miller
Weldmaster T-500 and T-100. These symbols are to alert the operator
of potentially hazardous areas on the machine. Familiarize yourself
with the their placement.
Figure 1.3: Caution, Unplug Machine…
The Caution, Unplug Machine sticker is placed near the opening of
the cabinet and all access panels. To prevent electrocution, the
welder should always have the power disconnected before the cabinet
door is opened.
Figure 1.4: Warning, High Temperature Air...
The Warning High Temperature Air sticker is placed on the Heater
Assembly. The T-500 and T-100 are capable of temperatures reaching
1350 degrees F.
Figure 1.5: Caution, Do Not Apply Stress...
The Caution, Do Not Apply Stress sticker is placed on the Heater
Assembly. Do not apply any unnecessary force on this part of the T-
500 and T-100.
Figure 1.6:
Pinch Points...
The Pinch Point decal is placed on the protective guard of the T-
100 and T-500. The symbol is to alert the user of the pinch point of
the two weld rollers.
Figure 1.7: Heat...
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.
Page 1-7
Chapter 1: Machine Overview | Section 1.5: Explanation of Symbols
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.
Figure 1.8: Model & Serial Number Tag
At Miller Weldmaster, we take pride in the quality and
craftsmanship that goes into each machine. Each welder is built
specifically to your needs. Each technician that helped to
manufacture your welder is proud to leave his or her signature.
Figure 1.9: Quality Control Sticker
NOTE: Contact information is listed here, for your convenience.
Page 1-8
Chapter 1: Machine Overview | Section 1.6: Controls: Purposes and Functions
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.
Flipped to the on position, the Circuit Breaker will supply the
machine with electricity for operation.
Flipped to the off position, the Circuit Breaker will prevent the
supply of electricity to the machine.
Figure 1.11:
In Line Shop Air
Valve
In Line Shop Air Valve
The purpose of the In Shop Air Supply Valve is to connect and
disconnect the shop air supply to the machine.
Tu r n e d t o t h e o p e n p o s i t i o n a s s h o w n (Figure 1.11), shop air will
run the pneumatics of the machine.
Turned to the off position, shop air will be cut off from the
machine. This will disable the machine from working properly.
Figure 1.12:
Weld Roller Foot
Switch
Weld Roller Foot Switch
The purpose of the Weld Roller Foot Switch is to control the
raising and lowering of the weld rollers.
Engaging or depressing the Weld Roller Foot Switch will raise the
top weld roller assembly.
Disengaging or releasing the Weld Roller Foot Switch will lower
the top weld roller assembly in a controlled manner.
Figure 1.13:
Drive Foot Switch Drive Foot Switch
The purpose of the Drive Foot Switch is to begin and end the
welding process. When the Drive Foot Switch is depressed, the heat
source will swing into place and the weld rollers and puller rollers
will begin to turn.
When the Drive Foot Switch is released, the heat source will
return to the static position and the weld rollers and puller rollers
will cease to rotate.
Page 1-9
Chapter 1: Machine Overview | Section 1.6: Controls: Purposes and Functions
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.
When using hot wedge if the Power Switch is turned to the on
position, the drive system is ready for operation.
When using hot air and the Power Switch is turned to the off
position, the machine will continue to run for approximately 3
minutes through a cool down cycle and then automatically shut off.
When using hot wedge and the Power Switch is turned to the off
position, the machine will immediately shut off
Figure 1.15:
Hot Air Switch Hot Air Switch
The purpose of the Hot Air Switch is to control the power supply
to the hot air temperature controller, which generates heat from the
heat elements.
When the Hot Air Switch is turned to the on position, the
temperature controller will be activated and begin raising the
temperature to the preset temperature. It will take approximately
3-5 minutes for the temperature to reach the set point.
When the Hot Air Switch is turned off, the hot air temperature
controller will shut down and power will be removed from the heat
elements.
Figure 1.16: Wedge Switch
The purpose of the wedge switch is to control the power supply to
the wedge temperature controller, which generates heat to the
wedge.
When the wedge switch is turned to the on position, the wedge
temperature controller will be activated and begin raising the
temperature to the preset temperature. It will take approximately
3-5 minutes for the wedge to reach the set point.
When the wedge switch is turned off the wedge temperature
controller will shut down and power will be removed from the
wedge.
Wedge Switch
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