Drader W30000 Guide

MODEL W30000
Instruction Manual & User Guide

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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

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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.

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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.

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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.

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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

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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

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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.

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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.

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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