Miller Weldmaster 112 Extreme User manual

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 [e-mail].
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

Instruction Manual
Page 11
5.0 Definition of Controls
CHAPTER 5 DEFINITION OF CONTROLS
Operator Configuration: In this screen, the operator has control over
different configurations.
1. Temperature Notification: When this is selected, the 112
Extreme will notify the operator to check nozzle placement when
the temperature controller is changed+/- 160 F.
2. Swing: When this is selected, it will turn green and the nozzle will
swing in. If Swing is not selected, the nozzle will not swing in.
3. Auto Return: When this is selected, it will turn green and the carriage will return on its own when the
stop ramp is used.
4. Auto Clear Mode: When this is selected, it will turn green and at the end of a run, when using the stop
ramp, the vacuums and fabric clamp will turn off.
5. Weld Pressure: When this is selected, the operator can adjust the weld pressure. The purpose of Weld
Pressure is to vary the amount of pneumatic pressure between the weld roller and the welding track.
6. Drive Delay: When this is selected, the operator can adjust the drive delay. The purpose of the drive
delay is to stall the weld roller temporally and allow the hot air nozzle to swing into place. If the drive
delay is set to high, it will cause the material to burn at the start. If the drive delay is set to low, it will
leave a spot not welded at the start.
Head 1
1. Actual Temperature: Is what the temperature is reading from the heat system.
2. Set Point: Is the desired setting for the heat system. The operator can change this by touching and
entering a new number.
3. +/- Alarm Band: Is a number that can be set by the operator by touching and if the temperature changes
+/- the setting an alarm will go off.
4. Heat: When this is selected and turns to green, the heat system will turn on. To turn the heat system off,
press the Heat button and the button will go gray and the heat system will go through a cool down cycle
of 3 minutes.

Instruction Manual
Page 12
5.0 Definition of Controls
CHAPTER 5 DEFINITION OF CONTROLS
Production
1. Last Cycle: Time calculates the time the 112 extreme takes to complete a seam. Note the stop ramp
and auto return has to be turned on to allow this function to work.
2. Heat System Reset Times: When this is selected the heat system totalizer will reset to 0:00:00.
3. Heat System Totalizer: The purpose of the heat system totalizer is to monitor the hours on the
heat elements. This setting is resettable every time the elements are changed by pressing and holding
the heat system reset time in.
4. Time Totalizer: The purpose of the time totalizer is to monitor the hours of use on the 112 extreme.

Instruction Manual
Page 13
5.0 Definition of Controls
CHAPTER 5 DEFINITION OF CONTROLS
Maint Configuration
This screen is accessed with a password and is very similar to
the operator configurations. The difference is this screen under
the head 1 setting allows the operator to adjust the temperature
controller and auto tune the temperature controller.
Main: By selecting this the operator will be taken to the main-
screen.
Language: Press this to choose different languages of which the
machine can be run.
Heat System Reset Times: When this selected the heat system
totalizer will reset to 0:00:00.
Operator Control
Operator Control Seam Select: This screen is used to select the
recipe of the seam type. Each seam type button, when pressed,
will load the saved control settings to the weld temperature, drive
delay, speed, weld roller pressure, and clutch pressure.
Nozzle Alert: This screen will appear when Temperature Notifica-
tion is activated. The notification will appear when a temperature
change has been made that exceeds 160°c in change. When the
Nozzle Alert notification appears please make sure to adjust your
nozzle for proper weld setup.
Cutter to start: Press this button to move carriage to cutter posi-
tion. Cutter will also drop down to the weld track.
Return: Press this button to raise the cutter, and return carriage to
home position.
Cutter Down: Press the button to drop the cutter to the weld track.
When the cutter is down, this button will read Cutter Up. Press this
button to raise the cutter.

Instruction Manual
Page 14CHAPTER 5 DEFINITION OF CONTROLS
Language Selection
Choose what language the operator wants to use. Example:
(Press English to run machine in English).
Language: Press this button to choose different languages
of which the machine can be run.
Active Alarms
This screen shows the operator the alarm that faulted out the
machine.
ACK: Press this button to access the Alarms Active screen.
Alarms History: This button takes the operator to the Active
History screen which shows any past alarms.
Operator Control: Press this button to return to the Operator
Control screen.
Previous: Press this button to return to the previous screen.
Active History
This screens shows the operator all the alarms in the machine’s
history.
Alarms Active: Press this button to access alarms history
screen.
Operator Control: Press this button to return to the Operator
Control screen.
Emergency Stop/Rope Pull
The purpose of the Emergency Stop and the Rope Pull is to stop
all operation in the event of an emergency. *Note: In order
to return to normal operation, the Emergency Stop Button
needs to be twisted to reset. If the Rope Pull is pulled, the
switch needs to be reset. Then the Blue Reset Button needs
to be pressed to restore power and air to the system.
Reset: The purpose of the Reset Button is to restore power and
air to the machine.
Pause: The purpose of the Pause Button is to momentarily
pause the operation being performed. Continue the operation by
pressing the Start Button.
Start Button: The purpose of the Start Button is to initiate the
chosen operation.
5.0 Definition of Controls

Instruction Manual
Page 15
6.0 Recommended Replacement Parts
CHAPTER 6 RECOMMENDED 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.

Instruction Manual
Page 16
7.0 Adjustments
CHAPTER 7 ADJUSTMENTS
Nozzle Adjustment
Nozzle placement is a key component in heat sealing. A
properly-placed nozzle will be centered on the weld roller
approximately ¼-inch away and have a slight whistle during
the welding process. When an adjustment is needed, turn
the speed control to a low setting. Make the adjustment
and check the nozzle placement by engaging the Start
Switch. Remember that the nozzle placement will change
when welding at different temperatures. Check the place-
ment when the temperature is changed more than 160
degrees C.
1. X Nozzle Adjustment - The X Nozzle
Adjustment allows left and right fine-tuning of the Hot
Air Nozzle. The proper X-Nozzle Adjustment (fig.22) will
leave the Hot Air Nozzle centered on the Weld Roller.
2. Y Nozzle Adjustment - The Y Nozzle
Adjustment allows up and down fine-tuning of the
Hot Air Nozzle. The proper Y-Nozzle Adjustment (fig.22)
will leave the Hot Air Nozzle directed at the pinch point
of the Weld Roller and the Welding Track. A whistling
sound should be heard as the air from the nozzle hits
this pinch point.
3. Z Nozzle Adjustment - The Z Nozzle
Adjustment allows in and out fine-tuning of the Hot Air
Nozzle. The proper Z-Nozzle Adjustment (fig.22) will
leave the Hot Air Nozzle approximately ¼ to ½ inch away
from the pinch point.
4. Nozzle Adjustment Finished
When finished, the Hot Air Nozzle should be placed in the
center of the weld roller left to right, 1/4 to 1/2 inch.

Instruction Manual
Page 17
7.0 Adjustments
CHAPTER 7 ADJUSTMENTS
Laser Alignment
Double Laser Line
1.Turn the POWER on.
2. Leave the Heat Switch in the OFF position. Load some sample fabric (white is best) under the fabric
clamp and extend to the end of the machine.
3. Turn the Left and Right Vacuums ON.
4. Engage the Weld Roller to the DOWN position and align the inside edge of the weld roller to the edge
of the first row of vacuum hole on the vacuum welding track.
5. Turn the Speed Control to a speed of 20.
6. Using a ballpoint pen, place it on the inside edge of the Weld Roller, where the laser should be.
Repeat for outside laser line.
7. Depress the START button and edge the roller the length of the welding track.
8. If needed, make the first adjustment by loosening the laser mount knob to calibrate the laser in and
out to the drawn line. When satisfied, tighten the laser mount knob.
9. If needed, make the second adjustment by loosening the laser mount knob and calibrate the laser by
turning the top of it. This will rotate the laser line. When satisfied, tighten the laser mount knob.
Butt Seam
1. Flip the Laser Switch to the Butt Seam mode.
2. Move the Weld Roller over so that the edge is against the laser, considering the double laser line has
been adjusted properly and the fabric with pen lines remain in place. Measure to the middle point of
the double laser making a mark at this point. Move the edge of the weld roller to this mark and
tighten. Follow step seven of the above. Align laser.
Warning! When adjusting the lasers, do not look directly into the laser
source. Use caution when calibrating lasers.

Instruction Manual
Page 18
Guide Adjustments
Welding a Hem: The hem guide needs to be 1/16 to 1/8inch off track and aligned perpendicular to
track. The outside of guide needs to be adjusted to outside of weld roller. After running a test if there
is a pocket on the hem move guide away from operator.
•Set machine to the desired settings, install your hemming guide to the machine.
•Align the hemming guide so the outside edge is aligned with the edge of the weld roller.
•Generally the clutch pressure needs to be adjusted to a higher setting when welding a hem.
•Do not pull the fabric sideways when feeding the fabric into the hemming guide, roll the
fabric into the guide. If you pull the fabric sideways it will become tight and bind up in the
guide.
1. Install hem guide.
2. Slide edge of material through guide pinching material on top of itself.
3. Making sure it is square with the edge.
4. While pinching, slide material under weld roller.
5. Put weld roller down than put clamp down.
6. Pull material tight, make sure the material between the wheel and guide is tight so that the nozzle
will swing in free.
7. Press start and hold the material against the right side of the guide.
8. If needed turn clutch pressure up a little to help keep the material in the guide.
9. When finished with run, press return (if auto return is not engaged).
10. Lift clamp.
11. Check weld.
12. No vacuum needed.
7.0 Adjustments
CHAPTER 7 ADJUSTMENTS

Instruction Manual
Page 19
7.0 Adjustments
CHAPTER 7 ADJUSTMENTS
Welding a Hem with Rope: Welding a hem with rope is the same as welding a straight hem except
you are adding rope through the rope eyelet or leaving a void for the open pocket.
1. Install hem and rope guide.
2. Slide rope through guide.
3. Slide edge of material through guide pinching material on top of itself.
4. Making sure it is square with the edge.
5. While pinching, slide material under weld roller keeping rope to left side of the wheel.
6. Put weld roller down, make sure wheel is not on rope, then put clamp down.
7. Pull material tight, make sure the material between the wheel and guide is tight so that
the nozzle will swing in free.
8. Press start and hold the material against the right side of the guide.
9. If needed turn clutch pressure up a little to help keep the material in the guide.
10. When finished with run, press return (if auto return is not engaged).
11. Lift clamp.
12. Check weld.
13. No vacuum needed.

Instruction Manual
Page 20
7.0 Adjustments
CHAPTER 7 ADJUSTMENTS
Welding an Overlap
•The overlap guide needs to be high enough so the nozzle can swing in and not hit the
bottom of the guide. The guide also needs to be perpendicular to the track.
•The overlap guide is used to control the exact positioning of the top fabric panel being
welded. The guide controls the final position of the top fabric panel.
•The guide will be lined up with the edge of the weld roller.
1. Place bottom side of panel to be welded under the right clamp 1/4 – 3/8 inch, aligning
edge with inside laser line.
2. Turn on right vacuum (cover unused track with magnet).
3. Smooth panel on vacuum and check alignment with laser line.
4. Place top side of panel to be welded under the left clamp 1/4 – 3/8 inch, aligning edge
with outside laser line.
5. Lower weld roller.
6. Install overlap guide.
7. Turn on left vacuum (cover unused track with magnet).
8. Smooth panel on vacuum and check alignment with laser line (1/4 inch over).
9. Press start and hold material into the guide being careful not to stretch it.
10. When finished with run, press return (if auto return is not engaged).
11. Turn off left and right vacuums.
12. Lift clamps.
13. Check weld.