T300 Manual

This instruction manual is intended to be a guide when operating the T300 Seam welder. To ensure optimal performance from your welder, please follow the recommendations and specifications precisely.

Table 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: Machine Specifications
• Chapter 8: Maintenance
• Chapter 9: Transportation Specs and Storage
• Chapter 10: Technical Requirements
• Chapter 11: Additional Machine Documents

For more technical information regarding this machine call our Resolution Center at 1-855-888-WELD or email service@weldmaster.com.

1.0 Intended Use

The T300 is a rotary hot wedge 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.

  

 Allows you to go through and write a recipe from scratch.

Settings: 

 

 

Engages the table and puller with the 2 front rollers. Best for long, straight seams
Engages the puller. Swing arm down. Best for inflatables or curved products
Single Roller Beam. Takes the table off and going to swing this underneath by dropping the lower weld roller and changing the setup

Auto-Reverse: This adjusts the reverse speed of the rollers when the machine stops welding. This function is to minimize missed welding and make a perfect product. The UP and DOWN arrows increase and decrease the reverse speed.

ON/OFF Switches: The Drive FWD/REV, Drive System ON/OFF, and Foot Pedal Override ON/OFF switches are used to turn the functions ON/OFF.

Foot pedal Control: You can hold the foot pedal to control the rollers and when you release the head swings out of position. Or you can press and it runs and press again to release

Hours Meter: The hour meter manages how long the machine has been running. Broken our between the machine, maintenance, hot air, and hot wedge

Features

• Suitable for multiple-sized tents, inflatable boats, banners, tarps, awnings, and etc.
• User Friendly HMI allows the operators to easily adjust the machine for a wide variety of products.
• Auto-Control Temperature controller allows the system to accurately 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 - 1350°F (730°C)
• General Air Pressure - 120psi (8.3 bar)
• Machine Speed - 3 ft/min to 80 ft/min (1 m/min to 25 m/min)
• Overall Dimensions - 69in x 26in x 58in (1750mm x 650mm x 1450mm)
• Seal Width - 5mm to 50 mm
• Maximum Noise - 70 dbA
• Net Weight - 730lbs (330kg)
• Electrical Document Number - The documentation number is the serial number of the machine. This number is located on the serial tag on the machine.

Mechanical Section

• Removable Roller Table Top: The roller table top assembly is used for paneling applications, edging, edge finishing, and general seaming applications.

  • 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 similar to the fasteners previously loosened. Remove these knobs while supporting the weight of the table assembly.
    3. Lastly, lift up and pull the table assembly out of the throat of the machine through the backside (puller side).

     

• Swing Arm: The swing arm is used when products include shapes, curves, and tubes of the seaming area.  Can be positioned up or down.

• Single Roller Beam: The single roller beam is best for products that have tight curves. Easy to move the material through the machine.

Warning! The operator must disconnect the power from the machine before proceeding.

Electrical Element

1. Turn the power off on the machine and remove the grey phoenix plug located beside the black air hose on top of the machine (shown in picture).

2. Remove the 11 screws that hold the orange heat guard in place. Once removed it should be in 3 pieces as shown in the picture.

3. Loosen the plastic hex nuts to expose the 2 lead wires going into the heating element.

4. Unscrew the green and yellow ground wire.

5. Pull the silver cap off of the top corked portion of the heating element.

6. Loosen the two set screws shown in the picture to remove both lead wires

.     

7. Slide the old heat element out of the housing and put the new element in its place.

Electrical Circuits

1. When replacing parts and components, you must use the part or components of the same type as the original or equivalent to the original type. Original equipment replacement parts should be purchased through Miller Weldmaster and or a Miller Weldmaster authorized distributor.
2. The electrical cabinet must be cleaned every six months. To properly clean the electrical cabinet: disconnect the power supply, using compressed air and a blow gun, gently blow air across the electrical component and control cabinet 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 if the chains are too loose. Tighten as needed.
3. Check if the nozzle is parallel with and at the center of the Weld Roller. If not, it shall be adjusted as per Hot Air Heat System Adjustment.
4. Check if the up and down movement of the Upper Unit is smooth.

NOTICE: The glass tube is easily broken and can already be broken, be very careful.

 Cleaning/Replacing Air Filter (For Hot Air Machines Only)

The Miller Weldmaster T300 has an external air compressor that supplies airflow to the heat element. 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 element.

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. Loosen and remove the 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.

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.

1. Remove the Air Filter Cartridge End Cap.
2. Remove the Air Filter Cartridge.
3. Replace with a new Air Filter Cartridge, part number 330297.
4. Reinstall the Air Filter Cartridge and Air Filter Cartridge End Cap onto the internal air compressor.

Tightening/Oiling Chains

The Miller Weldmaster T300 has several chains that are used to drive weld rollers and puller rollers. Although not a high maintenance item, chains should be inspected once a year to ensure there is not excessive corrosion, rust, or dirt. Also inspect for any looseness or slack. If 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 chains. Perform any maintenance to the chains as needed.

5. Remove the out puller cover and weld roller upper unit covers. Perform any maintenance to the chains as needed.

Replacing Wedge Tip

1. Remove power to the machine by switching the main circuit breaker to the off position.

2. Ensure the wedge has cooled down to a temperature that can be handled.

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 a turn so the wedge has some “float” to it.

Hot Air Heat System Adjustments

Begin by turning your hot air on and setting to the desired temperature. Set weld rollers to the closed position by engaging the Weld Roller Pedal.

1. Left to right nozzle position, check this by engaging the Drive Foot Pedal and watch the tip of the nozzle. It should be centered left to right on the weld rollers, if so, move on to next alignment step. If not, locate the left to right Lockdown Knob and loosen by two turns. This will allow adjustment of the left to right Micrometer. Now locate the left to right Micrometer which is located about eye level with the operator. Rotating the left to right Micrometer Knob so the numeric value is increasing will move the nozzle tip to the left. Rotating the left to right Micrometer Knob so the numeric value is decreasing will move the nozzle tip to the right. After the nozzle is centered on the weld rollers, tighten down the left to right Lockdown Knob.
2. Up and down nozzle position, check this by engaging the Drive Foot Pedal and watch the tip of nozzle. It should be pointing at the pinch point of the two weld rollers, if so move on to next alignment step. If not locate the Height Lockdown 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 aligned, tighten down the Height Lockdown Knob.
   Note: Nozzle tip will move up or down when heat is changed. After a heat change of more than 100 degrees, be sure to check height of nozzle tip.
3. Depth of your nozzle should be at approximately ¼ - ½ of an inch from the pinch point of your weld rollers. Check this by engaging the Drive Foot Pedal and watch the tip of nozzle. If the nozzle is aligned, perform a test weld. If not locate the Depth Lockdown Knob and loosen by two turns. This will allow us to adjust the Depth Micrometer Knob. The Depth Micrometer Knob is located on the back of the heat system facing the direction of fabric flow. Rotating the Depth Micrometer Knob so the numeric value is increasing will move the nozzle tip closer to the weld rollers. Rotating the Depth Micrometer Knob so the numeric value is decreasing will move the nozzle tip away from the weld rollers. After nozzle is aligned, tighten down the Depth Micrometer Knob. When the nozzle is aligned, perform a test weld.

Puller Adjustments

1. With the table assembly in place, adjust the height of the material puller by using the steel collar and lock nut to achieve the desired height of the material puller.
2. For most applications the material puller wheel should first be adjusted until it is slightly touching the stainless steel roller.
3. Next adjust the puller wheel slightly lower by turning the adjusting collar one half turn counterclockwise. This will ensure full contact of the mating surfaces.

Hot Wedge Heat System Adjustments

A note before beginning; the wedge should be a bit loose (3/16 inch of play). Begin by setting the Master Speed to zero and closing the weld rollers.

First Alignment Step

When the wedge arm swings in and drives forward, it is imperative that the point of the Alignment Pin fits into the Recess of the wedge arm. Check this by engaging the Drive Foot Pedal. If this is OK, move on to the second alignment step. If not, locate the Centric Adjustment Knob on top of the wedge arm. By loosening the Centric Adjustment Knob, you will be able to rotate the Knurled Shaft by ¼ turns until the Alignment Pin fits into the Recess. Tighten the Centric Adjustment Knob when proper alignment is achieved.

Second Alignment Step

The tip of the wedge must be the same height as the pinch point of the weld rollers. Check this by engaging the Drive Foot Pedal and watching the tip of the wedge. It should drive straight to the pinch point of the weld rollers without touching the top or bottom weld roller first. At the same time, the tilt of the wedge needs checked. Ensure that the left tip is not placed higher or lower than the right tip. You must inspect this by getting eye level with the weld rollers. If these are OK, move on to the third alignment step. If not, locate the Height Lockdown knob and loosen by two turns. This will allow adjustment of the Height Micrometer Knob. Rotating the Height Micrometer Knob so the numeric value is increasing, will raise the wedge. Rotating the Height Micrometer 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 Foot Pedal and watching to see if the tip is centered on the rollers after it drives forward. If this is alright, move on to the Fourth Alignment Step. If not, locate the Left/Right Lockdown Knob and loosen by two turns. This will allow the adjustment of the Left/Right Micrometer Knob. Rotate to decrease the numeric value on the Left/Right Micrometer Knob will move the wedge to the right. Rotate to increase the numeric value on the Left/Right Micrometer Knob will move the wedge to the left. After the wedge tip is aligned left to right with the weld rollers, tighten down the Left/Right Lockdown Knob.

Fourth Alignment Step

The tip of the wedge must be squared to the weld rollers. Check this by engaging Drive Foot Pedal and looking over the top face of the wedge. See that the wedge squares evenly with the weld rollers. If this is aligned properly, move on to the Fifth Alignment Step. If not, slightly loosen the Wedge Mounting Bolts, very slightly rotate the entire heat system in the desired direction and retighten the Wedge Mounting Bolts. Check the wedge squareness again. Keep repeating until the Wedge is mounted square.

Fifth Alignment Step

The last step involves the wedge depth. Check this adjustment by engaging the Drive Foot Pedal to check the contact between the wedge and the weld rollers. Not enough contact, and the wedge will barley touch the rollers. This will cause there to be a lack of heat transfer through to the material. Too much contact, the wedge will come into contact with the rollers and the upper swing unit of the wedge will deflect. This will cause the wedge to be sucked in by the weld rollers during seaming. If aligned properly, turn the heat switch on and set up for a test weld. If not, locate the Depth Lockdown Knob and loosen by two turns. This will allow for the adjustment of the Depth Micrometer Knob. Rotating the Depth Micrometer Knob to increase the numeric 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.

Changing the Heat System between Hot Air and Hot Wedge:

First thing you’ll want to do is to unplug our phoenix plug.

Unscrew the four bolts that’s behind the Hot Wedge Heat System.

Take it out and replace it with the Hot Air Heat System by screwing in the four bolts, plugging in the phoenix plug along with plugging in the air hose.

Now that the Hot Air is set up, we’ll need to install the nozzle into the heat system.

Swing the Heat System into position

insert the nozzle in, clamp it tight and square it up to the weld roller.

Once that’s set up, you’ll want to go to your HMI screen to adjust the alignment of the nozzle.
Start by moving it to the left, adjust it down and bring it into the weld rollers.
Unlike the Wedge, you will have a gap behind it so you won’t be able to touch the wheels.
Click your save button, and return to the home page.

***IMPORTANT NOTE:  When changing the heat system from hot air to hot wedge or vice versa, you are required to autotune your machine:

1. Turn or Keep Heat turned off
2. Set temp to 200 Degrees 
   
3. Press Auto Turn Function
   1. This will turn the heat on by itself
      
4. During auto-tuning - do not touch the machine or try to operate it.
   
   1. Allow the machine to run the cycle
      
5. Heat will remain on once auto-tune has completed its cycle
   
6. Temperature should remain stable with a +/- 5 Degrees
   
   

Replace HMI Battery

**To replace HMI Battery - Always leave power on when replacing to ensure all factory settings are saved.  If not left on while replacing the battery, you risk the loss of memory and programs.

1. Remove the side cover Allen bolts on both sides of the HMI Screen

2. You then will be able to remove the HMI screen from the back plate

3. Take a small flat heat screw driver to loosen the green power plug screws located on each side (do not remove any of the screws securing the 3 wires in place)

4. Once the screws are removed you will be able to unplug or pull out the green power plug

5. Loosen the knurled set screws to the HMI cable (VGA Cable)

6. Now that your HMI has been unplugged you can unscrew the 4 corner screws to  the back cover plate of the HMI and this will remove the frame from the screen

7. You can now take a flat head screwdriver and press in the 3 tabs and remove the 1 screw holding the back plate

8. You will now have access to the circuit board which holds the battery

9. The battery can now be removed by taking a small flat head screwdriver to release the battery

Replace Battery

When replacing the PLC battery it is important to have the machine POWER ON during the entire procedure to ensure there is no memory loss.

1. Remove access cover from PLC.

2. Remove battery cover

3. Remove battery.

4. Install new battery and put on the access cover. The machine should be good to proceed with normal operation.

9.0 Transportation Specs and Storage

Warning! It is recommended to use a forklift when moving or removing a crated machine from a pallet.

Transporting Within a Production Facility

Due to the weight of the Miller Weldmaster machine, 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 ensure proper placement of forks.

Transporting Outside Production Facility

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, it must be protected from excess dust and moisture. The operator should familiarize themselves with the warning symbols on the machine to be alert to the potentially hazardous areas on the machine.

NOTE: The manufacturer will not be held liable for any damage or injuries occurring from any  inappropriate use of this machine.