Miller Weldmaster PS150 User manual
1.0 Machine Overview …………………………………………………………………… 1
1.1 Intended Use ………………………………………………………………………………… 1
1.2 Explanation of Warnings …………………………………………………………………… 2
1.3 Electrical and Air Requirements …………………………………………………………… 4
1.3.1 Preparation - World Power ………………………………………………………… 4
1.3.2 Electrical Supply ……………………………………………………………………… 4
1.3.3 Shop Air Supply ……………………………………………………………………… 5
1.4 Principles of Heat Sealing ………………………………………………………………… 5
1.5 Controls: Purposes and Functions ………………………………………………………… 6
1.5.1 Operator Control Screen …………………………………………………………… 6
1.5.2 Main Menu Screen, Operator Level ………………………………………………… 7
1.5.3 Operator Configuration, Operator Level …………………………………………… 8
1.5.4 Main Menu Screen, SU Level ……………………………………………………… 9
1.5.5 Recipe Configuration Screen ………………………………………………………10
1.5.6 Recipe Active Screen ………………………………………………………………12
1.5.7 Heat Control Weld Nozzle Screen …………………………………………………13
1.5.8 Heat Control Pre Heat Nozzle Screen ……………………………………………14
1.5.9 Machine View Operator Panel Screen ……………………………………………15
1.5.10 Machine View Top Slide Screen …………………………………………………16
1.5.11 Remote Interface Screen …………………………………………………………16
1.5.12 Active Alarm Screen ………………………………………………………………17
1.5.13 Alarm History Screen ………………………………………………………………17
1.5.14 Information Screen …………………………………………………………………17
1.5.15 Login Screen ………………………………………………………………………18
1.5.16 Machine Configuration Screen ……………………………………………………18
1.5.17 SU maintenance ……………………………………………………………………20
1.5.18 Manual Menu Screen ………………………………………………………………22
2.0 Machine Specifications
2.1 Features ………………………………………………………………………………………25
2.2 Technical Specifications ……………………………………………………………………25
2.3 Features and Functions ……………………………………………………………………25
2.3.1 Mechanical Section …………………………………………………………………25
Table of Content
2.3.2 Operator Controls Section ……………………………………………………………26
2.3.3 Pneumatic System ……………………………………………………………………26
3.0 Component Replacement and Maintenance …………………………27
3.1 Replacement of Heating Element …………………………………………………………27
3.2 Maintenance …………………………………………………………………………………27
3.2.1 Electrical Circuits ……………………………………………………………………27
3.2.2 Drive System …………………………………………………………………………28
3.2.3 Maintaining Belts and Pulleys ………………………………………………………28
3.3 Machine Adjustments ………………………………………………………………………29
3.3.1 Hot Air Heat System Adjustment …………………………………………………………29
3.3.2 Adjusting the Height of the Machine ……………………………………………………30
3.3.3 Transportation and Storage …………………………………………………………30
3.3.4 Technical Requirements ……………………………………………………………31
1.1: Intended Use
The PS150 is a rotary hot air welding machine intended to heat-seal weldable thermal
plastics such as:
Polypropylene (PP) Coated Fabric
Polyethylene (PE) Coated Fabrics
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.
Table of Content (continued)
1.0: Machine Overview
CHAPTER 1: MACHINE OVERVIEW
CHAPTER 1: MACHINE OVERVIEW 2
1.2: Explanation of Warnings
There are several different warning symbols placed on the Miller Weldmaster PS150. These symbols
are to alert the operator of potentially hazardous areas on the machine. Familiarize yourself with the
their placement.
Caution: Hot. (fig.01)
The “Caution: Hot” symbol is placed on a guard near hot
surfaces.
Danger: Pinch Points. (fig.02)
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. (fig.03)
The “Caution: Unplug Machine” sticker is placed near the open-
ing of the cabinet and all access panels. To prevent electrocu-
tion, the machine should always have the power disconnected
before the cabinet door is open.
Warning: Keep Hands Clear. (fig.04)
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.
(fig.01) Caution: Hot
(fig.02) Danger: Pinch Points
(fig.03) Caution: Unplug Machine
(fig.04) Warning: Keep Hands Clear
CHAPTER 1: MACHINE OVERVIEW
1.2: Explanation of Warnings (continued)
Warning: High Temperature Air (fig.05)
The “Warning: High Temperature Air” sticker is placed on the
Heater Assembly.
Caution: Electricity (fig.06)
The “Caution: Electricity” sticker is placed near areas that contain
electrical components.
Caution: Sharp (fig.07)
The “Caution: Sharp” sticker is placed near areas that contain
sharp components.
(fig.05) Warning: High Temperature Air
(fig.06) Caution: Electricity
3
Lockout Tagout (fig.08):
Each AC variable frequency drive power is supplied by a fuse block
which can be locked out and tagged out. A screw driver is used in
the slot on the face of the handle to start the handle to open. Once
started then the user can pull open by hand and lockout tagout the
device.
(fig.08) Caution: Electricity
(fig.07) Caution: Sharp
CHAPTER 1: MACHINE OVERVIEW
Warning! Only a qualified electrician may connect the electrical power.
4
1.3: Electrical and Air Requirements
1.3.1: Preparation - Power and Air
1. Make sure the Power Supply is at 230v, 30amp, 50/60hz or 480v,30amp, when the appropriate
step down transformer has been supplied, 50/60hz. and the Pressure Supply comes up to 100
psi (6.9 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 ma-
chine.
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
1.3.2: 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 PS150 requires one
of the following electrical requirements:
30 Amp - Three phase - 230 Volts
30 Amp - Three phase - 480 Volts (When the appropriate step down transformer has
been supplied)
The Attention (fig.09):
The tag is located near the lower limit of the height adjustment sys-
tem. Once the machine has been adjusted to the desired operating
height then raise the clamping collar to bottom of bracket and tighten
in place. By doing so creates a lower height adjustment limit so that
the machine will lower a minimal amount from operation height.
(fig.09) Caution: Electricity
1.2: Explanation of Warnings (continued)
1.4: Principles of Heat Sealing
Heat: Hot Air Heating System: The Heat required for the welding operation is created elec-
trically by one (or two depending on the application) heating element located inside the Heat
Element Housing. The shop air supply provides air over the heat element and carries the heat
through the Hot Air Nozzel, applying the heat to the material to be welded. The hot air tempera-
ture ranges from 25 to 800 Degrees Celsius (77 to 1472 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 Rollers compresses the heated material together to com-
plete the welding process.
Summary
The correct combination of Heat, Speed, and roller Pressure will allow you to achieve a properly-
welded seam.
CHAPTER 1: MACHINE OVERVIEW
5
1.3.3 Shop Air Supply
The Miller Weldmaster PS150 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 3/8 inch NPT (National Pipe Thread) to
match your female quick-connect. The Miller Weldmaster PS150
requires the following shop air requirements:
Minimum of 20 cfm at 100 psi
Not to exceed 565 liters/min at 6.9 Bar
An in-line water and dirt separator
(fig.10)
1.5: Controls: Purposes and Functions
1.5.1: Operator Control Screen
Top center text box: The text field will list current alarms.
The up/down buttons next to the text box will allow the user to
scroll up/down the list of current alarms.
MSG0 text box: The text box field will indicate the current
state on the machine. System Idle, System Running, Pause,
Forward Job, Conv Door Open, Alarm Active, Reset EPO, Op-
erator Control Side E-Stop, and Non Operator Control Side
E-Stop
Red indicator light: The red indicator light will display the
same color as the stack light in the solid color mode.
0 Bag/Min: The “0” indicates the current average bags per
minute passing through the machine.
0 Feet/Min: “0” indicates the current average bags per min-
ute passing through the machine.
Weld Nozzle OFF: Pressing the button will toggle the heat
system on/off. Press once to toggle to the opposite condition.
Actual (F): The number displayed is at what temperature the
thermo-couple is currently reading at the base of the element
housing.
Setpoint (F): The number displayed is at what temperature the
temperature controller is being told to hold temperature at. By
touching the text box on the screen a key pad will appear allow-
ing the user to change the setpoint.
Pre-Heat Nozzle OFF: Tressing the button will toggle the
heat system on/off. Press once to toggle to the opposite condi-
tion.
Actual (F): The number displayed is what temperature the
thermo-couple is currently reading at the base of the element
housing.
Setpoint (F): The number displayed is at what temperature the
temperature controller is being told to hold temperature at. By
touching the text box on the screen a key pad will appear allow-
ing the user to change the setpoint.
(fig.11) Operator Control Screen
Principles of Operation
The PS150 is a heat sealing machine which welds thermal plastic fabrics or films by Hot Air,
through applying pressure, consistent speed, and accurate temperature for perfectly sealing thermal
plastic materials.
CHAPTER 1: MACHINE OVERVIEW 6
1.5.1: Operator Control Screen (continued)
Weld Roller: Pressing the button will open/close the weld rollers.
Press once to toggle to the opposite condition.
Transport Belt: Pressing the button will open/close the transport
belts. Press once to toggle to the opposite condition.
Jog FWD: Pressing the button will jog the drive system in the for-
ward direction at a slow rate of speed. This function is intended to
test motion of the motors and drive system only. It is not intended
to operation in a synchronized function. Jog FWD will only appear
when the machine is in a paused state.
Menu: Pressing the menu button will take the user to the Main
Menu screen.
1.5.2: Main Menu Screen, Operator Level:
Operator Config: Pressing the Operator Configuration button will
take the user to the Operator Configuration, Operator Level.
Alarms History: Pressing the Alarm History button will take the
user to the Alarm History Screen.
Machine View: Pressing the Machine View button will take the
user to the Machine View Operator Side Screen.
Login: Pressing the Login button will take the user to the Login
Screen.
Logout: Pressing the Logout button will Logout and return user to
the base viewable screens.
Operation: Pressing the Operation button will take the user to the
Operator Control Screen.
CHAPTER 1: MACHINE OVERVIEW
7
(fig.12) Main Menu Screen, Operator
control
Table of contents
