Drader W30000 Guide

MODEL W30000
Instruction Manual & User Guide

Page | 2
Table of Contents
Congratulations on your purchase of Drader Manufacturing’s plastic welding equipment .....................................................3
1. Read These Instructions to Protect Yourself and Others........................................................................................4
2. General Information...................................................................................................................................................4
3. Safety..........................................................................................................................................................................5
4. New Welder Details ...................................................................................................................................................6
5. Parts and Service.......................................................................................................................................................6
6. Operating Instructions...............................................................................................................................................7
Unpack the welder and inspect the contents .............................................................................................................................7
The heated barrel and tip system ...............................................................................................................................................8
Welding Tip Selection..................................................................................................................................................................8
Changing tips –The welder should be hot, but turned off ........................................................................................................9
Connect the air supply...............................................................................................................................................................10
Plug the welder into an appropriate electrical outlet .............................................................................................................11
Set the temperature, then turn the welder on...........................................................................................................................11
Temperature settings –Drader Injectiweld..............................................................................................................................12
Feed the welding rod into the welder........................................................................................................................................13
Make Welds ...............................................................................................................................................................................14
7. Proper Welding Techniques –General Considerations ....................................................................................... 15
8. Proper Welding Techniques –Drader Injectiweld ................................................................................................ 16
9. Proper Welding Techniques –Drader Injectiweld –Fillet welds ......................................................................... 17
10. Proper Welding Techniques –Drader Injectiweld –Butt Welds........................................................................ 18
11. Daily Maintenance –Drader Injectiweld ............................................................................................................. 19
12. RoHS and WEE compliance on Drader Injectiweld Products............................................................................. 20

Page | 3
Congratulations on your purchase of
Drader Manufacturing’s plastic welding equipment.
To get the most out of your purchase, be sure to read this manual carefully and keep it on hand
for future reference. The Injectiweld plastic welding system uses a combination of heated tip
and injection pressure to form its welds. The hot (interchangeable) tip melts the surface of
the plastic and creates a weld zone into which molten plastic is injected. There is a physical
mixing of the weld bead and the plastic.
While every effort has been made to ensure the information in this manual is accurate and
complete, in no event shall our company be liable for any direct, indirect, punitive, incidental,
special consequential damages, to property or life, whatsoever arising out of or connected
with the misuse of our products. Drader Manufacturing reserves the right to change the
specifications of the products described herein at any time without written notice.
To ensure safe work practices and correct operation of the
W30000 Injectiweld, the manufacturer strongly recommends
before welding, all operators read this manual.

Page | 4
1. Read These Instructions to Protect Yourself and Others
Be aware, serious injury or death may result if welding equipment is not properly installed, used, and
maintained. Misuse of this equipment and other practices can be both hazardous and dangerous to the
operator and any persons in the general work area. The operator and supervisor must read, and understand the
following safety warnings and instructions before using this welding equipment.
The Drader Injectiweld is to be operated by qualified people in accordance with this manual. Only authorized
service personnel should perform any maintenance that requires opening the welder housing.
Opening the welder housing voids the Drader Warranty.
2. General Information
Information, presented in this manual should be read, understood and followed for the safe and effective use
of this equipment. Safety instructions specially pertaining to this unit appear throughout this manual,
highlighted by a symbol that identifies levels of hazard. There are also welding tips and hints throughout this
manual that will make your welds better and your welder usage more effective.
Symbols used throughout this manual:
HIGH VOLTAGE - The lightning flash symbol will alert the user to the presence of
“dangerous voltage” that may be of sufficient magnitude to constitute a risk of electric
shock.
HOT SURFACE -The heat symbol will alert the user to the fact that they might get a
serious burn if they touch the part.
WARNING / CAUTION -The exclamation point symbol will alert the user to important
operating and maintenance instructions.
TIP - The Injectiweld symbol identifies tips and hints to obtain the most efficient
operation of this tool.

Page | 5
3. Safety
The operation, maintenance and troubleshooting of the Injectiweld requires practices and procedures which
ensure personal safety and the safety of others.
Read and follow the safety instructions in this manual.
The Injectiweld is equipped with a ground-contact plug. The Injectiweld must be
plugged into an outlet that is properly installed and grounded. If you do not know if
your power outlet is grounded, check with a qualified electrician. Do not modify the
plug. If it will not fit the outlet, have the proper outlet installed by a qualified
electrician.
Never touch the welding tip at any time, unless you are sure that it is cool. Severe
burns may result. Wear heat resistant gloves when handling hot welder parts.
Always unplug the unit before examining it or when leaving the welder
unattended. Air line may remain connected to cool the welder.
Never allow the welder’s hot tip to touch the power cord as it could melt the
wire’s insulation and cause a dangerous condition. Purchase a replacement
cord if your hot tip touches the power cord.
Protect your eyes from hot plastic. While operating the welder, wear safety glasses.
Consider your work environment. Do not immerse the welder in water, expose it to
rain, or use it in excessively damp or wet environments.
Use the welder in well ventilated areas. Some plastics may give off noxious
gasses as they melt. Know the plastic that you are working with and use
breathing protection if warranted.
Keep the work area well lit and clean for maximum safety.
Use only certified Drader replacement parts.

Page | 6
4. New Welder Details
Please fill out the information below for future reference. Once completed, photocopy this page and fax it
or email it to Drader Manufacturing. This will register your welder.
Company Name: _______________________________________________________________________________________
Serial Number: __________________________________________ Date of Purchase: __________________________
Name of Distributor (if applicable): _____________________________________________________________________
Technical Data:
5. Parts and Service
Call Drader Manufacturing (or your distributor) if you need to purchase parts, or to have your welder serviced.
Have the welder serial number on hand.
Model:
W30000
Power:
120 Volt / 60 Hz
240 Volt / 50 Hz
Watts:
400 Watt
Weight:
4.4 lb
2.6 Kg
Temperature Range:
392 ºF - 572 ºF
200 ºC - 300 ºC
Air Consumption:
4 cfm @ 90psi
0.113 m3 @ 6.2 bar
Air Requirements:
Min. 80 psi, Max. 100 psi
Min. 5.5 bar, Max. 6.9 bar
Rod Diameter [ø]:
5/32 inch (.156)
4 mm
Fuse Rating:
1 x 4A Fuse (120 Volt)
1 x 2A Fuse (240 Volt - UK model)
2 x 2A Fuse (240 Volt - all others)
Max Output (HDPE):
2 lb per hour
0.9 kg per hour
Warranty:
One year - parts and labour
Head Office
Drader Manufacturing Industries Ltd.
5750 –50 Street
Edmonton, AB T6B 2Z8, Canada
Tel: [phone]
Toll Free (North America): 800 661 4122
Fax: [phone]
[e-mail]
www.drader.com
Service Centre
(For US Clients only)
Drader Service Centre
6825 S. Kyrene Rd
Tempe, AZ 85283
USA
Your Distributor

Page | 7
6. Operating Instructions
This section will provide you with an overview of using the Injectiweld. Follow these steps to learn how to
operate your welder.
•Unpack the welder and inspect the contents
•Select welding tip
•Connect the air supply
•Plug the welder into an appropriate electrical outlet
Unpack the welder and inspect the contents.
•Set the temperature, then turn the
welder on
•Feed the welding rod into the welder
•Make welds
#
Description
Item ID #
1
W30000 Injectiweld
Unique serial number
2
Barrel Washer
IPAR-A-BARWSH
3
3/16" Fillet Weld Tip
ITIP-2F6
4
Repair Tip
ITIP-2RP
5
Tip Nut Wrench
IPAR-A- TIPWRN
6
Tip Nut
IPAR-A-TIPNLO
7
Scraping Blade
IPAR-A-SCRBLD
#
Description
Item ID #
8
Stick Scraper
IPAR-A-SCRSTK
9
Air Filter Assembly
IASS-A-AIRFILT 2
10
Screw Driver
IPAR-A-SCREWD
11
4AMP Fuse
2AMP Fuse
IPAR-A-FSEALL
IPAR-A-FSE2A
12
Heat Transfer Compound
IPAR-A-HTTRCO
Quick Manual (not shown)
Carrying Case (not shown)
IPAR-A-CASE

Page | 8
The heated barrel and tip system:
#
Item ID
Description
1
IPAR-A-BARW30
W30000 Barrel
2
Shop Supply
Indexing Pin
3
IPAR_A_RTDSE4
RTD Sensor
4
Various ID Numbers
Heater
Welding Tip Selection
The correct tip will make a difference on the
quality and appearance of the weld. There are
different tips for various applications. The two
welder kit tips are the repair tip (photo #3) and
the 3/16” fillet weld tip (photo #5).
#
Description
Item ID
Main Usage
1
Blank Tip
ITIP-2BL-5.5
Custom tips; design your own for your special application
2
Prototyping Tip
ITIP-2PR
Prototyping, repairs, filling holes, spot welding tight areas
3
Repair Tip
ITIP-2RP
Repairs, filling holes, spot welding tight areas, prototyping
4
Bull Nose Tip
ITIP-2BN
Repairs, filling holes, filling voids
5
3/16” Fillet Weld Tip-Legacy
ITIP-F316LEGACY
90º fillet welds, butt welds, repairs
6
1/4” Fillet Tip
ITIP-2F4
7
3/8” Fillet Tip
ITIP-2F8
8
1/2“ Fillet Tip
ITIP-2F5
9
5/8” Ribbon Weld Tip
ITIP-2RW
Sealing; re-enforcement; non-pressure welds
10
3/16" Fillet Weld Tip-New Style
ITIP-F316
90º fillet welds, butt welds, repairs
Please note, there are other barrel parts that are not listed here.

Page | 9
The Injectiweld kit comes with 2 tips. Both tips are versatile and can provide the operator with numerous types
of welds. Tip choice is important as it determines the type of plastic weld. Use this manual to assist you in your
tip choice.
Changing tips –The welder should be hot, but turned off.
The tip and barrel will be hot. Wear protective gear to protect yourself from burns.
When removing the tip nut, do not use excessive force. Excessive force
will twist the barrel and ruin it, the heater, and the RTD sensor.
The tip must be hot before changing, but the welder should be off. The tip needs to be
hot in order to melt the plastic in the transition area between the tip and the barrel. If the
tip nut is hard to loosen, wait 3 to 5 minutes, then try again. Tip nuts have a different
expansion ratio than barrels.
Use heat transfer compound frequently. Heat transfer compound makes it easier for the
barrel heat to transmit to the tip as well as to remove the tip nut. Apply the compound at
every tip change or every 8 hours of operating time.
Use a copper, or brass brush to clean away burned heat transfer compound. Clean parts
make heat transfer more efficient.
Make sure you always use the Barrel Washer (IPAR-A-BARWSH). It goes between the
barrel and the tip.
•Place the welder on a flat, stable surface, with the on/off button facing up.
•Loosen the tip nut (IPAR-A-TIPNLO) with the tip nut wrench (IPAR-A-TIPWRN).
•Turn the tip nut wrench counter clockwise, until the tip nut is free.
•Using pliers, take the tip nut off and place it on a heat resistant surface.
•Using pliers, pull the tip from the barrel and place it on a heat resistant surface.
•Separate the barrel washer (IPAR-A-BARWSH) from the tip.
•Use a copper, or brass brush to clean the old heat transfer compound from the barrel, barrel washer, and tip.
•Open the bottle of heat transfer compound (IPAR-A-HTTRCO) and apply the compound onto the welder barrel
threads, both sides of the barrel washer, and on the tip’s collar. Since the welder is hot, there might be smoke from
the heat transfer compound. Be careful not to inhale fumes.
•Place the barrel washer onto the barrel. The small hole on the barrel washer goes over the barrel’s indexing pin.
There must always be a barrel washer between the barrel and the tip. The barrel washer blocks molten plastic
from backing up into the barrel.
•The tip goes next onto the barrel. The locating pin fits into one of the tip’s holes.
•Slide the tip nut over the tip, and screw it onto the barrel using the tip nut wrench.

Page | 10
Connect the air supply.
Never use air compressors with automatic oiling systems. Too much oil in the compressed air will
cause damage to the printed circuit board and to the air valve.
Keep the compressed air as dry and oil free as possible. Always use the Drader supplied air
filtration units and keep them well maintained.
The Drader Injectiweld, Model W30000 requires compressed air. The welder operates at 90 psi (6.2 bar) and
consumes 4 cfm (113 lt) at maximum output. The air compressor requirements are:
•Air pressure: Minimum: 80 psi (5.5 bar), Maximum: 100 psi (6.9 bar)
•Horsepower: At least 1.5 horsepower per welder (1120 Watt)
The W30000 kit ships with an air filter assembly. The filter helps to remove particulate, water and oils from the
compressed air. Use it at all times.
•The Air filter assembly attaches directly to the welder’s air line.
Air Filter Assembly (IASS-A-AIRFILT 2)
#
Description
Code
1
Quick Disconnect Fitting
IPAR-A-FITQUICKF2
2
Air Filter Unit
IPAR-A-AIRFILT2
3
Air Line Fitting
IPAR-A-ARFITN2

Page | 11
Plug the welder into an appropriate
electrical outlet
•Plug the welder in the appropriate electrical
outlet (120V or 240V).
Set the temperature, then turn the welder on.
•Set the temperature on the welder using the Drader screwdriver. Gently turn the dial to the required
temperature mark. The next page has some suggested temperature settings.
•Turn the On/Off switch on.
•When first turned on, the LED will start off solid RED, then, as the welder heats towards the set
temperature, it will start flashing RED and GREEN. At the set temperature, the LED will turn solid
GREEN.
•During operation, the LED will alternately switch between GREEN and/or RED when it is maintaining the
set temperature.
•Above set temperature or out of range (LED OFF) LED will go to GREEN as temp falls.
The high temperature cutoff switch [HTCO] may shut the unit off if the temperature
inside the welder housing exceeds the temperature limit. Once the welder cools off,
the unit will operate normally. This feature should not be used on purpose.
Proper temperature is crucial for high quality welds. Set the proper temperature.
If you change welding materials and decrease the temperature, by the time you purge the
original welding rod from inside the barrel, the welder should be cool enough to resume
welding at the right temperature. If in doubt about the temperature, wait a few minutes.
If the Injectiweld is not being used for a period of ½ hour or more, either turn the welder
off or turn it down to the lowest temperature level.
The temperature control is a dial that does not rotate more than 3/4 of a turn. Overturning the
dial will damage the temperature dial. Only authorized people should touch the temperature
setting dial. Do not exceed the MIN/MAX limits.

Page | 12
Temperature settings –Drader Injectiweld
Please contact your Drader representative before using a material that is not listed below.
Material
Description
Temperature in ºC
Temperature in ºF
HDPE
High Density Polyethylene
265 ºC
509 ºF
LLDPE
Linear Low Density Polyethylene
265 ºC
509 ºF
HMWPE
High Molecular Weight Polyethylene
280 ºC
536 ºF
PP
Polypropylene
280 ºC
536 ºF
ABS
Acrylonitrile Butadiene Styrene
265 ºC
509 ºF
HIPS
High Impact Polystyrene
255 ºC
491 ºF
PA 6*
Polyamide
300 ºC
572 ºF
PC*
Polycarbonate
300 ºC
572 ºF
TPU
Thermoplastic Polyurethane
300 ºC
572 ºF
* Requires butane pre-heater. Please contact Drader for more details.
WARNING / CAUTION - Do not use PVC [Polyvinylchloride] with the Injectiweld. The
temperature and pressure used by the Injectiweld will degrade PVC and chlorine gas
will be released. This aggressive gas is harmful and it can damage the aluminum parts
of the welder.

Page | 13
Feed the welding rod into the welder
The Injectiweld Model W30000 accepts 0.156-inch (4mm) diameter welding rod. The feed is automatic once
the welding rod is properly fed into the welder.
•Turn the rod release knob until the knob feels tight. This opens the rod drive wheels and allows them to accept
welding rod.
•When the welder is powered up and the desired temperature is reached, feed the welding rod into the rod feed tube
and push it up into the welder until it comes to a stop.
•Turn the rod release knob until the knob feels loose. This locks the rod into the feed mechanism.
•Depress the trigger and the welding rod should feed automatically into the welder.
•To remove the welding rod, turn the rod release knob until it is tight, then gently tug on the welding rod out of the
welder.
Do not operate the welder without plastic welding rod. Running the welder without welding rod
may result in feed mechanism damage.
When finishing off a roll of welding wire, remove the last remaining welding rod from the welder and
start a fresh roll. This will reduce the chances of a rod jam.
When switching from one welding rod to another, clear the previous rod material by removing it
from the feed tube, then feed the new welding rod. Let the welder pump out about one meter (one
yard) of molten welding rod to ensure old material has been purged.
If the welding rod does not feed, make sure the rod release knob is loose, depress the trigger then
apply gentle pressure on the welding rod, pushing it into the welder. The feed mechanism will grab
the welding rod and start the automatic feed.
The rod release knob rotates 360+ degrees. When the knob feels loose, the welding rod is locked
into the feed mechanism. When the knob feels tight, the welding rod is not locked into the feed
mechanism.
Different types of welding rod (i.e. polyethylene, polypropylene, polycarbonate, ABS etc, have
different durometers. Because of this, slightly undersized welding rod is better than oversized
welding rod. With very hard welding rod (i.e. polycarbonate, try 1/8 inch (3.2mm).

Page | 14
Make Welds
The Ribbon weld tip is used to make a seam weld on thermoplastic materials
such as belting and thin sheets. Because this welding tip does not weld down to
the root side, it should not be used for regular butt welds.
Fillet Welds
Repair tips are used for crack
repairs, filling small holes, spot
welding, for reaching tight areas,
and for prototyping. Because of
their conical shape, the repair tip
and prototyping tip offer similar
types of welds. Choose the size
that best suits your application.
Repair Tip, Prototyping Tip
Fillet tips are used mainly for fillet
welds [90º] and butt welds. The
style of those tips allows one to
weld from inside corners out and
be able to seal the corners without
changing to another tip style. Fillet
tips can also be used for crack
repairs, as long as the crack is
somewhat straight. The longer
preheat section allows faster
welding speed than welding
cracks with the conical tip.
Ribbon Weld Tip

Page | 15
7. Proper Welding Techniques –General Considerations
Consider these variables when welding plastics.
Material
In order to achieve quality welds, ensure that the welding rod matches the parent
material. For example, match polyethylene with polyethylene rod and match
polypropylene with polypropylene rod.
Do not expect a quality weld if the parent material and welding rod do not match.
Heat
Each plastic melts within a certain temperature range. When you drift outside this
zone, the weld quality diminishes.
Some people turn up the heat in order to weld faster, yet they sacrifice weld strength.
Do not be tempted to weld faster by raising the weld temperature!
Pressure
Pressure allows the plastic molecules of the materials to mix. Best bonding occurs
when there is a physical mixing of the plastics.
Pressure, when too high or too low, reduces weld quality.
Time
Plastic needs time to melt and time to cool down. Do not speed up the cooling time.
After welding, plastic molecules need 24 hours to come to a complete rest.
Plastic should be at “room temperature” for at
least 24 hours before it is welded.
+
=
+
=

Page | 16
8. Proper Welding Techniques –Drader Injectiweld
Welding from one side
•Butt welding two sheets together
•Plastic crack repair
Bevel each side of the plastic so that their combined
angle is 90 degrees.
You may use the stick scraper to give you the proper
angle.
Leave a gap between the parent materials so that
molten welding rod can penetrate the root.
Excess welding rod may be trimmed off (after it
cools). You may use the scraping blade to perform
this function.
Welding from two sides
• Fillet welding two sheets together
The amount of welding rod injected onto the parent
material should be about 70% of the thickness of the
plastic sheet.
Increase or decrease welding rod thickness by:
•Changing tips
•Adjusting speed control bolt
•Adjusting the speed of how fast your welder
travels

Page | 17
9. Proper Welding Techniques –Drader Injectiweld –Fillet welds
Welding tip is in
correct alignment
when it is at a 45°
angle
Fillet Welds –Correct Alignment
Fillet Welds –Incorrect Alignment
Welding tip is in correct
alignment when it is at a
45°angle
Welding tip is in correct
alignment when it is flat
against both sides of the
parent plastic material
Welding tip is in correct
alignment when it is flat
against both sides of the
parent plastic material
When welding from one
side, leave a root gap of
0.8 to 1.5mm so that
welding rod can penetrate
to the other side
Welding rod should
penetrate to the root side
of the parent plastic
Welding tip is not incorrect
alignment when the fillet weld
tip is not at a 45o angle or
when it does not come into
contact with both sides of the
parent plastic material
Welding tip is not in correct
alignment when it does not
come into contact with both
sides of the parent plastic
material
Welding tip is not in
correct alignment when
the bottom edge is not flat
against the parent plastic
material
Welding tip is not in
correct alignment when
the bottom edge is not
flat against the parent
plastic material
Lack of penetration to
the root will result in a
poor weld
Since molten welding
rod did not penetrate
the root, a poor weld
will result

Page | 18
10. Proper Welding Techniques –Drader Injectiweld –Butt Welds
Butt Welds –Correct Alignment
Butt Welds –Incorrect Alignment
Welding tip is in
correct alignment
when it is at a 90°
angle
Welding tip is not in
correct alignment when
it is not at a 90°angle
Welding tip is in
correct alignment
when it can reach the
root of the other side
of the parent plastic
Welding tip is incorrect
alignment when its edges
contact each side of the
parent plastic material
Welding tip is in correct
alignment when molten
welding rod penetrates the
root of the parent plastic
material
If welding from one side,
welding rod must fill the
root of the parent plastic
material
If you can weld from both
sides, make two 90°bevels
before welding
Welding tip is not in
correct position when its
melting surface does not
contact the plastic
Welding tip is not in
correct position when its
melting surface does not
contact the plastic
Welding tip is not in
correct alignment if molten
welding rod cannot
penetrate the root
A poor weld because
molten welding rod did not
penetrate the root.
Lack of penetration will
result in a poor butt weld

Page | 19
11. Daily Maintenance –Drader Injectiweld
A well-maintained welder will give you years of service. Follow the steps in this section to
take care of your welder.
Compressed air should be as dry and clean as possible. Use the air filtration system
supplied with the welder. Use of an air compressor with a dryer / dehumidifier in is
recommended.
Use heat transfer compound frequently. Heat transfer compound makes it easier for the
barrel heat to transmit to the tip, as well as to remove the tip nut. Apply the compound at
every tip change or every 8 hours of operating time.
Use a copper (or brass) brush to clean away burned heat transfer compound. Clean parts
make heat transfer more efficient.
At the beginning of each shift (or every 8 hours of welder operation):
•Turn welder on and bring up to heat.
•Turn welder off, unplug it from the electrical socket then wait 2 - 3 minutes. (This allows the aluminum
barrel to shrink smaller than the steel tip nut).
•Remove tip nut, tip and barrel washer. Be careful –they will be very hot!
•Using copper or brass brush, clean the old heat transfer paste from the tip nut, tip, barrel, and barrel
washer.
•Apply a new layer of heat transfer compound to the tip, barrel, and barrel washer.
•Reassemble the welder by placing the barrel washer onto the barrel first. Then place the tip onto
the barrel, followed by the tip nut. Use the tip nut wrench and hand tighten the tip nut. Do not
tighten the nut too much.
•Plug the welder in, and then turn it on. Bring it up to the set temperature, and then commence
welding.
•Make sure the tip nut is snug periodically throughout the day.

Page | 20
12. RoHS and WEE compliance on Drader Injectiweld Products
Drader Manufacturing products that comply with the European
Community directive 2002/95/EC with respect to the restriction of
hazardous substances in electrical and electronic equipment. EU
products will be marked with this RoHS symbol.
Drader Manufacturing is compliant with the European Community
directive 2002/96/EC (Waste Electrical & Electronic Equipment, WEEE)
with respect to products sold within the European Union. This directive
restricts the disposal of electronic equipment and states that it must be
marked to indicate it is not to be disposed of in unsorted waste starting
August 13, 2005. This marking has been added to Drader products sold
in the EU.