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Section 7.1: Maintenance

Section 7.1: Maintenance

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.

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.

Clean Air Filter Cartridge Every Week

If the surrounding conditions in your production area are not clean, it is

recommended that you clean the Air Filter Cartridge twice a week.

1. Turn the Circuit Breaker to the off

position.

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.

3. Unlock the front cabinet door and open.

4. Loosen and remove the Air Filter

Cartridge End Cap.

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Summary of Contents for T-100

Page 1: ......

Page 2: ...ene 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 t...

Page 3: ...hoose 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...

Page 4: ...t 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 ...

Page 5: ... 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 for...

Page 6: ...nd 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 46 250 41 500 Center of Gravity Units in Inches Fork Fork Table 1 1 Spe...

Page 7: ...nected 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 ...

Page 8: ...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 informa...

Page 9: ...igure 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 ra...

Page 10: ... 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...

Page 11: ...puller rollers will rotate in the welding direction when the Drive Foot Switch is depressed When the Drive Switch is turned to the reverse position the weld rollers and puller rollers will rotate in the opposite or reverse direction when the Drive Foot Switch is depressed The hot air nozzle will not swing into position in the reverse setting The hot wedge however will for maintenance purposes Figu...

Page 12: ...turned to the lower position the inboard puller assembly will automatically lower itself to the pulling position The rollers will turn when the Drive Foot Switch is engaged When the Inboard Puller Switch is turned to the raise position the Inboard Puller Assembly will return to the raised position The puller rollers will not rotate when the Drive Foot Switch is engaged Figure 1 22 Master Speed Con...

Page 13: ...ounterclockwise the Inboard 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 Weld Roller Pressure The purpose of the Weld Roller Pressure R...

Page 14: ...from the welding process in conjunction with the double roller welding arm Engaging the Rear Roller Tensioner Lever to the vertical position will apply pressure between the two rear rollers By turning the Rear Roller Tensioner Lever clockwise the pressure between the Rear Rollers will increase causing more stretch in the material Figure 1 28 By turning the Rear Roller Tensioner Lever counterclockw...

Page 15: ...Machine Overview Section 1 6 Controls Purposes and Functions Figure 1 29 By decreasing the Upper Weld Roller Sync or the Vari Drive the upper weld roller speed will decrease in relation to the lower weld roller Vari Drive ...

Page 16: ... Control to the lowest setting Make the adjustment and then check the Nozzle placement by engaging the Drive Foot Switch The angle of the Nozzle must be adjusted after the machine has cooled down to avoid personal injury While all other Nozzle adjustments must be made after the machine has been brought up to welding temperature The Weld Roller Pressure and the temperature of the Nozzle both play a...

Page 17: ...to place and check angle of the Nozzle If not properly placed Figure2 1 release the Drive Foot Switch to swing Nozzle out and proceed with the following The angle of the Nozzle must be adjusted after the machine has cooled down to avoid personal injury 1 Turn the Override Switch to the on position which will swing the Nozzle into place so that the angle can be adjusted 2 Loosen the Nozzle Clamp en...

Page 18: ...n The Nozzle will expand as the temperature is increased changing its position on the Weld Rollers 2 Set the Weld Roller Pressure to desired setting so that the Weld Roller Pinch Point is set Figure2 4 3 Turn the Master Speed Control to 000 to insure the Weld Rollers will not turn Figure2 5 4 Depress the Drive Foot Switch to swing Nozzle into place and insure it will not hit the Weld Rollers If th...

Page 19: ...zzle out and proceed with the following 1 The Front Locking Bolt must be loosened before adjustments can be made Use a 3 16 Allen Wrench to loosen the Front Locking Bolt The bolt should be just loose enough to allow for the height of the Nozzle to be adjusted Figure2 8 Figure2 9 2 Adjust the height of the Nozzle so that it is vertically aligned with the Weld Roller Pinch Point by turning the Heigh...

Page 20: ...the Nozzle too far away may result in slower welding speeds Depress the Drive Foot Switch to swing Nozzle into place and check the distance If not properly placed Figure2 11 release the Drive Foot Switch to swing the Nozzle out and proceed with the following 1 Adjust the depth of the Nozzle so that it is 0 25 to 0 50 away from the Weld Rollers by turning the Depth Adjustment Knob Figure2 12 a cloc...

Page 21: ...press the Drive Foot Switch to swing the Nozzle into place and check the left right alignment If not properly placed Figure2 14 release the Drive Foot Switch to swing the Nozzle out and proceed with the following 1 Adjust the left right alignment so that the Nozzle is centered on the weld rollers by turning the Left Right Nozzle Adjustment Knob Figure2 15 a clockwise to adjust the Nozzle to the le...

Page 22: ... the position of the Weld Roller Pinch Point causing the Wedge to become misaligned Ensure that the Master Speed Control is set to 000 so that the Weld Rollers do not turn Having the Speed Control turned up with no material in the machine will allow the Weld Rollers to possibly suck the Wedge into the pinch point possibly causing damage to the machine and giving an inaccurate wedge position Turn t...

Page 23: ... 19 1 The Front Locking Bolts must be loosened before adjustments can be made Use a 3 16 Allen Wrench to loosen the Front Locking Bolt The bolt should be just loose enough to allow for the height of the Wedge to be adjusted Figure2 20 2 Adjust the height of the Wedge so that the Wedge Tip is vertically aligned with the Weld Roller Pinch Point by turning the Height Adjustment Knob Figure2 21 a Cloc...

Page 24: ...ip and if not properly placed Figure2 23 proceed with the following 1 Loosen the two green clamping collars not the top stainless steel just enough to allow from rotation of the Wedge Shaft Figure2 24 2 Rotate the Mounting Shaft until the Wedge Tip is parallel with the Weld Rollers Figure2 25 3 Tighten the green Clamping Collars a As the green clamping collars are tightened the wedge squareness ma...

Page 25: ...e seam will be uneven across the width of the weld Check the Tilt of the Wedge and if not properly placed proceed with the following Figure2 27 1 Loosen the 2 clamping collars on the Pivot Shaft for the Air Cylinder Mounting Bracket Figure2 28 2 Pivot the Wedge Assembly until the Tilt of the Wedge is properly aligned in relationship with the Weld Rollers 3 Securely tighten the clamping collars Che...

Page 26: ... the side that the Wedge Tip is favoring leaving the opposite side unwelded Check the left right alignment Figure2 30 If not properly placed proceed with the following 1 The left right adjustment bolts on the Wedge assembly must be loosened before adjustments can be made Use a 3 16 Allen Wrench to loosen the 2 adjustment bolts approximately one turn the bolts should be just loose enough to allow t...

Page 27: ... Wedge is contacting the fabric with the proper amount of pressure pushing the material against the Weld Rollers producing a quality seam Should the Wedge Pressure need to be adjusted proceed with the following NOTE Different thicknesses of material will require different Wedge Pressures Weld a test strip to test the material with the Wedge Pressure 1 To adjust the pressure of the Wedge loosen the...

Page 28: ...the air line which will allow you to remove it Third bleed off the remaining air in the system by slowly turning the ball valve to the on position Once all the remaining air has escaped and the air cylinders are relaxed turn the ball valve back to the off position Figure3 2 4 Once the machine has sufficiently cooled down and the Main Power an Air Supply have been disconnected remove the Fabric Gui...

Page 29: ...he slide and sliding the assembly down until the mounting angle is against the Height Adjustment Knob Figure3 10 11 Connect the two grey connectors into the sockets on top of the machine and tighten screws finger tight Note that the connectors will only fit into their correct socket Figure3 11 Figure3 12 12 Install the Green Air Line into the black y fitting by pushing in on the white plug and sli...

Page 30: ... in the system by slowly turning the ball valve to the on position Once all the remaining air has escaped and the air cylinders are relaxed turn the ball valve back to the off position Figure3 16 4 Once the wedge has sufficiently cooled down and the Main Power an Air Supply have been disconnected remove the Fabric Guide from the machine This will help clear obstructions while changing the Heating ...

Page 31: ...sockets on top of the machine and tighten screws finger tight Note that the plug will only fit into it s correct socket Figure3 23 Figure3 24 11 Install the Green Air Line into the black air fitting by pushing in on the white plug and sliding the airline into place Figure3 25 12 Connect the black Hot Air Supply Line by pushing in disconnect tab and installing line Figure3 26 13 Tighten the Front L...

Page 32: ...d temperature It will take 3 5 minutes for the machine to reach the desired temperature 9 Check for the proper alignment of the weld rollers Make any adjustments necessary 10 Check for the proper alignment of the fabric guides Make any adjustments necessary 11 Turn the Heat Swing Switch to the on position 12 For Hot Air Machines When the machine has reached the desired temperature check for proper...

Page 33: ...sition 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 It will then shut down completely The Hot Wedge machines do not have a cool down cycle and should shut down immediately 3 After the machine has shut off rotate the In Shop Air Supply Valve to the off position 4 After the machine has shut off turn the C...

Page 34: ...ect the power cord from the power supply If the power cord is hard wired in shut the power supply off at the junction box and leave on air supply 3 Unlock and open the end cabinet door Locate and loosen the tensioner bracket bolts 4 Loosen the setscrew on the lower drive gear and remove the gear and key 5 Loosen and remove the 4 nuts on the mounting flange 6 Using two or more persons slide the Wel...

Page 35: ...sired welding arm 9 Install the new welding arm 10 Tighten the 4 nuts onto the mounting flange 11 Insert the key and install the lower drive gear Tighten the setscrew Place key with the set screw indentation facing up so key will always fit into keyway 12 Tighten the chain tensioner assembly and tighten the bolts Ensure chain is not loose Close and lock cabinet doors ...

Page 36: ...his is a good weld The fabric is welded 100 You can see that the fabric is delaminating over the entire width of the seam Figure 6 3 Upper Weld Roller going To Slow Upper Weld Roller going To Slow This is an example of the upper weld roller going too slow The green panel goes through the left side of the welder and the yellow panel goes through the right side The upper weld roller is going slower ...

Page 37: ...e 6 5 Too Much Shrinkage Too Much Shrinkage This is an example of too much shrinkage in the material Many thermoplastics tend to shrink when heated Engaging the Rear Roller assembly or increasing the tension in the Real Roller Assembly will stretch the material and give a smoother appearance Figure 6 6 Too Much Rear Roller Tension Too Much Rear Roller Tension This is an example of too much Rear Ro...

Page 38: ...e 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 Clean Air Filter Cartridge Every Week If the surrounding conditions in your production area are not clean it is recommended that you clean the Air Filter Cartridge twice a week 1 Turn ...

Page 39: ...End Cap onto the internal air compressor and tighten 9 Close and lock the front door Module 7 1 2 Replace Air Filter Cartridge Every 3 6 Months If the surrounding conditions in your production area are not clean it is recommended that you change the Air Filter Cartridge every month Warning Only a qualified technician may perform maintenance on this machine This may be a Miller Weldmaster represent...

Page 40: ...wer supply turn the power off at the junction box 3 Unlock the front cabinet door and open 4 Remove the Air Filter Cartridge End Cap 5 Remove the Air Filter Cartridge 6 Replace with a new Air Filter Cartridge part number 30297 7 Reinstall the Air Filter Cartridge and Air Filter Cartridge End Cap onto the internal air compressor 8 Close and lock the front cabinet door ...

Page 41: ...intenance 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 1 Turn the Circuit Breaker to the off position 2 Disconnect the power cord from the power supply If the power cord is hard wired shut the power supply off at the junction box 3 Unloc...

Page 42: ...he chain through the gap 10 On the inboard puller assembly if applicable locate the gap in the guard 11 If needed apply a few drops of lubrication to the chain through the gap 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 Mach...

Page 43: ... It is recommended that both elements be changed even if only one burns out 1 Turn the Service Disconnect to the off position 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 3 Remove the 3 sheet metal screws from the top of the element housing 4 Carefully unplug the 2 Thermocouple leads being careful not to p...

Page 44: ...uminum air divider 11 Carefully remove the heat elements from the element housing NOTE Inspect each element for any broken off fragments of glass or wire Any missing fragments will be in the dual element housing These fragments must be removed before installing new elements 12 Carefully install 2 new heat elements into the dual element housing 13 Install the aluminum air divider 14 Install the 4 s...

Page 45: ...ple wire leads wire 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 thermocouple should be replaced if the machine does not maintain a constant temperature of 2 Degrees F 1 Degree Celsius or heat el...

Page 46: ...er supply turn the power off at the junction box 3 Unplug the 2 thermocouple leads 4 Remove the hot air nozzle by loosening the clamp 5 Remove thermocouple wire mounts 6 Remove the bottom cover and some of the fiberglass insulation from the element housing 7 Using an 7 16 wrench carefully loosen and remove the thermocouple nut 8 Remove the thermocouple carefully it may be snug ...

Page 47: ...de up 14 Plug in the thermocouple leads wire 1 to red and wire 2 to yellow Module 7 2 2 Heater Rely 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 if the machine is experiencing erratic temperatures on the Temperature Controller or The Heat Elements are burning ou...

Page 48: ... power supply If the power cord is wired into the power supply turn the power off at the junction box 3 Unlock and open the rear cabinet door on the machine 4 Locate the Heater Relay located on the aluminum heat sink 5 Remove the plastic cover an disconnect the 4 wires connected to the Heater Relay 6 Remove the 2 mounting bolts and remove the Heater Relay 7 Install the new Heater Relay using the 2...

Page 49: ...ection 7 2 Replacing Components 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 ...

Page 50: ...k 330207 Air Filter Cartridge Quantity 2 330033 Heater Relay Quantity 1 379594 1 0 Amp Fuse Quantity 2 379595 2 5 Amp Fuse Quantity 1 330305 Heat Elements Quantity 4 322291 K Thermocouple Assembly Quantity 1 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 dow...

Page 51: ...inless 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 1 750 inch width 360025 2 000 inch width 360031 2 250 inch width 360034 2 500 inch width ...

Page 52: ...Page 9 2 Chapter 9 Accessories Section 9 2 Silicone Molded Weld Rollers Section 9 2 Silicone Molded Weld Rollers ...

Page 53: ...5 inch width 379453 0 750 inch width 379454 1 000 inch width 379455 1 250 inch width 379456 1 500 inch width 379457 1 750 inch width 379458 2 000 inch width 379459 2 250 inch width 379460 2 500 inch width Table 9 4 Silicone Molded Weld Rollers 3 200 inch O D 70 Durometer 379451 0 500 inch width 379452 0 625 inch width 379453 0 750 inch width 379454 1 000 inch width 379455 1 250 inch width 379456 1...

Page 54: ...Rear Tension Rollers Section 9 4 Nozzles Table 9 5 Smooth Steel Rollers 3 200 inch O D 360225 2 000 inch width 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 380709 1 000 inch width ...

Page 55: ...uld be for special applications If your nozzle does not resemble any of the pictured nozzles consult a Miller Weldmaster representative Section 9 5 Guides 381032 Hot Air Hot Wedge Universal Overlap Guide Top Mount Style 380713 1 250 inch width fluted style 380717 1 500 inch width 380721 1 750 inch width 380725 2 000 inch width Table 9 7 T 100 T 500 Left Hand Hot Air Nozzle with Ball End 380729 0 5...

Page 56: ...9 T 100 T 500 Adjustable Tape or Webbing Guide 381128 T 100 T 500 1 1 4 Hem Guide For Wedge 379762 T 100 T 500 1 1 4 Hem Guide For Hot Air Top Mount The Hem Guide is available with different widths and material gaps Sometimes a sample of your material will be needed to insure the proper guide is supplied The Hem Guide is also be modified to have a rope accompany the hem The diameter of the rope is...

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