How-Tos

Wood Welder

Basic Set-up of Workrite Wood Welders

Receiving Your Workrite Electronic Welder

After removal from the box/s, check components for any shipping damage (contact factory immediately if damage noted).

MODEL 5000 Generator Chassis, Hand Unit, and 2 Power tubes.

Remove chassis cover, install power tubes, connect braided cables per the enclosed diagram sheet.
Remove 4 black lifting lugs from inside of chassis cover (discard) and replace cover.
Install Handgun Coax/Electrical cables to the corresponding sockets on the front panel.
Plug 110V pciower cord into electrical, making sure that no extension cords are used, as they will reduce incoming voltage to machine.
Watch the instructional video and read the instruction sheets before proceeding to operation.

MODEL 3000/4000 Generator Chassis, Hand Unit, and 2-Power tubes (3000), 4-Power tubes (4000).

Remove back panel, unpack and install power tubes, connect braided cables per the diagram on inside of back panel.
Install Handgun Coax/Electrical cables to the corresponding sockets on front panel.
Plug 110V power cord into electrical, making sure that no extension cords are used, as they will reduce incoming voltage to machine.
Watch the instructional video and read the instruction manual before proceeding to operation.

Do’s and Don’ts for the wood welder

DO NOT:

Do not touch the hand unit electrode feet to metal. Will cause arcing.
Do not allow electrode feet to touch a metal workbench. Will ground energy and cause arcing.
DO NOT TOUCH HANDGUN UNIT WITHIN 2” OF ELECTRODE FEET WITH YOUR FINGERS WHILE OPERATING UNIT. Arcing can burn your fingers.
Do not make any coil adjustments inside the generator unit.
Do not drop hand unit or generator unit. This will cause a tuning problem.
Do not allow arcing in hand unit or on glue line. Arcing will overheat tubes.
Do not continue to operate unit with low or too high (pegging) milli-amp reading.

DO:

The WorkRite Electronic hand unit has been designed to be rugged, lightweight, and versatile. Its primary function is to apply the electronic energy to the glue joint. The inside of the hand unit consists of a large coil of 14-turns with a larger single-link coil around it. This inside 14-turn coil is called the “Tuning Coil”. The single outside coil is the “Pickup Coil“. THE “TUNING COIL” AND THE “PICKUP COIL” SHOULD NOT TOUCH EACH OTHER OR ARCING WILL OCCUR.

Using the Hand Unit

There are six metal plates inside the hand unit. Two of these plates are stationary and four are movable. Moving the thumb-tuning lever up or down achieves low-to-high heat ranges shown on the milli-amp meter.This is similar to tuning in a radio station on your radio.

Moving the thumb-tuning lever on the hand unit allows the operator to change from one size project to another quickly and at the same time, be assured of maximum heat. Whenever you change from one type of material to another, the material width varies, or the amount of glue used changes, the tuning lever must be moved to compensate for the change in load. Moving the thumb lever is necessary for each weld. This will continue to give you the highest heat possible.

To attain high heat on wider projects, position feet with a wider space between them (farther apart from each other). The small electrode feet will attain high heat on wider projects because they are farther apart from each other. In some cases, using one small and one flat electrode will give the best results.

Note: Placing a narrow piece of wood under the electrode feet will generally help to tune in higher heat. The energy will penetrate through 2 1/2 inches. Do not allow arcing at glue line.

The electrode feet DO NOT have to touch or come in contact with your project or the glue line to operate.
The heat zone is between the electrode feet.
Maximum tuning can be obtained by spacing the electrode feet farther apart.
Experiment with the electrode feet in different gap positions using the position that offers the most electronic heat into the joint to be set. Usually the widest position should be used on wide heavy boards, and the narrow position on small narrow boards.
Electrode feet should always be placed perpendicular (across) the glue line.
Always try to keep the panel meter at a medium to high reading.
Maximum heat is indicated in two ways: the panel meter and the glow lamp on the hand unit (most convenient).
When either the panel meter or the glow lamp is at its maximum reading, you are now receiving the greatest amount of electronic heat.
Set time averages 5 seconds, but no longer than 10 seconds.
Moving the tuning lever forward or backward varies the electronic heat. It is similar to tuning in a radio station.

Note: We recommend, before using your hand unit on a regular job, to try the above application steps with two scraps of wood, ¾” x 1” x 6”

Recommended Glues

The glues listed above are but a few of the many types that may be used with success. It may be stated that any Urea or Resorcinol Resin should give satisfactory results, as will cross-link polyvinyl adhesives. The welder heats the water in these glues to cause it to set.

Some glues of the type mentioned above require a high pressure while others require only minimal pressure. If a glue problem arises it is best to contact your local adhesive representative and they will answer your questions.

Remember that overheating any glue will make it become less strong. Never weld longer than 10 seconds maximum time. Polyvinyl resins and ready-mixed white glue can be used under certain conditions. Your project should remain clamped under strong pressure until the joint cools. It will cool in about 2 minutes.

Trouble-shooting the wood welder

Lack of power-low reading on the meter

Due to rough handling, the hand unit may go out of tune. This will minimize the welder’s energy output and cause arcing.

Tune hand unit to generator unit.

1. Holding the hand unit in the air (not on the wood), pull the trigger, and move thumb adjuster forward, then backward.

2. Watch the milli-amp meter on the front of the welder. It should correspond with the thumb lever. Meter needle must move 10 milli-amps (between two divisions) to be in tune. If the needle moves more than two divisions, pull the 14-turn coil apart slightly. If needle does NOT move at all, push the coil together slightly.

3. DO NOT UNSCREW COIL. The 14-turn coil is located inside the hand unit box. No components within the hand unit should touch each other, as this will cause arcing and rob the power.

4. Coaxial cable from welder to hand unit should be inspected. The shielded woven ground on the outer part of the cable may be worn through or broken loose.

5. Connector center should be un-soldered and cable cut back.

6. Re-solder center portion and re-clamp outer woven grounded portion to the connector.

7. Hand unit must be tuned each time the coaxial cable is shortened.

COAXIAL CABLE MUST BE 13' IN LENGTH

Note: If after all these steps, the meter still gives low or no milli-amp reading, see WARNING BELOW: REMOVE POWER CORD FROM WALL BEFORE OPENING REAR OF CABINET OR REPLACING ANY PARTS. Remove the back of welder and depress interlock switch. Watch lower #866-A tubes. IN ALL MODELS PRIOR TO 1984, tubes should glow “blue” when the trigger is pulled. If the glow is not “blue” replace tube with a solid-state 866-S and rewire diagram. Late model 1984 and newer models have SOLID STATE 866-S and may not need replacement. These tubes do not glow blue. They appear as black posts.

● WARNING - CAUTION

BEWARE OF DANGEROUS ELECTRICAL SHOCK DISCONNECT POWER CORD FROM WALL BEFORE OPENING REAR OF CABINET, BEFORE REPLACING ANY PARTS OR PUTTING HANDS INTO REAR OF CABINET.

Use a screwdriver with an insulated handle to ground any stored electrical charge. Touch screwdriver to inner condenser plate (connected to tube top) and at the same time touch outer condenser plate (screwed to chassis) to ground any stored electrical high voltage. Tube can then safely be replaced. EACH TIME MACHINE IS PLUGGED IN AND TESTED THIS SAFETY PROCEDURE MUST BE REPEATED.

● WELDER BLOWS FUSES

NOTE: If welder is operated with one faulty #810 tube, it will over work other tubes, which could also become inoperative. All trouble shooting is done in conjunction with the milli-amp meter. Watch meter from time to time to avoid extensive repairs. Your welder is a push/pull type circuit. Trigger should be released – the same amount of time as it is depressed. Complete your project. Set the hand unit down and position your next project. This will insure longer tube life. Spot-weld your assembly – 5 seconds will set the glue properly. Longer periods will overheat the glue and be less adhesive.

Coaxial Cable and Trigger Repairs

In most cases, a break in the coaxial cable will occur at one of the ends due to twisting of the cable.

1. Remove cable clamp from around the rubber strain relief by sliding it back

2. Push rubber strain relief back from the coax cable fitting.

3. Remove ring clamp from around the copper braid on the end of the coax fitting.

4. With hot soldering iron heat end tip of coax fitting and remove fitting from end of cable.

5. Cut off cable about two inches back and fix end exactly as it was before. Re-solder tip and reassemble. Newer cable ends do not use fixing collar, contact factory for help re-soldering and screwing connector onto cable end.

Note: If either insulation of male or female fitting is burned, they must be replaced. To replace S-4 trigger switch, remove the top of hand unit and remove pistol grip handle. Disassemble grip and replace switch. The S-4 trigger switch replacement requires you to drill a 1/2 hole in the pistol housing.

USES:

Edge-gluing

HOW TO DO EDGE GLUING

After removal from the box/s, check components for any shipping damage (contact factory immediately if damage noted).

Apply glue to one or both edges depending on the condition of the wood.
Apply ample side pressure using bar clamps or other means.
Always place the electrode feet across the glue line on all joints (where the glue line is exposed).
Press trigger switch and move tuning lever to maximum heat.
Allow glue to stop boiling. Three to five seconds will usually suffice on woods like soft pine. Five to seven seconds of the heavier, denser woods. Never more than 10 seconds.
Weld about every eight inches apart and near each end.
Release side pressure. Board is ready for use and may be worked right away.

Moldings/Self-Edge

How To Apply Moldings and Self-Edging

MOLDINGS

1. Apply glue to molding.

2. Place molding on edge to be glued and place electrode feet across the molding.

3. Apply ample pressure with hand unit.

4. Pull trigger switch and tune lever. Hold pressure until glue stops boiling.

5. Sand and finish.

NOTE: The electrode feet are usually in the small gap position when doing narrow moldings.

SELF-EDGING (Plastic and Wood)

1. Apply glue evenly to both surfaces.

2. In most cases, the glue application should be a little heavier as it soaks into the end grain.

3. Press the electrode feet, in the small gap position, across the edging strip and apply pressure. Start at one end and slide or walk the hand unit along the edge keeping an even, flat pressure.

4. If a self-edging strip is to be added after the plastic top is on, then a piece of masking tape must be put along the top edge to insure ease of removing any excess glue that may boil out and over the finished top.

5. Edge is ready to be finished.

6. Maximum cure will result in about 24 hours.

NOTE: We feel the best method of applying edging is to place a piece of quarter ply or Plexiglas on top, then use the roller electrode feet as described.

Paneling

How To Apply Paneling

1. If panels are to be applied directly to studding, it is necessary to apply glue to the full length of the studs.

2. Apply glue heavily as it will soak in rapidly. A double coat in some cases may insure a better bond.

3. Place panel against studding firmly so part of the glue on the studding will transfer to the back of the panel.

4. With the hand unit, apply maximum pressure.

5. Place electrode feet across the studs. The electrodes are usually placed in the wide gap position for paneling.

6. Start at the top of the panel and weld along the top edge first.

7. Start down, approximately every eight inches.

8. Allow the glue to set, 6 to 8 seconds (no more than 10 seconds).

9. Panels that are to be put on a solid wall require the entire surface glued. The same procedure is followed insofar as setting the glue. Be sure to set all the glue at the seams.

Picture Frames

How To Do Picture Frames

Picture frames may be welded in a picture frame clamp or in a home-made wooden jig. If the pressure applied to the picture frame joint is tight, the heat produced will set the glue in about 3 seconds.
Hold electrode feet across the glue line, usually in the medium or large gap position, and apply the electronic heat. Do not over-heat the joint - it will hold better if heated for a short time, 3 to 5 seconds.

NOTE: The above method of welding a picture frame is satisfactory, in so far as setting the joint. However, we feel that the additional wooden spline or dowel will add to the strength of the joint and will ensure better squaring of the frame during fabrication.

Faceframes

Faceframes And Similar Joints

1. Apply glue to end grain part of joint or into dowel hole.

2. Apply pressure with bar clamps.

3. Place electrode feet across the glue line and press trigger switch on hand unit.

4. Heat a few seconds. Overheating will over-dry the glue and it will be a weak joint.

5. Using dowels, spines or other type of lock joints is highly recommended.

6. When the facing is to be added to the front of a cabinet, you may find it more applicable to leave the lock type joint out. When the cabinet will support the face frame, the dowels are no longer adding strength. We suggest welding an end grain joint to a side grain, apply glue to the end grain, apply heavy pressure, and then set the joint.

Note: If the facing must stand any great stress, support any weight or will be subject to any extensive abuse, we recommend using a dowel. Always allow the glue to cool a few minutes before releasing pressure. Cool glue is stronger than hot glue.

Furniture Repairs

NOTES ON FINISHED PARTS: In all cases where it is desirable to retain the present finish, the repaired joint must be set as fast as possible. Do not overheat the glue, just enough to set it. To patch a veneer, apply glue under the veneer that has come loose. Wipe away the excess glue with a damp cloth. Place a small piece of quarter ply over the spot to be repaired and weld. Put a drop of water in a dent. Cover with quarter ply and apply electronic heat. Dent will rise from the resulting steam.

Parts

We are introducing the first new Tube-based RF machine in over 15 years, with many improvements.

New-Improved Vacuum Tube for longer life and lower heat signature.
Modern electrical architecture operating on single-phase115 VAC 18 Amps.
24” x 24” Chassis, allowing for easy access to all components for cleaning and maintenance on a single level, compared to 3000/4000 2-level layout.
Traditional Handgun design with new “U-shaped handle comfort grip, 13 foot length cord/coax cable.
New safety switch system cuts all power to unit when chassis cover is removed.
Penetrates approx 2” of wood for glue setting.
27.12 RF Frequency.
1-Year Factory Warranty on Machine components, including power tubes w/machine purchase..
MADE IN USA.

Factory Refurbished: Model 3000 and Model 4000

We refurbish, service and supply parts for all WorkRite Model 3000 and 4000 wood welders, ensuring they leave our plant ready for many more years of trouble-free operation. Many of our 3000 and 4000 machines have been in use from the late 1960s and require little in parts or maintenance to continue reliable operation due to the basic simplicity of design and quality of components.

Many repairs can be done with phone advice and repair parts, with machines rarely returned to the plant for repairs.

Although WorkRite has discontinued production of the Model 3000/4000 wood welders, we usually have factory re-conditioned with 1 year warranty 3000/4000 units available on an ongoing basis for customers who need a budget-friendly product. Contact factory for machine availability and pricing.

Restoration and Refurbishment Process:

Unit and handgun are completely disassembled and cleaned for inspection.
Any worn/poorly functioning part is repaired or replaced with genuine WorkRite parts.
Exterior cabinet and handgun housings are repaired and professionally refinished.
Unit is reassembled and bench-tested to ensure proper operation and performance.
Any part that fails during bench-testing is replaced, and the unit is retested.
A new certification label with the date of rebuild is affixed and the machine is crated for delivery back to the customer.

All refurbished units come with a 1-year Factory warranty excluding the primary transformer and tubes (90-day tube warranty with purchase).

Prices:

Complete restoration and refurbishment of customer unit and matching handgun including parts – $2,200.00 plus shipping.
Complete restoration of customer unit without handgun, including parts – $1800.00 plus shipping.
Complete restoration of customer hand unit including parts – $400.00 plus shipping.
Partial repairs are done on an hourly basis at $75.00 shop rate.
90-day warranty applies to all repairs.
Prices subject to change due to Tariffs, etc….etc….etc….

MODEL 4000 WOOD WELDER REBUILT
MODEL 3000 WOOD WELDER REBUILT
ROLLER ELECTRODES (pair)
INSIDE MITER ELECTRODES (pair)
OUTSIDE MITER ELECTRODES (pair)
FLAT STANDARD ELECTRODES (pair)
SMALL SPECIAL ELECTRODES (pair)
HAND UNIT REBUILD KIT With Pistol
HAND UNIT REBUILD KIT W/O Pistol
HAND UNIT PISTOL ASSEMBLY
HAND UNIT COMPLETE
CORD, 110 VOLT FOR HAND UNIT
COAXIAL CABLE COMPLETE
PANEL FITTING #83-1R
CABLE FITTING #83-1SP
SWITCH: S-3 INTERLOCK
SWITCH: S-4 TRIGGER
HAND UNIT INSULATING LEG (each)
ELECTRODE HOLDING BAR (each)
HAND UNIT COIL: 14 TURN
HAND UNIT COIL: SINGLE LINK
HAND UNIT STATIONARY ELECTRODE
HAND UNIT MOVABLE ELECTRODE
RELAY/ CONTACTOR
TUBE: #810 POWER
TUBE: #866 SOLID STATE
METER: (All Styles) Specify Model#
TRANSFORMER POWER
CONDENSER: HIGH VOLTAGE
GRID COIL ASSEMBLY COMPLETE Specify Model#
RESISTOR Specify Model #
R. F. CHOKE
ELECTRODE PLUGS MALE
PANEL LAMP
GLOW LAMP
GLOW LAMP SOCKET
FUSE
FUSE HOLDER
ELECTRODE PLUGS FEMALE

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