Miller Weldmaster T3 Extreme User manual

Instruction Manual
Page 1
This instruction manual is intended to be a guide when operating the T3 Extreme Seam welder. To ensure opti-
mal 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 up-
dates, 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: Operation
Chapter 7: Adjustment
Chapter 8: Welding Tips
Chapter 9: Accessories
Chapter 10: Maintenance
Chapter 11: Recommended Replacement Parts
Chapter 12: Transportation and Storage
Page 3
Pages 4
Page 5
Page 6
Page 7-11
Page 12
Pages 13 - 17
Pages 18 - 19
Page 20
Pages 21 - 22
Page 23
Page 24
Table of Contents

Instruction Manual
Page 3
1.0 Intended Use
CHAPTER 1 INTENDED USE
The T3 is a rotary hot wedge welding machine intended to heat-seal weldable thermal plastics
such as:
•Vinyl (PVC) laminated and coated fabrics
•Vinyl (PVC) and Polyurethane (PU) films
•Polyurethane (PU) and Polypropylene (PP) coated fabric
•Polyethylene (PE)
•Thermoplastic rubber (TPR) film and fabrics
•Non-woven Polyester and Polypropylene
•Various Fusing Tapes
•Weldable Webbing
•Rigid Extruded Products
The manufacturer does not approve of:
•Any other uses for these machines.
•The removal of any safety guards while in operation.
•Unauthorized modification of the machines.
•Using replacement parts that are not manufacturer-approved.
Only a properly-trained technician may operate and/or perform any routine
maintenance or repairs to the machines.
NOTE: The manufacturer will not be held liable for any damage or injuries occurring
from any inappropriate use of this machine.

Instruction Manual
Page 4CHAPTER 2 EXPLANATION OF WARNINGS
2.0 Explanation of Warnings
There are several different warning symbols placed on the Miller Weldmaster T3. The symbols are
to alert the operator of potentially hazardous areas on the machine. Familiarize yourself with their
placement and meaning.
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: Electricity
The “Caution: Electricity” sticker is placed near areas
that contain electrical.
Caution: Read Document
Read accompanying documentation before use.

Instruction Manual
Page 5
3.0 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 compatible 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 T-3 requires the following power supply.
•16 Amperes - Single phase - 230 Volts
Shop Air Supply
The Miller Weldmaster T-3 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 T-3 requires the following shop air requirements:
•Minimum of 3 cfm at 120 psi (standard) or 85 liters/min at 8.3 Bar (metric)
CHAPTER 3 ELECTRICAL AND AIR REQUIREMENTS

Instruction Manual
Page 6
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 7
5.0 Definition of Controls
CHAPTER 5 DEFINITION OF CONTROLS
The manufacturer suggests that all operators are familiar with all the controls of their machine. It is in the
operators best interest to know the purpose of all these controls and their functions.
Start Button: The start button initiates the wedge swing and
motor controls. By depressing the start button the welding
process will begin.
Stop Button: The stop button will pause the welding operation.
By depressing the stop button the welding operation will stop.
Weld Roller Open/Close: The push/pull knob will open or
close the weld rollers. By pushing the knob the weld rollers
will close. By pulling the knob the weld rollers will open.

Instruction Manual
Page 8CHAPTER 5 DEFINITION OF CONTROLS
5.0 Definition of Controls
Emergency Stop Button: The emergency stop button will stop
the system operations in the event of an emergency. Depress
the emergency stop button in the event of an emergency. Twist
to release the emergency stop button.
Reset Button: The reset button turns power ON to the control
system of the machine. The reset button must be pushed
after the power disconnect has been turned ON and after the
emergency stop button has been turned and released.
Temperature Controller: The temperature controller is
used to set the desired temperature of the wedge. The
temperature range is 0OC to 430OC. The UP arrow increases
the set temperature, the DOWN arrow decreases the set
temperature. The EZ, scroll, and double circle buttons are used
for programming functions. The top display is of the actual
temperature and the bottom display is of the set temperature. If
the display is not showing the set and actual temperatures, turn
the power disconnect to the OFF position for 30 seconds then
back on again.

Instruction Manual
Page 9 CHAPTER 5 DEFINITION OF CONTROLS
5.0 Definition of Controls
Pressure Gauge and Regulator: The pressure gauge and
regulator displays and controls the weld roller pressure. To
increase or decrease the weld roller pressure, pull the regulator
knob out then rotate. Rotate clockwise to increase the pressure
and counter clockwise to decrease the pressure. Push the
regulator in to lock the knob in place.
Speed Control: The speed control adjusts the speed of the
weld rollers. 0 is the lowest speed and 10 is the fastest speed.
Turn the knob to the desired speed setting
Drive Delay Control: The drive delay control delays the weld
rollers from starting until the start button or foot pedal has been
depressed. The drive delay control should be set to allow the
wedge to be in proper position before the weld rollers begin to
turn. Adjustment will be needed for individual products being
welded.

Instruction Manual
Page 10
5.0 Definition of Controls
CHAPTER 5 DEFINITION OF CONTROLS
Power Disconnect: The power disconnect turns power ON/
OFF to the machine. For power to be turned ON rotate the
handle to the ON position and to turn OFF turn to the OFF
position. The power disconnect should always be turned
OFF when the machine is not in use or being serviced.
Foot Pedal Plug: The foot pedal plug connects the foot
pedal to the control system of the machine. Insert the
male end of the plug into the female end of the plug, then
tighten the threaded nut finger tight. The foot pedal should
be connected only when the machine is used in a stationary
mode.
Air Supply: The air supply should be connected to the
supply side of the ball valve, 1/4" NPT. The ball valve
should be turned to the horizontal position whenever the
machine is not in use and locked in the OFF position when
the machine is being serviced.
Foot Pedal: The foot pedal initiates the wedge swing and
motor controls. By depressing the foot pedal the welding
operation will begin.

Instruction Manual
Page 11 CHAPTER 5 DEFINITION OF CONTROLS
6.0 Operation
NOTE: Before starting up the machine, please check it carefully and guarantee that there are
no foreign objects under the welding area. Be sure the surrounding area of the machine is
free of flammable debris. Only authorized persons are permitted to use machine.
Start Up
1. Connect the power cord to the appropriate power supply.
2. Connect air to the appropriate air supply and turn the air supply ball valve to the OPEN
position.
3. Turn the power disconnect to the ON position. This will power up the machine and the
heat system.
4. Make sure the emergency stop button is released.
5. Depress the reset button. Depressing the reset button turns ON the control system of
the machine.
6. Assuming the machine adjustments and control settings are to the desired point, the
machine is ready for use.
Shut Down:
1. Turn the power disconnect to the OFF position. This will power down the machine and
the heat system.
2. Turn the air supply ball valve to the OFF position.

Instruction Manual
Page 12
7.0 Adjustments
CHAPTER 6 OPERATION
Wedge Adjustment
Wedge placement is the most important component with wedge
welding. When the wedge arm swings in and drives forward, it is
imperative that the point of the alignment pin fits into the recess
of the wedge arm. Before adjusting the wedge system be sure
the weld roller pressure is set to the desired pressure setting. For
most application the weld roller pressure should be set to 40-50
psi. Check this by engaging the drive foot pedal. Having correct
placement will ensure a proper weld.
Wedge Height Adjustment
Before checking the wedge alignment, set the speed control to its
lowest setting, the drive delay to its highest setting, and close the
weld rollers.
1. Swing the wedge into place by depressing the drive foot pedal
or the start button. Once the wedge swing has reached the weld
position, view the placement of the wedge with respect to the weld
rollers then release the drive foot pedal or depress the stop button.
2. The height of the wedge must be level with the pinch point of the
weld rollers.
3. If the height of the wedge is high or low of the pinch point an
adjustment will be required.
4. To adjust the wedge height alignment the wedge must first be in
the home position.
5. Locate and loosen the height adjustment locking bolts and adjust
the wedge system up or down depending on required level position
of the wedge to the pinch point.
6. After adjustments have been made, re-check the position of the
wedge with respect to the weld roller pinch point. See step one.

Instruction Manual
Page 13 CHAPTER 7 ADJUSTMENTS
7.0 Adjustments
Wedge Squareness Alignment
Before checking the wedge alignment, set the speed control to its
lowest setting, the drive delay to its highest setting, and close the
weld rollers.
1. Swing the wedge into place by depressing the drive foot pedal
or the start button. Once the wedge swing has reached the weld
position, view the placement of the wedge with respect to the weld
rollers then release the drive foot pedal or depress the stop button.
2. The squareness alignment of the wedge must be on center line
with the weld rollers.
3. If the squareness of the wedge is rotated off the center line of the
weld rollers an adjustment will be required.
4. To adjust the wedge squareness, the wedge must first be in the
home position.
5. Locate and loosen the left/right adjustment locking bolts and
adjust the wedge system rotation depending on required position of
the wedge to the weld rollers.
6. After adjustments have been made, re-check the position of the
wedge with respect to the weld rollers. See step one.

Instruction Manual
Page 14
7.0 Adjustments
CHAPTER 7 ADJUSTMENTS
Wedge Tilt Alignment
Before checking the wedge alignment, set the speed control to its
lowest setting, the drive delay to its highest setting, and close the
weld rollers.
1. Swing the wedge into place by depressing the drive foot pedal
or the start button. Once the wedge swing has reached the weld
position, view the placement of the wedge with respect to the weld
rollers then release the drive foot pedal or depress the stop button.
2. The tilt of the wedge is best viewed from the operators
perspective, eye level with the wedge and weld roller pinch point
when the wedge has swung into place.
3. If the tilt alignment of the wedge is not horizontal with the pinch
point of the weld rollers an adjustment will be required.
4. To adjust the wedge tilt alignment the wedge must first be in the
home position.
5. Locate and loosen/tighten the tilt adjustment locking knobs
and adjust the wedge system left or right depending on required
position of the wedge to the weld rollers. For example, if the wedge
tilt requires movement to the left then first loosen the tilt knob on
the left one or two turns, then tighten the tilt knob on the right. This
will adjust the wedge tilt to the left.
6. After adjustments have been made, re-check the position of the
wedge with respect to the weld rollers. See step one.

Instruction Manual
Page 15 CHAPTER 7 ADJUSTMENTS
7.0 Adjustments
Wedge Left/Right Alignment
Before checking the wedge alignment, set the speed control
to its lowest setting, the drive delay to its highest setting, and
close the weld rollers.
1. Swing the wedge into place by depressing the drive foot
pedal or the start button. Once the wedge swing has reached
the weld position, view the placement of the wedge with respect
to the weld rollers then release the drive foot pedal or depress
the stop button.
2. The squareness alignment of the wedge must be on center
line with the weld rollers.
3. If the squareness of the wedge is rotated off the center line of
the weld rollers an adjustment will be required.
4. To adjust the wedge squareness, the wedge must first be in
the home position.
5. Locate and loosen the left/right adjustment locking bolts
and adjust the wedge system rotation depending on required
position of the wedge to the weld rollers.
6. After adjustments have been made, re-check the position of
the wedge with respect to the weld rollers. See step one.

Instruction Manual
Page 16
7.0 Adjustments
CHAPTER 7 ADJUSTMENTS
Wedge Depth Alignment
Before checking the wedge alignment, set the speed control
to its lowest setting, the drive delay to its highest setting, and
close the weld rollers.
1. Swing the wedge into place by depressing the drive foot
pedal or the start button. Once the wedge swing has reached
the weld position, view the placement of the weld with respect
to the weld rollers then release the drive foot pedal or depress
the stop button.
2. The depth alignment of the wedge must be in contact with
the weld rollers to allow contact and heat transfer to the fabric.
3. If the depth alignment of the wedge is back too far or too far
into of the pinch point of the weld rollers an adjustment will be
required.
4. To adjust the wedge depth alignment the wedge must first be
in the home position.
5. Locate and loosen the depth adjustment locking bolts and
adjust the wedge system depth depending on required position
of the wedge to the weld roller pinch point.
6. For proper wedge depth first adjust the tip of the wedge to
just contacting the pinch point of the weld rollers. Once the
wedge tip has been adjusted to this point then slide the wedge
system 1/8” more into the pinch point of the weld rollers. This
will allow proper pressure of the wedge against the fabric and
the weld rollers.
7. After adjustments have been made, re-check the position of
the wedge with respect to the weld rollers. See step one.

Instruction Manual
Page 17 CHAPTER 7 ADJUSTMENTS
8.0 Welding Tips
Bad Weld (Fig. 01)
This is not a good weld. Although the fabric is somewhat
welded, it is not what could be considered 100%. One of two
things must happen for this weld to become accepted. Either
the speed must be decreased or the heat must be increased.
Good Weld (Fig. 02)
This is a good weld. The fabric is welded 100%. You can
see the fabric is delaminating over the entire width of the
seam.
Uneven Fabric Tension (Fig. 03)
This is an example of too much tension held on the top
fabric panel. It is important for the operator to hold even
(equal) tension on both the top and bottom fabric panels as
the machine is welding. As illustrated the green panel goes
through the left side (top) of the welder and the yellow panel
goes through the right side (bottom ) of the welder. When
more tension is held on the top panel, the bottom panel will
show wrinkling next to the weld. Adjust the tension held to
give a smoother finish.

Instruction Manual
Page 18
8.0 Welding Tips
CHAPTER 8 WELDING TIPS
Uneven Fabric Tension (Fig. 04)
This is an example of too much tension held on the bottom
fabric panel. It is important for the operator to hold even
(equal) tension on both the top and bottom fabric panels as
the machine is welding. As illustrated the green panel goes
through the left side (top) of the welder and the yellow panel
goes through the right side (bottom ) of the welder. When
more tension is held on the bottom panel, the top panel will
show wrinkling next to the weld. Adjust the tension held to
give a smoother finish.
Perfect Seam (Fig. 05)
This is an example of a perfect seam. There is no waviness,
wrinkles, or puckers. The heat, speed, and pressure,
combined with the operators tension applied are perfect.

Instruction Manual
Page 19 CHAPTER 8 WELDING TIPS
9.0 Accessories
Guides
The Miller Weldmaster T3 gives the user the ability to switch from one application to the next with our
quick change guides.

Instruction Manual
Page 20
10.0 Maintenance
CHAPTER 9 ACCESSORIES
The Miller Weldmaster T3 has certain items that need maintained to keep the machine running as
effective as possible. The T3 has three chains which are used to drive the weld rollers and travel roller
on the machine. Although not high maintenance items, chains should be inspected every 3 months
to ensure there is not excessive corrosion, rust, or dirt. Also inspect for any looseness in the chain,
sprockets, or gears. If needed, lubricate chains and gears once every 3 months with 80-90w gear oil.
1. Before starting inspections or maintenance of any kind the power disconnect and air valve must be
turned to the off position.
2. Remove the back cover of the machine and inspect the chains, sprockets, gears, and all other
mechanical parts. During the inspection, look for wearing surfaces, dark dust under the sprockets and
gears, dry chains, or any other signs of wear.
3. Oil chains, sprockets, and gears as needed. Replace worn out parts as needed.
4. Once the mechanical system has been inspected and maintained then inspect the electrical system.
Begin the inspection by first lightly blowing out the inside of the machine with a compressed air blow
gun (be sure compressed air is completely dry and clean). Inspect electrical components, wire, and
wire terminals for dark/discolored areas.