Miller Weldmaster Triad Extreme User manual
Instruction Manual
Page 1
This instruction manual is intended to be a guide when operating the Triad 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 1-855-888-WELD or email
service@weldmaster.com.
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
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Instruction Manual
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Chapter 1: Introduction
Chapter 2: Material Set-up
Chapter 3: Operating Instructions
Chapter 4: Material Guides
Chapter 5: Welding
Chapter 6: General Maintenance
Chapter 7: Wedge Cleaning and Honing
Chapter 8: Wedge Adjustment
Chapter 9: Wedge Replacement
Chapter 10: Wedge Installation
Chapter 11: Troubleshooting
Chapter 12: Schematics
Chapter 13: Commonly Used Parts
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Page 9-10
Pages 11
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Page 13-16
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Pages 18-19
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Page 21-48
Page 49
Table of Contents
TABLE OF CONTENTS
Instruction Manual
Page 4
1.0 Introduction
The Triad Extreme Seam hot wedge welding machine is designed for in house fabrication of a wide
range of flexible membranes. This includes, but is not limited to, PVC, PP, PE, LDPE, Urethane, etc.
Thickness of material that can be welded will vary also with product. Normal range is 5-100 mil thick-
ness and can be supported or non-supported material.
The Triad comes complete with three different guides. This will allow you to perform the overlap weld,
hem weld, prayer weld and many more welding options.
The Triad uses a hot wedge as its heat source. This method will give you smokeless and quiet opera-
tion. The wedge also allows for welding thinner products without distortion.
The Triad can be used as a stationary welder or in an automatic mode. When using the Triad in an
automatic mode, a track system is suggested. Please refer to Track System Specifications.
We suggest that you make samples welds of your product to achieve the correct settings for heat,
speed and wedge alignment before you start welding
CHAPTER 1 INTRODUCTION
Instruction Manual
Page 5 CHAPTER 1 INTRODUCTION
1.1 Intended Use
The Triad Extreme Seam Welder is a hot wedge welding machine intended to heat-seal weld-
able 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
Weldable Webbing
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 6CHAPTER 2 MATERIAL SET-UP
2.0 Material Setup
Material should be laid out as flat as possible, either on the floor or table depending on how you set
up your fabrication area. With most material and especially thinner goods, it is prefered to pull out
the wrinkles or pull taunt. The use of sheet metal in or next to the machine on the table, allows for
the use of magnets to position and hold the material. Taping material taunt is a good practice.
To perform overlap welds, always overlap material more than the final weld width. Example: With a
1-1/2” weld width, overlap the end of material or run 2 to 2 1/2”. The machine and front guides will
push the material to the desired overlap. If the material is not overlapped or positioned properly, the
machine will not make the desired overlap weld. See sample below.
Instruction Manual
Page 7 CHAPTER 3 OPERATING INSTRUCTIONS
3.0 Operating Instructions
The following procedures should be followed only after you have followed the Wedge Adjustment and
Guide adjustment procedures.
1. Pull up on Red Power Switch #3 to turn machine on. The Green Power Light #4 will go on with a
one second delay. The Green light will remain on as an indicator that you have power to the ma-
chine. (Push down on Red Power Switch #3 to turn machine off)
2. Temperature Controller #7 will come on with a 1-2 second delay after Green Power Light goes on.
Units are set in celsius at the factory. Press the Set Button and hold, now press the up or down
button until you reach your desired temperature. Heat up time is only one to two minutes. Do not
adjust heat over 510 degrees C. For sample welds, set controller to 400 degrees C. This may not
be your final setting.
3. Set For/Rev Switch #5 to Forward position. This indicates direction of machine and drive/pressure
roller movement.
4. Set Man/Auto Switch #2 to Auto position. This will engage or start Drive/Pressure rollers when
wedge is moved into welding position.
5. Swing Drive Wheel Assembly #10 under bottom Pressure Roller. This will make the machine move
or automatic. With Drive Wheel Assembly out, the machine can be used in a stationary mode.
6. #1 is the Speed Control. It is adjustable from 0-30 feet per minute. Normal setting will be in the
30 to 60 range, for 12-30 mil goods.
7. #8 is the Pressure Knob. It can be adjusted for more or less pressure, depending on the thickness
of material.
8. Insert material into the machine with proper guides installed and close Pressure Wheel Handle #9.
9. Swing Wedge Engagement Handle #11 in toward the machine, this will automatically start forward
motion of the Triad and engage wedge with material.
10. Adjust speed control up or down until you can verify you are getting a proper weld.
Instruction Manual
Page 8CHAPTER 4 MATERIAL GUIDES
4.0 Material Guides
All Guides shown below are included with the purchase of the standard machine. Each guide will give
you a specific type of weld and more. You can only use one guide system at a time.
The Top Guide will be used with all three different welding functions, overlap, hem and prayer
welds. All Guides are adjustable.
To achieve a precise weld with no loose flap on top or bottom of sheet, guides should be adjusted so
that they are even with the width of wedge, or welding area
Overlap Guide
Top Guide
Hem Guide
Prayer or Fin Guide
Instruction Manual
Page 9 CHAPTER 5 WELDING
5.0 Welding
5.1 Overlap Weld
Attach Overlap Guide #1 to base plate with the two screws provided. Loosen screw (A) to adjust bottom side
of overlap for proper alignment and re-screw.
5.2 Hem Weld
Slide Hem Guide #2 onto the three stainless rods up to the outer Horn Guide #3 (Diagram #1), leaving
enough area between the two so material will slide easily. Tighten thumbscrew (B) (Diagram #1), this will
allow the outer Horn guide and Hem guide to move as one. This dictates the size of the hem to be welded.
Push on Hem Slide #4 (Diagram #2) to achieve desired hem width or size. When this is done, tighten thumb-
screws (C) (Diagram #1) to lock in place.
Instruction Manual
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5.3 Prayer or Fin Weld
Position the Prayer Guide #5 under the Welding Horn, placing the key way into the slot. Fasten with screw
provided once proper alignment is completed.
5.4 Front Guides
Front Guides #6 are adjustable to pre-align material before you reach the welding process. This will help
the operator in feeding material into machine properly.
CHAPTER 5 WELDING
Table of contents
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