Habasit PQ-18 User manual

Habasit AG
Postfach, CH-4153 Reinach-Basel
Phone ++41 61 715 15 15
Fax ++41 61 715 15 55
Operating Instructions
36009
Author: Nyk/Ni/AA Page 1 of 14
Edition: 03/0404 Subject to alterations
Replaces: Edition 02/9912
Welding Device PQ-18
The PQ-18 is a simple and cost effective tool for welding of Polycord round
belts. The joining operation is by blunt welding: Ends of the belt are melted by
pressing them against the surface of a precisely regulated hot welding plate.
After sufficient heating belt ends are pressed against each other with a
defined pressure and left to cool in a defined position. After removing the
resulting bead with a knife or by grinding an optimum quality round belt is
ready for use.
The PQ-18 is well suitable for on-site installation and small to medium size
series fabrication in the workshop.

Operating instructions 36009
Welding device
PQ-18
Page 2 of 14
Edition: 03/0404 Subject to alterations
Table of contents
1. General information............................................................................................................................ 3
1.1 Application............................................................................................................................................. 3
1.2 Important safety terms .......................................................................................................................... 3
1.3 Scope of supply..................................................................................................................................... 4
1.3.1 Available accessories ........................................................................................................................... 4
1.4 Ordering of accessories/spare parts..................................................................................................... 5
1.5 Warranty................................................................................................................................................ 5
1.6 Technical advice ................................................................................................................................... 5
2. Mode of operation............................................................................................................................... 6
3. Initial start-up ...................................................................................................................................... 6
4. Welding of Polycord round belts....................................................................................................... 7
5. Service.................................................................................................................................................. 8
5.1 Maintenance.......................................................................................................................................... 8
5.2 Measuring of the plate temperature...................................................................................................... 8
5.3 Adjusting of the thermostat................................................................................................................... 9
5.4 Replacement of the power cord............................................................................................................ 9
6. Illustrations........................................................................................................................................ 10
7. Technical data................................................................................................................................... 11
8. Drawing and spare part numbers.................................................................................................... 12
9. Required accessories....................................................................................................................... 13
9.1 Cutting device S-16............................................................................................................................. 13
Appendix:
Product Liability

Operating instructions 36009
Welding device
PQ-18
Page 3 of 14
Edition: 03/0404 Subject to alterations
1. General information
1.1 Application
The welding device PQ-18 has been specifically designed for rapid and safe welding of Polycord round belts
up to a diameter of 15 mm / 0.6 in.
The PQ-18 welding device was developed solely for the purposes described in the operating instructions.
Improper use, or use for other reasons than those described in the instructions, is not permissible. Habasit
accepts no liability for the consequences of improper application.
The welding device PQ-18 is manufactured according to recognized engineering principles and state-of-the-
art technology, and complies with applicable regulations.
These operating instructions imply that all assembly, maintenance, and repair work, as well as operation of
the press, be carried out by skilled personnel or monitored by responsible specialists.
For reasons of scope, these instructions cannot cover all possible aspects of operation, maintenance, or
repair. The indications given herein refer to the use of the machines according to their designated purpose
by skilled personnel.
In case of doubt or if further detailed information is required, please consult the manufacturer (Chapter 1.4)
1.2 Important safety terms
In these operating instructions, you will find the terms WARNING, CAUTION, and INDICATION. They signal
dangers or special information to be borne in mind.
WARNING If disregarded, there is a danger of severe injury, and/or severe material damage.
CAUTION If disregarded, there is a danger of injury, and/or material damage may be caused.
INDICATION Technical information is emphasized if it is important and not readily apparent, even for
skilled personnel.
Please observe all indications for assembling, operating, and maintaining the machines, as well as all
technical data! This will prevent possible trouble and/or damage to people or materials.
Skilled personnel refer to persons authorized to perform the required work. These people have been
sufficiently trained and introduced to their field of activity so that they are able to recognize and prevent
dangers. They are aware of the pertinent provisions and safety regulations.

Operating instructions 36009
Welding device
PQ-18
Page 4 of 14
Edition: 03/0404 Subject to alterations
1.3 Scope of supply
Qty. Item Order No.
1 Welding tool 230V~, EURO 709 008
or
1 Welding tool 120V~, USA 709 006
1 Guiding tongs with holding device 690 240
1 Operating instruction
1.3.1 Available accessories
Also refer to chapter 9.
•Cutting device S-16 (690010)
•Temperature measuring device (N-28714 or N-28715) for checking the welding temperature

Operating instructions 36009
Welding device
PQ-18
Page 5 of 14
Edition: 03/0404 Subject to alterations
1.4 Ordering of accessories/spare parts
Spare parts and accessories can be ordered directly from the manufacturer.
Address: Habasit Italiana S.p.A.
Via A. Meucci 8, Zona Industriale
I-31029 Vittorio Veneto/TV
Tel. ++39 438 91 13
Fax ++39 438 91 2374
Please accurately describe the parts required.
State the numbers according to Section 8. Drawing and spare part numbers and, if applicable, the required
electric voltage for connection to the mains.
WARNING The use of parts by other manufacturers not meeting Habasit specifications is not
admissible.
Habasit declines all responsibility for the consequences if non-Habasit parts are
used.
1.5 Warranty
All tools undergo a strict final inspection. On the assumption of correct handling, they are warranted against
material and manufacturing defects for 1 year.
1.6 Technical advice
Our specialists will be pleased to advise you. For technical questions concerning function and condition of
the welding device, please contact the manufacturer (see Chapter 1.4 for the address).

Operating instructions 36009
Welding device
PQ-18
Page 6 of 14
Edition: 03/0404 Subject to alterations
2. Mode of operation
The heating power and the output control of the welding tool (2) in combination with the welding plate (1) are
optimally adapted to the energy requirement for butt-end welding of Polycord round belts.
The design of the guide heads (11) on the guiding tongs (5), which is adjustable in 3 positions makes it
possible to join the ends of Polycord round belts under approximately optimum joining pressures. The label
on the guiding tongs (5) indicates the spring position for the relevant Polycord round belt diameter.
The holding device (6) facilitates handling. With a corresponding number of guiding tongs (5) and holding
devices (6), efficient production in series is possible.
3. Initial start-up
Clamp holding device (6) to work table by means of clamping screw (7)
Place guiding tongs (5) on holding device (see illustration 1)
Check parallel adjustment of welding plate to flat support area of handle of welding tool (2). When laid
down on a table, the welding plate may not touch the supporting table.
Check to make sure that the voltage indicated on the welding tool conforms to the electrical
connection voltage.
Check to make sure that the welding plate (1) is clean.
Connect welding tool (2) to mains and place it on a sufficiently flat surface. Respect preheating time of
14 min.
Check temperature of the welding plate. The temperature is preset at the factory at 270 °C / 520 °F.
If a lower temperature is required, the temperature regulator can be adjusted accordingly (see 5.2,
Measuring of the plate temperature).
WARNING Do not touch the hot zone of the welding tool!.
Keep device away from water and meltable substances.
CAUTION Do not suspend the welding tool (2) from its cable.
The heat rising from the welding plate (1) may destroy the welding tool (2)
electronic regulator. If need be (e.g. when joining a belt in a machine), bend a wire
into a support hook, from which you can hang the welding tool by the welding plate.

Operating instructions 36009
Welding device
PQ-18
Page 7 of 14
Edition: 03/0404 Subject to alterations
4. Welding of Polycord round belts
Process: Engineering manual 1260
Cut Polycord round belt to length at right angles with cutting device S-16 (-> available accessories).
For determination of belt length -> manual 1260
Lock locking spring (3) in appropriate position -> label (8).
Open guiding tongs (5) and secure them by closing the bracket (4)
Open guide heads (11) by turning the knurled nuts (12).
Introduce belt ends laterally into guide heads (11) and let ends protrude 2-4 mm / 0.08-0.16 in.,
depending on diameter (larger diameters to protrude more).
Fix belt ends by turning knurled nuts (12).
INDICATION Fix belt without twisting, i.e. according to its „inner disposition“!
Introduce welding tool (2) with heating plate (1) between guide heads (11).
Free securing bracket (4) and carefully close guiding tongs (5).
Let belt ends melt until the bead measures about 1-2 mm / 0.04-0.08 in., depending on belt diameter.
Then block the handles of the guiding tongs (5) by hand, so that the guiding tongs (5) can not close
any further. This makes the belt ends stay in contact with the welding plate but without pressure
(about 5-10 s, depending on the diameter of the belt). This permits the belt ends to melt to the core
without further enlarging the bead.
WARNING Do not inhale vapors generated during welding. Join Polycord round belts only with
good ventilation!
Slightly open the guiding tongs (5) by pressing the handles.
Pull out the welding tool (2) and place it on a flat table. At the same time, carefully close guiding
tongs (5) (joining the two melted sections).
WARNING Do not touch the hot zone of the welding tool!.
Keep device away from water and meltable substances.
Let joint cool in guiding tongs (5) for about 1-2 min.
Open guide heads (11) by loosening the knurled nuts (12) and remove joined belt.
Open guiding tongs (5) and lock securing bracket (4).
Whenever the welding tool is not in use, pull out mains plug.
Remove bead with pliers, file or grinding disk. Æsee illustrations 2 and 3
The Polycord round belt is now ready for use.
WARNING After use, disconnect the welding device from the power supply and allow it to cool
completely before storing it.

Operating instructions 36009
Welding device
PQ-18
Page 8 of 14
Edition: 03/0404 Subject to alterations
5. Service
5.1 Maintenance
Keep the welding device clean at all times. Clean the welding plate (1) regularly and remove all
material residues. Clean the welding plate (1) while heated with a cotton cloth.
WARNING Burning hazard! Fold cotton cloth in several layers to assure good insulation!
Do not touch hot surfaces!
CAUTION Never clean welding plate (1) with hard objects (such as screwdrivers, spatulas
etc.)! This will damage the Teflon coating.
Check guiding tongs (5) for smooth running. If necessary clean and very slightly oil axle pin (9) and
guide bar (10).
Periodically inspect the power supply cable and connector plug for defects (insulation damage, etc.)
and rectify or replace with the correct type where necessary.
5.2 Measuring of the plate temperature
Check the operating temperature of the welding device once a month.
The tool temperature scale could not indicate the same temperature: it depends on the presence of welding
plate. We suggest to verify periodically the temperature on the plate and, if necessary, adjust it.
Carry out this check in an interior room in a draft-free environment with an ambient temperature of
between 18 °C / 64 °F and 25 °C / 77 °F
Heat up for at least 15 minutes.
Hold sensor of temperature gauge against the welding plate (1)
The temperature gauge ought to indicate 270°C ± 10°C / 520°F ± 18°F
If this is not the case, the temperature regulator has to be adjusted. See 5.3, Adjusting of the
thermostat.

Operating instructions 36009
Welding device
PQ-18
Page 9 of 14
Edition: 03/0404 Subject to alterations
5.3 Adjusting of the thermostat
The maximum plate temperature of 270 °C / 520 °F, preset at the factory, must not be exceeded by more
than ± 10 °C / ± 18 °F from 270 °C / 520 °F. It can therefore only be adjusted with a precision temperature
measuring device (see 1.3.1, Available accessories).
WARNING All work on the welding device involving electrical parts has to be carried out by the
respective specialists only.
Observe your local laws about required training of such personnel.
If the measured temperature deviates above the maximum value of 280°C / 538°F or below 260°C / 502°F,
the heating control is to be adjusted as follows:
Move adjustment potentiometer of the heating control, using a screwdriver, turning it ever so slightly:
clockwise: temperature will rise,
counterclockwise: temperature will drop.
After 5 minutes measure plate temperature to check as described above.
Proceed carefully and adjust gradually. Observe temperature change.
5.4 Replacement of the power cord
Check power cord periodically. In case of damage replace with the same type. To make sure only skilled
staff will do this repair, special tools are required for this operation.
WARNING All work on the welding device involving electrical parts has to be carried out by the
respective specialists only.
Observe your local laws about required training of such personnel.

Operating instructions 36009
Welding device
PQ-18
Page 10 of 14
Edition: 03/0404 Subject to alterations
6. Illustrations
1 2
5
4
11
8
10
67
9
12
3
Illustration 1: Overall view of PQ-18
1
2
3
4
5
6
Welding plate
Welding tool
Locking spring
Securing bracket
Guiding tongs
Holding device
7
8
9
10
11
12
Clamping screw
Label
Axle pin
Guide bar
Guide head
Knurled nut
Ill. 2: Polycord joint with bead Ill. 3: Polycord joint after grinding

Operating instructions 36009
Welding device
PQ-18
Page 11 of 14
Edition: 03/0404 Subject to alterations
7. Technical data
Belt diameter [mm] [in.] 2 ... 15 0.08 ... 0.6
Temperature (unsolicited) [°C] [°F] 270 520
Max. deviation of plate temperature [°C] [°F] ± 10 ± 18
Heating up time to 270 °C / 520 °F [min] 14
Power consumption [W] 40 ... 200
Voltage [V~] 230 (PQ-18/8) or 120 (PQ-18/6)
Dimensions (L x W x H) [mm] [in.] 420 x 140 x 115 16.5 x 5.5 x 4.5
Net weight [kg] [lbs] 0.68 1.50

Operating instructions 36009
Welding device
PQ-18
Page 12 of 14
Edition: 03/0404 Subject to alterations
8. Drawing and spare part numbers
700024 702024 709006 120Vac USA plug
709008 230Vac Euro plug
701015
700534 700025
702021 701022
701020 701017
700029 700027
702020 702516
708035
702019
701021
701019
701018
702022
700529
700026 700028
701016

Operating instructions 36009
Welding device
PQ-18
Page 13 of 14
Edition: 03/0404 Subject to alterations
9. Required accessories
9.1 Cutting device S-16
The cutting device S-16 (operating instruction 3890) is a manual cutting tool to cut Polycord round belts to
the required length before the Quickmelt joining procedure takes place.
The S-16 allows to perform a proper right-angled cut up to 15 mm/0.6 in. diameter. Æill. (4)
Illustration 4

Operating instructions 36009
Appendix
Welding device
PQ-18
Page 14 of 14
Edition: 03/0404 Subject to alterations
Product liability, application considerations
If the proper selection and application of Habasit products are not recommended by an authorized Habasit
sales specialist, the selection and application of Habasit products, including the related area of product
safety, are the responsibility of the customer.
All indications / information are recommendations and believed to be reliable, but no representations,
guarantees, or warranties of any kind are made as to their accuracy or suitability for particular applications.
The data provided herein are based on laboratory work with small-scale test equipment, running at standard
conditions, and do not necessarily match product performance in industrial use. New knowledge and
experiences can lead to modifications and changes within a short time without prior notice.
BECAUSE CONDITIONS OF USE ARE OUTSIDE OF HABASIT’S AND ITS AFFILIATED COMPANIES
CONTROL, WE CANNOT ASSUME ANY LIABILITY CONCERNING THE SUITABILITY AND PROCESS
ABILITY OF THE PRODUCTS MENTIONED HEREIN. THIS ALSO APPLIES TO PROCESS RESULTS /
OUTPUT / MANUFACTURING GOODS AS WELL AS TO POSSIBLE DEFECTS, DAMAGES,
CONSEQUENTIAL DAMAGES, AND FURTHER-REACHING CONSEQUENCES.