Miller Weldmaster T600 Extreme Instruction Manual Download

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Instruction Manual

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1.0

Intended Use

CHAPTER 1

INTENDED USE

The T600 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.

Summary of Contents for T600 Extreme

Page 1: ... 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 ...

Page 2: ...apter 4 Principles of Heat Sealing Chapter 5 Definition of Controls Chapter 6 Recommended Replacement Parts Chapter 7 Machine Specifications Chapter 8 Maintenance Chapter 9 Transportation Specs and Storage Chapter 10 Technical Requirements Page 3 Pages 4 5 Page 6 Page 7 Page 8 10 Page 11 Pages 12 14 Pages 15 24 Page 25 Page 26 Table of Contents ...

Page 3: ...oven 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 mainten...

Page 4: ...inch 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 ho...

Page 5: ...PTER 2 EXPLANATION OF WARNINGS Caution Electricity The Caution Electricity sticker is placed near areas that contain electrical Warning High Temperature Air The Warning High Temperature Air sticker is placed on the Heater Assembly ...

Page 6: ...o the number of different style outlets available the cord will not include a plug It is recom mended that your electrician install a 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 The Miller Weldmaster T600 requires one of the following elec...

Page 7: ...s from 25 to 450 Degrees Celsius 100 to 915 Degrees Fahr enheit 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...

Page 8: ...elding your thermal plastics Heat Switch This is for turning the Temperature Controller ON OFF Heat Swing Button Turns the Heat Swing ON OFF The swing arm will not swing in when this is set to OFF Puller Switch Turns the Out Board Puller ON OFF The puller will remain in the up position and will not turn when in the off position Menu Screen Welding Functions This screen fig 03 is to adjust the spee...

Page 9: ... Stop Delay Time has reached the set point The Roller Stop Delay Time will be adjusted by the operator to the desired setting Auto Reverse Time Once the foot pedal is released the weld rollers will turn in reverse until the Roller Stop Delay Time has reached the set point and the Auto Reverse time has reached the set point The Auto reverse Time will be adjusted by the operator to the desired setti...

Page 10: ... limit the machine will stop heating automatically Over Temp Alarm When the actual temperature is higher than the Over Temp Alarm Temperature there is an on screen alarm that notifies the operator MAX Output Limits the amount of output power to the heating system NOTE There are two different PID parameters saved in the machine according to heating system used hot air or hot wedge Press the Default...

Page 11: ...DED REPLACEMENT PARTS Miller Weldmaster recommends keeping the following spare parts in stock NOTE The manufacturer will not be held liable for any damage or injuries occurring from any inappropriate use of this machine Parts Order Call 855 888 9353 or email service weldmaster com ...

Page 12: ...curately provide heat to the products being produced Dual Pedal Control allows for easy operation for extended periods of time with high efficiency An automatic Auto Reverse function allows the machine to start and stop with a void free seam Technical Specifications Amp Rating 25amp at 230volt 16amp at 400 volt Rated Power 4000 W Rated Voltage 230v AC 50 60hz or 400v AC 50 60hz Maximum Temperature...

Page 13: ...couple Hot Wedge hot wedge tip contains the heating elements and thermal couple Upper Unit Upper Weld Roller up and down motion Heat System Adjustment Assembly Allows for accurate positioning of the Hot Air Nozzle or wedge tip Outboard Fabric Puller Assembly Assists operator with material handling while producing flatter seams Operator Controls Section Control Panel The HMI Human Machine Interface...

Page 14: ...ge is used for displaying the pressure setting of the Upper Weld Roller Air Cylinder The upper unit puller Air Cylinders are used for opening and closing the weld roller and puller roller The heat system cylinder controls swing in and swing out of the heat system Puller Pressure Limit Control Reference page 21 for adjustment procedure Other Power Supply Circuit Breaker Used for the protective cont...

Page 15: ...ce 4 Remove the bolt securing the element in the housing 5 Loosen the 2 upper set screws 1 on each side on the element securing the electrical leads and remove the leads 6 Pull out the element vertically 7 Replace the old element with a new element by following the procedure in reverse When reinstalling the element be sure to align the key to the slot of the element housing to the element Warning ...

Page 16: ...net cleaning dust and debris from the area 3 To avoid damaging the PLC Display and Operating Panel never plug or unplug the cables connecting the PLC Display and Operating Panel while the power is on 4 If there is any fault that cannot be removed please immediately contact the service department at Miller Weldmaster Drive System 1 Check if the Driving Sprockets are dislocated or loosened 2 Check i...

Page 17: ...Air Filter Cartridge End Cap 2 Remove the Air Filter Cartridge 3 Using brake cleaner or a product containing high amounts of Ether spray the Air Filter Cartridge from the inside out 4 Dry the Air Filter Cartridge by blowing the Air Filter Cartridge from the inside out with shop air 5 Reinstall the Air Filter Cartridge and Air Filter Cartridge End Cap onto the internal air compressor and tighten Re...

Page 18: ...f needed lubricate chains once a year with 80w 90w gear oil 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 Remove the cover on the end cabinet and inspect the chains Perform any maintenance to the chains as needed 4 Remove the end caps on the lower beam and inspect the ...

Page 19: ...dled 3 Loosen and remove the housing cover 4 Disconnect the male from the female leads on the thermocouple and wedge wires 5 Loosen the two set screws located on the side of the wedge 6 Remove both bolts from the rear mounting bracket and remove the wedge assembly 7 Install the new wedge assembly reversing the above instructions When tightening the bolts to the rear of the wedge loosen by a 1 8 of...

Page 20: ...ockdown Knob and loosen by two turns This will allow us to adjust the Height Micrometer Knob The Height Micrometer Knob is located at the bottom of the heat system pointing downward Rotating the Height Micrometer Knob so the numeric value is increasing will raise the nozzle tip Rotating the Height Micrometer Knob so the numeric value is decreasing will lower the nozzle tip After the nozzle is alig...

Page 21: ...htly lower by turning the adjusting collar one half turn counterclockwise This will ensure full contact of the mating surfaces Installing Removing Adjusting Table Assembly 1 Begin by loosening the two black knobs to the right of the operator removal of these knobs is not necessary 2 Next go around to the puller side of the machine Just beneath the material puller there will be two black knobs simi...

Page 22: ...ometer Knob so the numeric value is decreasing will lower the wedge Adjusting the tilt requires a combination of loosening and tightening the Left Tilt Knob and the Right Tilt Knob After the wedge tip height and tilt is aligned tighten down the Height Lockdown Knob Third Alignment Step The tip of the wedge must be aligned left to right and centered on the rollers Check this by engaging the Drive F...

Page 23: ...meric value will move the wedge back away from the weld rollers Rotating the Depth Micrometer Knob to decrease the numeric value will move the wedge towards the weld rollers When aligned properly tighten down the Depth Lockdown Knob Turn the Heat Switch on and set up for a test weld Upper Weld Roller Speed Adjustments The T600 has an Upper Weld Roller Speed adjustment that allows you to vary the s...

Page 24: ...ace adjust the height of the material puller by using the air cylinder shaft and lock nut Pictured 2 For most applications the material puller wheels should be adjust ed until they are slightly touching the stainless steel roller 3 Be sure to adjust each side evenly As adjusting one side will slightly affect the other side ...

Page 25: ...acility The manufacturer requires the Miller Weldmaster machine to be placed on a pallet and loaded into a truck 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 and protect the various controls and features by crating the machine Storage The manufacturer recommends that any time the machine is not in use...

Page 26: ...d properly the edges of the two rollers should be parallel and aligned 5 Heat System Swing The swing in out of the heat system should be smooth and natural at moderate speed 6 Air lines and air fittings should be free of leaks NOTE Changes in factors such as thickness of materials qualifications of the op erators and different environment and weather may directly affect the product The operator sh...

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