Miller Weldmaster Extreme T300 User manual

Instruction Manual
Page 1
This instruction manual is intended to be a guide when operating the T300 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: 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 15-23
Page 24
Page 25
Table of Contents

Instruction Manual
Page 3
1.0 Intended Use
CHAPTER 1 INTENDED USE
The T300 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 T300. 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.
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.

Instruction Manual
Page 5 CHAPTER 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.

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.
Preparation - World Power
1. Make sure the Power Supply is at 230v, 25amp, 50/60hz or 400v, 16amp, 50/60hz
and the Pressure Supply comes up to 120 psi (8.3 bar) when the machine is working.
2. Make sure the voltage and current is dedicated to the machine and to the above
specification.
3. An appropriate ground connection must be made to the ground terminal provided on
the machine.
4. Before operation of the machine be sure the surrounding area of the machine is free
of flammable debris. Only authorized persons should be in the area of the machine
while in use.
5. In the event of an emergency, press the Emergency Stop Button.
Electrical Supply
Due to 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 T300 requires
one of the following electrical requirements:
•25 Amp - Single phase - 230 Volts
•16 Amp - Single phase - 400 Volts
Shop Air Supply
The Miller Weldmaster T300 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
T300 requires the following shop air requirements:
•Minimum of 5 cfm at 120 psi
•Not to exceed 140 liters/min at 8.3 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
Hot Air Heating System
The Heat required for the welding operation is created electrically by one heating element
located inside the Heat Element Housing. The Internal Air Compressor pumps air over the heat
element 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).
Hot Wedge Heating System
The Hot Wedge heat system uses four cartridge heat elements to electrically heat the Wedge.
The Hot Wedge temperature ranges from 25 to 490 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 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 Screen - HMI Operation
Recipe Number: This is a particular combination of the parameters of
heat and speed used to weld different types of fabric. This shows which
recipe you’re currently using on the machine. 0 - 24 Available recipe
settings. In order to change recipes the heat on/off switch must be in the
off position.
Machine Speed: This is the speed of the Weld Roller. The speed can be
adjusted by pressing the up or down arrows. Each push of the button
increases or decreases the speed by .01 m/min. If you hold the buttons
for 1 second, it will increase or decrease the speed by .1 m/min.
Actual Temperature: This is how hot the machine is currently.
Temperature Set Point: This is how hot you want the machine to be for
the purpose of welding 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 speed percentages of the Upper Roller
and Puller Roller. When all of the rollers are in sync, the speed shows
100.0%. Adjust the percentages to change the speeds of each individual
roller. The actual speed of the roller can be checked at the Machine
Speed Display Screen.
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 de-
crease 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.

Instruction Manual
Page 9
5.0 Definition of Controls
Delay Settings: These are used to eliminate voids in seam.
Drive Start Delay Time: Once the foot pedal is depressed, the Drive Start
Delay Time will delay the weld rollers from turning until the set point is
reached. The Drive Start Delay Time will be adjusted by the operator to
the desired setting.
Drive Stop Delay Time: Once the foot pedal is released, the weld rollers
will continue to turn until the Roller 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 setting.
Parameters Menu Selection: When this button is pressed, a password
needs to be input. The
original password is 12345678.
Language: Select the language according to demand.
Password Change: The machine administrator may change the ma-
chine’s eight-digit password.
Temperature Parameter: For adjusting the PID (Proportional
Integral Derivative) value.
KP = Proportion Factor
TI = Integral Time
TD = Rate Time
CHAPTER 5 DEFINITION OF CONTROLS

Instruction Manual
Page 10
5.0 Definition of Controls
Hi-Temp Limit: maximum heating temperature of the machine.
Once the actual temperature is out of this 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 for 1 second, and the PID will go
back to the factory settings.
Hour Meter: The hour meter will count total time of which the
heating system is on.
Recipe Settings: When changing parameters, pressing the SAVE
button will save the adjusted settings to the selected recipe.
CHAPTER 5 DEFINITION OF CONTROLS

Instruction Manual
Page 11
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.
Parts Order? Call 855-888-9353 or email [e-mail]

Instruction Manual
Page 12
7.0 Machine Specifications
CHAPTER 7 MACHINE SPECIFICATIONS
Principles of Operation
The T300 is a heat sealing machine which welds thermal plastic fabrics or films by Hot Air
or Hot Wedge, through applying pressure, consistent speed, and accurate temperature for
perfectly sealing thermal plastic materials.
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.

Instruction Manual
Page 13
7.0 Machine Specifications
CHAPTER 7 MACHINE SPECIFICATIONS
Mechanical Section
•Removable Roller Table Top: The roller table top
assembly is used for paneling applications, edging,
edge finishing, and general seaming applications.
•Swing Arm: The swing arm is used when products
include shapes, curves, and tubes of the seaming area.
Heat Source
•Hot Air: heat element housing contains the heating
element and thermal-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)
Digital Touch Screen allows you to set system controls.
•Power On/Off Button: Power button turns the
machine on and off.
•Emergency Stop: The emergency stop button, when
depressed, will stop the seaming operation in the event
of an emergency.

Instruction Manual
Page 14
7.0 Machine Specifications
CHAPTER 7 MACHINE SPECIFICATIONS
Pneumatic System
•Pressure Adjustment Regulator: Filters out water and dirt in the air. The Pressure Adjusting
regulator, regulates the pressure to the machine. Increase the pressure by rotating clock-
wise, and decrease the value by rotating counter-clockwise.
•Solenoid Valve: Controls the actions of the Air Cylinders.
•Pressure Gauge: Used for displaying the pressure setting. The Upper Weld Roller
gauge 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 control of the General Power Supply
of the complete machine.
•Right Pedal Switch: It controls the lifting of the weld roller, and the opening and closing of
the weld rollers and puller (if the puller switch is on).
•Left Pedal Switch: Controls the starting and stopping of the seaming operation.

Instruction Manual
Page 15
8.0 Maintenance
CHAPTER 8 MAINTENANCE
1. Loosen and remove the protective cover from the element
housing.
2. Unpack the fiberglass insulation around the front of the
element housing. Be cautious to avoid eye contact when
handling the insulation.
3. Loosen and remove the two bolts to the bracket holding
the element housing in place.
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! The operator must disconnect the power from the machine before proceeding.
NOTE: The glass tube is easily broken and can already be broken, be very careful.

Instruction Manual
Page 16
8.0 Maintenance
CHAPTER 8 MAINTENANCE
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 equip
ment replacement parts should be purchased through Miller Weldmaster and or
a Miller Weldmaster authorize 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 on page
4. Check if the up and down movement of the Upper Unit is smooth.
NOTICE: By not properly maintaining the machine, the performance may be effected. Please
contact Miller Weldmaster with any questions.

Instruction Manual
Page 17
8.0 Maintenance
CHAPTER 8 MAINTENANCE
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.

Instruction Manual
Page 18CHAPTER 8 MAINTENANCE
8.0 Maintenance
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 exces-
sive 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.

Instruction Manual
Page 19 CHAPTER 8 MAINTENANCE
8.0 Maintenance
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.

Instruction Manual
Page 20
8.0 Maintenance
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.
CHAPTER 8 MAINTENANCE