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: Principals of Heat Sealing
Chapter 5: Screen Shots
Chapter 6: Adjustments
Chapter 7: Maintenance
Chapter 8: Troubleshooting
Chapter 9: Notes
Page 3
Pages 4-5
Page 6
Page 7
Pages 7-13
Pages 14-24
Pages 24-31
Pages 32-35
Pages 36-38
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:
• Non-woven polypropylene
• 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
• 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.

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
•60 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
Safety notes
Do not adjust the material while the machine is moving. Keep hands, long hair, loose clothing,
and articles such as neckties away from the rollers have pinch points rollers to avoid
entanglement and entrapment that can trap body parts or clothing and cause serious injury.
Provide enough space around machine to ensure the safe and effective operation. The machine
must be motionless and moving parts blocked before any cleaning, oiling, adjusting, repairing
or maintaining work is done on any repairing or maintaining work is done on any part of the
machine. Always wear Personal protective equipment. (PPE) refers to protective clothing,
helmets, goggles, or other garment designed to protect the wearer’s body from injury.

Instruction Manual
Page 7
4.0 Principals of Heat Sealing
CHAPTER 4 PRINCIPALS OF HEAT SEALING
Hot Air
The heat required for the welding operation is created electrically by two heating element locat-
ed inside the heat element housing. The hot air temperature ranges from 100 to 1350 Degrees
Fahrenheit or 25 to 730 Degrees Celsius.
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.
5.0 Screen Shots
Disconnect: Switching this turn the electric on and off to the
machine.
Emergency Stop: Pressing this button will shut down the
machine and the button will need to be twisted and pulled
out to start the machine again.
Pause: Pressing this button stops the head carriage from
traveling.
Reset: Pressing this button will activate the machine on start
up or after an emergency stop is pressed.

Instruction Manual
Page 8CHAPTER 5 DEFINITION OF CONTROLS
5.0 Screen Shots
Clear All: The purpose of this is to give a simpler means to turn off all vacuums and fabric clamps by touching
one button.
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.
Weld Roller: The purpose of this function is to lift the weld roller up or down.
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.
Heat: The purpose of this function is to turn on and off the heat.
Temperature SP: The purpose of this box is to show the set point for the temperature and also allow the opera-
tor 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.
Arrow Button: Used to access the controls pop-up panel.

Instruction Manual
Page 9
5.0 Screen Shots
CHAPTER 5 DEFINITION OF CONTROLS
Control: Pressing this button opens the Control screen.
Welding Head: Pressing this button opens the welding head screen.
Main Menu: Pressing this button opens the main menu screen.
Heat 1: Pressing this button, opens up the controls for each welding head.
Recipe Active Screen: Displays all the current parameters for the selected recipe.
Recipe Edit: Pressing this button opens up the Recipe Edit screen.
Alarm: This displays the current active alarms if any.

Instruction Manual
Page 10
5.0 Screen Shots
CHAPTER 5 DEFINITION OF CONTROLS
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.
Auto Return: When this is selected, it will turn green and the carriage will return on its own when the end position is
reached.
Auto Clear Mode: When this is selected, it will turn green and at the end of a run, when using end position, the vacu-
ums and fabric clamp will turn off.
Chiller: Turns the weld roller chillers on and off.
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.
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 when the start button is pressed.
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.
Clutch Pressure: The purpose of clutch pressure is to vary the amount of drive force 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.
Weld Pressure: The purpose of Weld Pressure is to vary the amount of pneumatic pressure between the weld roller
and the welding track.
Mode: This will switch between weld and cut.

Instruction Manual
Page 11
5.0 Screen Shots
CHAPTER 5 DEFINITION OF CONTROLS
Heat 1: Pressing this button, opens up the controls for the selected welding head.
Alarms: This displays the current active alarms if any.
Recipe Active screen: Displays all the current parameters for the selected recipe.
Recipe Edit: Pressing this button opens up the Recipe Edit screen.
Info: Pressing this button will take you to the information screen.
Stats: Pressing this will take you to the stats screen.
Operator Control Screen: This is the main screen the operator will use. This is the screen the machine will
start up to.
Login: 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: TECH
Password: 1234. 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, change language and adjust cutter and return run speed.

Instruction Manual
Page 12
5.0 Screen Shots
CHAPTER 5 DEFINITION OF CONTROLS
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.
Alarm Band: Is a number that can be set by the opera-
tor by touching and if the temperature changes +/- the
setting a warning will be displayed on the screen.
Set Current Position: This will set the point of how far
the welding head will travel.
Set Point: This is distance the welding head will travel.
Actual: This is the position the head is currently.
Enable Endpoint: With this turned on it will enable the
welding head end point.
Reverse: Jogs the welding head in reverse.
Forward: Jogs the welding head forward.

Instruction Manual
Page 13
5.0 Screen Shots
CHAPTER 5 DEFINITION OF CONTROLS
Recipe #: The number of the current recipe.
Recipe Name: The name of the current recipe.
Weld Unit #: This is the temperature set point we are setting each welding head at.
Speed %: Controls the overall machine speed. This is the master speed control.
Clutch Pressure: The purpose of Clutch Pressure is to vary the amount of drive force on the weld roller.
Weld Pressure: The purpose of Weld Pressure is to vary the amount of pneumatic pressure between the
weld roller and the welding track.
Drive Delay: Is the amount of time between the start of your welding head, and the nozzles to swing in
before the welding head will start.
Alarm Active Screen: This displays the current active alarms if any.
Ack: This button is used to acknowledge any active alarms.
Alarm History: This is used to pull up any and all old alarms ever present on the machine.

Instruction Manual
Page 14CHAPTER 5 DEFINITION OF CONTROLS
6.0 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 placement 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 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 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 Ad
justment 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 from the pinch point of the weld roller and track.

Instruction Manual
Page 15
6.0 Adjustments
CHAPTER 6 RECOMMENDED REPLACEMENT PARTS
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 16
6.0 Adjustments
CHAPTER 7 ADJUSTMENTS
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.

Instruction Manual
Page 17 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.
6.0 Adjustments

Instruction Manual
Page 18
6.0 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.

Instruction Manual
Page 19
6.0 Adjustments
CHAPTER 7 ADJUSTMENTS
Welding a Pole Pocket
•The pocket guide needs to be high enough so the nozzle does not hit the bottom of the
guide. It also needs to be perpendicular to the track.
•The pocket guide is used to weld pole pockets. The guide is used to control the exact
positioning of the top flap of material.
•When welding a pocket 3 inches or larger, normally the overlap settings may be used. If
smaller then 3 inches, the speed will need to be turned up reducing the amount of heat
because the heat will become trapped.
•Do not pull the fabric sideways or backwards when holding the fabric into the pocket
guide, just hold the fabric with very little pressure against the guide. If you pull the fabric
sideways it will become tight and bind up in the guide. If you pull the fabric backwards it
may stretch leaving wrinkles.
1. Place panel to be welded under the clamps 1/4 – 3/8 inch, aligning edge of panel on the trough to
desired pocket size.
2. Turn on right vacuum (cover unused track with magnet).
3. Pull panel tight and check alignment of edge to desired pocket size.
4. Lift the left clamp.
5. Fold the edge side under the clamps and weld roller.
6. Align edge with right laser making sure panel is square under roller.
7. Lower weld roller and clamp.
8. Install pocket guide.
9. Press start and hold the material against the right side of guide.
10. When finished with run, press return (if auto return is not engaged).
11. Turn off right vacuum.
12. Lift clamps.
13. Remove pocket guide.
14. Check weld.

Instruction Manual
Page 20
6.0 Adjustments
CHAPTER 7 ADJUSTMENTS
Welding Webbings or Tapes
1. Install the adjustable webbing or tape guide to the machine.
2. Adjust the guide to the correct width of your webbing or tape.
3. Insure that the weld roller and nozzle will not touch the guide. The guide also needs adjusted
parallel to the wheel.
Butt seam tape guide
1. The butt seam tape guide is used to properly guide and place the tape when butt seaming.
2. The butt seam tape guide is adjustable for various tape widths. Make sure both adjustable parts of
the guide are aligned and the are both the same widths.
Weld Roller Adjustments
1. The weld roller is located on the traveling welding head.
2. The purpose of the weld roller is to compress the heated material together producing the welded
seam and to drive or feed the fabric through the system.
3. The weld roller always needs to be aligned on the edge of vacuum holes nearest the operator side
of the welding track.