Miller Weldmaster Impulse 3.0 Extreme User manual

Instruction Manual
Page 1
This instruction manual is intended to be a guide when operating the Impulse3.0 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: Safety Precautions
Chapter 7: General Description
Chapter 8: Technical Specifications
Chapter 9: Transportation Specs and Storage
Chapter 10: Maintenance
Chapter 11: Operation
Page 3
Pages 4-5
Page 6
Page 7
Pages 8-17
Pages 18-19
Page 20
Page 21
Page 22
Pages 23-26
Pages 27-30
Table of Contents

Instruction Manual
Page 3
1.0 Intended Use
CHAPTER 1 INTENDED USE
The Impulse Extreme is a Thermal Impulse 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
• Acrylic Fabrics (with the use of Extreme Seam Tape TM)
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 Impulse 3.0. The
symbols are to alert the operator of potentially hazardous areas on the machine. Familiarize your-
self 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 Impulse 3.0
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 include a plug. It
is recommended 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 Impulse Extreme has the following electrical requirements:
•40 Amperes - Three phase - 230 Volts
•40 Amperes - Three phase - 400 Volts
•40 Amperes - Single phase - 230 Volts
Shop Air Supply
The Miller Weldmaster Impulse 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 Weld-
master Impulse Extreme requires the following shop air requirements:
•Minimum of 5cfm at 120 psi
•140 liters/min at 8.2 Bar

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 on each sealing bar.
Time: The amount of time the heat and pressure is applied to the fabric or film. This time allows
the heat to penetrate into the fabric or film and then cool.
Pressure: The pressure is applied to the fabric or film through the sealing bars. The sealing bars
apply.
Summary: The correct combination of heat, pressure, and time will allow you to achieve a
properly welded seam.

Instruction Manual
Page 8CHAPTER 5 DEFINITION OF CONTROLS
5.0 Definition of Controls
Operator Control : System banner bar notifies the user of the ma-
chines current process as well as any alarms that may be present.
This will display many different phrases so the operator knows what
process the machine is currently in.
Recipe Bar: This is a reference as to what the current recipe is. As
well as the name of the recipe that the operator can change in
the recipe screen.
Weld Time:
SP: Set Point. Set point is the amount of time the heat elements are
on during the welding cycle. This is a changeable Value. To change the
Set point touch the screen area displaying the current Set point. A key
pad will pop up. This will allow the Set point to be entered. A minimum
time of 1 second to a maximum time of 30 seconds can be entered.
PV:Present Value. During the welding cycle the Weld Present
Value will display the elapsed time of the Heating cycle. This
time will start at 0.00seconds and count up to the Weld time
set point.
Cool Time:
SP: Set point. The Cool Time Set point is the amount of time the heat
elements are off during the welding cycle. This is a changeable set
point. To change the Cool Time Set point touch the screen area dis-
playing the current Cool Time Set point. A key pad pop up will allow
the Cool Time Set point to be entered. A minimum time of 1 second to
a maximum time of 99 seconds can be entered.
PV:Present Value. During the cooling cycle the Cool Time Present Val-
ue will display the elapsed time of the cooling cycle. This time will start
at 0.00 seconds and count up to the Cool Time Set point. (Fig.07)

Instruction Manual
Page 9
5.0 Definition of Controls
CHAPTER 5 DEFINITION OF CONTROLS
Function Button
This allows the operator to control what mode the machine is set to. There are 4 modes to
choose from as follows:
Weld: welding mode for overlap welding.
F/w: Fold and weld. This creates a fold from a flat hem to a 2.5” pocket, then
positions the seam for welding.
F/w/t: Fold With Tape. This is for inserting the heat welding tape for acrylic fabric
or traditionally non weldable fabrics.
Edging: This function is for applying all of your edging to a panel. Mainly used for
the zipper application. Utilizing the zipper guide as well as the prefolder.
Recipes
This takes the operator to the Recipe Screen.
Alarm
This takes the operator to the Recipe Screen.
Operator Configuration
This takes the Operator Configuration Screen.
Recipe Changed
This button flashes to notify you if the current recipe has been changed from the previously
saved version. If the current recipe is valid you can push the Recipe Changed button to
save the current recipe. This will make the button hide once again.

Instruction Manual
Page 10
5.0 Definition of Controls
Recipe Management Screen
This is where we can add edit and manage all the recipes we
have stored on the machine. The – and + Buttons are to change
the recipe up and down to choose the desired set recipe. By
pushing the “-“ button moves the recipe to the next lower recipe.
Pushing the “+” moves the recipe to the next higher recipe.
The Field directly to the right of the recipe number is for inputting
the recipe name. Touch in the field and an alphanumeric
keyboard will pop up allowing you the capabilities to input titles.
We can input items like material type, the material name, or
even the material weights.
Weld time: This is the amount of time we want the machine
to cycle the heat on for. This is a changeable value. To change
the Weld Time touch the screen area displaying the current
Weld Time. A key pad will pop up allowing the Weld Time to be
entered. A minimum time of 1 second to a maximum time of 30
seconds can be entered.
Cool Time: This is the amount of time we want the machine
to cycle for the water cool down. This is a changeable value. To
change the Cool Time touch the screen area displaying the current
Cool Time Set point. A key pad pop up will allow the Cool
Time Set point to be entered. A minimum time of 1 second to a
maximum time of 99 seconds can be entered.
Save button: This button allows us to save the current created
recipe.
Activate: This button allows us to activate the current recipe.
When changing between recipe settings you will have to activate
the current set recipe for it to properly take effect. Touch
the activate button to use that recipe.
Operator Control: This button will take you to the main Operator
Control screen.
CHAPTER 5 DEFINITION OF CONTROLS

Instruction Manual
Page 11
5.0 Definition of Controls
CHAPTER 5 DEFINITION OF CONTROLS
Operator Configuration Screen
Purge: This button allows us to purge the water pump manually.
The main reason for this is to be used after a water tank flush and
fill. This allows us to make sure all the air is removed from the
water pump prior to trying the welding cycle so we do not get a
low water flow alarm.
Heat: This button controls the heat to the machine. Any time
the machine is cycled to the on position the operator will have
to turn the heat switch on. It will illuminate green when depressed
notifying that it had been turned on.
Clamp: This is used to open and close the fabric clamp. This but-
ton is only used when a fold function is selected.
Pre Heat: This time is to allow the heating elements on the ma-
chine to stretch prior to engaging to the welding stage. During this
time the bars will remain open at the center point away from the
fabric. This time is to help lengthen the life expectancy of the bands
as well as shorten weld times on most substrates. This time needs
to be set between 4-7 seconds depending on the application.
Water: This time is for our second cool down cycle. When the
bars release the material we then cool the welding bars down a
second time. This allows us to maintain the same seam tempera-
ture repeatedly. This timer should be set between 10-20 seconds
depending on application.
Maintenance: This button allows MW technicians to trouble shoot
the machine.
Production status: This button takes you to the Production status
screen.
Operator Control: This button will take you to the main Operator
Control screen.

Instruction Manual
Page 12
5.0 Definition of Controls
CHAPTER 5 DEFINITION OF CONTROLS
Function Button
This allows the operator to control what mode the machine is set to. There are 4 modes to choose from
as follows:
Weld: welding mode for overlap welding.
F/w: Fold and weld. This creates a fold from a flat hem to a 2.5” pocket, then positions the
seam for welding.
F/w/t: Fold With Tape. This is for inserting the heat welding tape for acrylic fabric or traditionally
non weldable fabrics.
Edging: This function is for applying all of your edging to a panel. Mainly used for the zipper
application. Utilizing the zipper guide as well as the prefolder.
Recipes: This takes the operator to the Recipe Screen.
Alarm: This takes the operator to the Recipe Screen.
Operator Configuration: This takes the Operator Configuration Screen.
Recipe Changed: This button flashes to notify you if the current recipe has been changed from the pre-
viously saved version. If the current recipe is valid you can push the Recipe Changed button to save the
current recipe. This will make the button hide once again.

Instruction Manual
Page 13
5.0 Definition of Controls
CHAPTER 5 DEFINITION OF CONTROLS
Recipe Management Screen
This is where we can add edit and manage all the recipes we
have stored on the machine. The – and + Buttons are to change
the recipe up and down to choose the desired set recipe. By
pushing the “-“ button moves the recipe to the next lower recipe.
Pushing the “+” moves the recipe to the next higher recipe. The
Field directly to the right of the recipe number is for inputting the
recipe name. Touch in the field and an alphanumeric
keyboard will pop up allowing you the capabilities to input titles.
We can input items like material type, the material name, or
even the material weights.
Weld time: This is the amount of time we want the machine
to cycle the heat on for. This is a changeable value. To change
the Weld Time touch the screen area displaying the current
Weld Time. A key pad will pop up allowing the Weld Time to be
entered. A minimum time of 1 second to a maximum time of 30
seconds can be entered.
Cool Time: This is the amount of time we want the machine
to cycle for the water cool down. This is a changeable value. To
change the Cool Time touch the screen area displaying the current
Cool Time Set point. A key pad pop up will allow the Cool
Time Set point to be entered. A minimum time of 1 second to a
maximum time of 99 seconds can be entered.
Save button: This button allows us to save the current created
recipe.
Activate: This button allows us to activate the current recipe.
When changing between recipe settings you will have to activate
the current set recipe for it to properly take effect. Touch
the activate button to use that recipe.
Operator Control: This button will take you to the main Operator
Control screen.

Instruction Manual
Page 14CHAPTER 5 DEFINITION OF CONTROLS
Operator Configuration Screen
Purge: This button allows us to purge the water pump manually.
The main reason for this is to be used after a water tank flush
and fill. This allows us to make sure all the air is removed
from the water pump prior to trying the welding cycle so we do
not get a low water flow alarm.
Heat: This button controls the heat to the machine. Any time
the machine is cycled to the on position the operator will have
to turn the heat switch on. It will illuminate green when de-
pressed notifying that it had been turned on.
Clamp: This is used to open and close the fabric clamp. This
button is only used when a fold function is selected.
Pre- Heat: This time is to allow the heating elements on the ma-
chine to stretch prior to engaging to the welding stage. During
this time the bars will remain open at the center point away from
the fabric. This time is to help lengthen the life expectancy of the
bands as well as shorten weld times on most substrates. This
time needs to be set between 4-7 seconds depending on the
application.
Water: This time is for our second cool down cycle. When the
bars release the material we then cool the welding bars down a
second time. This allows us to maintain the same seam tem-
perature repeatedly. This timer should be set between 10-20
seconds depending on application.
Maintenance: This button allows MW technicians to trouble
shoot the machine.
Production status: This button takes you to the Production
status screen.
Operator Control: This button will take you to the main Operator
Control screen.
5.0 Definition of Controls

Instruction Manual
Page 15 CHAPTER 5 DEFINITION OF CONTROLS
Production Status Screen
Cycles: This is the number of time the weld bar has went to the
fully down or welding position.
Reset: This button allows us to reset the #of cycles counter.
This is useful when performing maintenance or routine
preventative maintenance. Keep a log if possible after any reset
and maintenance performed.
Total Cycle Times: This counter is a lifetime counter for the
machine cycles.
Time: This counter is to display the amount of time the heat has
been on for.
Reset: This button allows us to reset the Heat time. This is use-
ful when performing maintenance or routine preventative
maintenance. Keep a log if possible after any reset and
maintenance performed.
Total: This counter displays the lifetime heat time.
Operator Control: This button will take you to the main
Operator Control screen.
5.0 Definition of Controls

Instruction Manual
Page 16CHAPTER 5 DEFINITION OF CONTROLS
5.0 Definition of Controls
Maintenance Screen
Screen: Pressing the Maintenance Button will bring up a screen
to enter in a user name and password. The appropriate
password must be entered in order to gain access to the main-
tenance screens. Please check with your supervisor for the
password. Only Authorized persons are to enter into the mainte-
nance screen.
Alarm Active Screen: This will display any active current
alarms. (fig. 02)
Alarm History: This will take you to the Alarm History
screen.
ACK: This button is used to acknowledge any currently
active alarms.
Operator Control: This button will take you to the main
Operator Control screen.
Reset Button
Blue Push Button: Reset button. Any time the machine is turned
on or brought back from an e-stop state. The Blue reset button
will have to be pressed. (fig. 03)
Pause Button
Yellow Push button: Pause. This button is to pause the machine
at any point during any process. When pressed the machine will
return all bars to the home position and cycle water, this is to
cool the bars down if it was in a welding state.

Instruction Manual
Page 17 CHAPTER 5 DEFINITION OF CONTROLS
5.0 Definition of Controls
3 Way switch : Three way switch on side of machine is for
Lasers lights and lasers. This switch is on the right side of the
machine. In the laser position the lasers are on. The off position
turn them off. The lights/laser position turn the lights and lasers
on.
Forward/Reverse switch : Forward Reverse switch is for mov-
ing the fold system to create the desired pocket size. From a lay
flat hem to a 2.5” lay flat pocket.

Instruction Manual
Page 18
6.0 Safety Precautions
NOTE: For the safe and correct use of the machine, it is necessary to read through these
precautions carefully before use.
1. All the users who operate this machine should have this user’s manual in hand, and should keep
it in an accessible location after reading for future reference.
2. The warning instructions provided in this manual and on the machine are meant to prevent
personal injury. Equipment damages will be caused if relevant requirements are not observed and
corresponding measures are not taken.
3. The persons operating this machine are required to be familiar with the steps and requirements
for installation, adjustment and operation of this machine. They must also be familiar with the
corresponding measures to be taken for any emergencies that could possibly happen by meeting
the following conditions:
•Having received training.
•Able to switch the machine ON/OFF.
•Able to safely connect the machine to the power supply which is appropriate for local
electrical regulation and code.
•Able to conduct the proper maintenance, operation and protection of the machine.
4. There is dangerous voltage on this machine. During operation after power up, do not open the
electric cabinet door and the electrical control box to avoid possible electric shocks. This machine
is provided with grounding and its input power must be connected to permanent-fixed power lines.
5. All the adjustment devices of the machine are adjusted to their working state before delivery.
Any non-professional persons are not allowed to change the adjustment. If any adjustments are
necessary; such adjustments should be made by authorized persons.
6. Children and other persons except operators should be prevented from touching or accessing
the machine. Before installation and use of the machine, please read these safety rules, warnings
and warning labels fixed on the machine.
7. Ensure that warning labels are located at appropriate positions, and replace any damaged or
lost labels.
Tips: Putting the machine into service safely and successfully
•Get familiar with all the safety instructions; as well as installation, operation and
maintenance instructions provided in this manual.
•Understand the correct handling, loading/unloading and maintenance procedures for the
machine.
CHAPTER 6 SAFETY PRECAUTIONS

Instruction Manual
Page 19 CHAPTER 6 SAFETY PRECAUTIONS
6.0 Safety Precautions
Safety Precautions before Use
1. Before starting up the machine, please check it carefully and guarantee that there are no foreign
matters under the sealing area. If any unusual conditions are found during operation, immediately
press the Emergency Stop Switch and then check for abnormal conditions.
2. When the Sealing Cylinder rises, the fabric is not completely cooled. Hence, it should be raised
slowly from one side to the other side. Never pull it down suddenly. This will cause damage to the
sealing and affect the sealing quality.
3. If the machine is not in use, please turn off the air supply and power supply to avoid any dangers.
4. Avoid heating without fabric placed in position.
5. Do not use high temperature without prior testing in order to prevent damages caused to the Teflon
cloth. If plastics are melted and adhered to the cloth due to incorrect operation, do not remove it by
using a hard tool. Please remove it by using a soft cloth or other soft tools. Otherwise, the
Teflon cloth will be damaged and there will be direct adverse effects on the sealing quality.

Instruction Manual
Page 20
7.0 General Description
CHAPTER 7 GENERAL DESCRIPTION
The Impulse Extreme sealing machines are pneumatic instantaneously-heating double-sided
sealing machines that are applicable to the heat sealing of fabrics and films in a variety of
industries. They are horizontal sealing machines with a cylinder acting as the closing force
source. This provides consistent sealing pressure, improved sealing quality and improved
working efficiency. It has one upper heating wire and one lower heating wire for the heating of
the sealing area that provides high power, short heating time for sealing. The Impulse Extreme
machine offers unique capabilities which produce quality products that traditional heat sealing
machines do not.
The accurate heating and cooling time control of this machine provide for reliable heat sealing
of products. The Impulse Extreme machine can seal a wide variety of fabrics and films of many
different thicknesses.
This machine has a sealing area that is 118in. (3000mm) long. Its sealing width (namely the
width of the electric heating wire) ranges include 15mm, 20mm, and 25mm.