Habasit PQ-02 User manual

Habasit Italiana S.p.A.
Via del Lavoro 50
I-31016 –Cordignano (TV)
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Use and maintenance manual
PQ-02
Author: FT Page 1 of 4
Edition: 04/2018 R. 0
Replaces:
Welding kit
PQ-02
Use and maintenance manual

Habasit Italiana S.p.A.
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Use and maintenance manual
PQ-02
Author: FT Page 2 of 4
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SAFETY WARNINGS!
WARNING
This device can be used by children over age 8 and by individuals with limited
physical, sensorial or mental abilities or who lack experience and knowledge if
supervised and/or instructed on device use to ensure they understand the
involved risks. Children should not play with the device. Cleaning and
maintenance should be performed by adequately trained qualified personnel.
WARNING
Warning: Some product parts can be very hot and cause burns! Special caution
is required when used near children and vulnerable individuals.
WARNING
These operating instructions imply that all assembly, maintenance, and repair
work, as well as operation of the welding kit, 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.
WARNING
If the power cord is damaged, it must be replaced by the manufacturer or
distributor or qualified individual to avoid user hazards.
WARNING
All work on the welding kit involving electrical parts has to be carried out by the
respective specialists only.
Observe your local laws about required training of such personnel.

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CONTENTS
SAFETY WARNINGS ........................................................................................................................................2
0 INTRODUCTION......................................................................................................................................4
ANNEXES:
WELDER W-01
JOINING CLAMP CQ-02

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0 Introduction
The PQ-02 welding kit it’s a kit for the welding of thermoplastic round belts.
The splicing operation is performed by butt-end welding of the two ends of the belt.
In the first stage (heating), the belt ends are locked on the two screw clamps of the positioning device and
melted by pressing them on the hot surface of the heating plate.
In the second stage (welding), the heating plate is removed and the melted ends of the belt are pressed
together to weld the junction.
In the third stage (finishing), the junction is allowed to cool and then the burr on the junction is removed by
means of a blade or grinding, obtaining a high quality closed loop round belt.
The PQ-02 kit is suited for on-site installation or for medium/small mass production in a workshop.
The PQ-02 kit includes:
W-01 welder for 120V or 230V power voltage + Heating plate;
CQ-02 joining clamp;
According to power supply voltage of the included W-01 welder, the PQ-02 kit is divided into:
PQ-02/6 for 120V power voltage H088000540
PQ-02/8 for 230V power voltage H088000541
Q.ty
Description
Code
1
W-01/6 welder + Heating plate
H088000561
W-01/8 welder + Heating plate
H088000562
1
CQ-02 joining clamp
H088000476
Below are attached the user manuals of the devices making up the kit.

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Use and maintenance manual
W-01
Author: FT Page 1 of 15
Edition: 06/2017 R. 0
Replaces:
Welder
W-01
Use and maintenance manual

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I-31016 –Cordignano (TV)
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Use and maintenance manual
W-01
Author: FT Page 2 of 15
Edition: 06/2017 R. 0
Replaces:
SAFETY WARNINGS!
WARNING
This device can be used by children over age 8 and by individuals with limited
physical, sensorial or mental abilities or who lack experience and knowledge if
supervised and/or instructed on device use to ensure they understand the
involved risks. Children should not play with the device. Cleaning and
maintenance should be performed by adequately trained qualified personnel.
WARNING
Warning: Some product parts can be very hot and cause burns! Special caution
is required when used near children and vulnerable individuals.
WARNING
These operating instructions imply that all assembly, maintenance, and repair
work, as well as operation of the welding device, 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.
WARNING
If the power cord is damaged, it must be replaced by the manufacturer or
distributor or qualified individual to avoid user hazards.
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.

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W-01
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CONTENTS
SAFETY WARNINGS!.......................................................................................................................................2
0INTRODUCTION.........................................................................................................................................4
1GENERAL INFORMATION........................................................................................................................4
1.1 Application..........................................................................................................................................4
1.2 Important safety terms........................................................................................................................4
1.3 EC declaration of conformity ..............................................................................................................6
1.4 EC plates............................................................................................................................................7
2GENERAL DESCRIPTION.........................................................................................................................7
3TECHNICAL DATA ....................................................................................................................................8
4OPERATING MODE...................................................................................................................................8
5GETTING STARTED ..................................................................................................................................9
6WELDING OF ROUND BELTS................................................................................................................10
7MAINTENANCE........................................................................................................................................10
7.1 Measuring of the plate temperature on the welder W-01/6 or W-01/8.............................................10
7.2 Replacement of the power cord on welder W-01/6 or W-01/8.........................................................11
7.3 Accessory/spare parts orders...........................................................................................................11
7.4 Warranty...........................................................................................................................................11
7.5 Technical consulting.........................................................................................................................11
8DISMANTLING AND SCRAPPING..........................................................................................................12
9SPARE PARTS.........................................................................................................................................13
10 CUSTOMER SERVICE.............................................................................................................................13
11 A1 - PREVENTIVE MAINTENANCE CHECKLIST..................................................................................14
12 A2 - PREVENTIVE MAINTENANCE SUMMARY SHEET.......................................................................15

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W-01
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0 Introduction
The welder W-01 is a device for welding of thermoplastic round belts (Polycord).
Its use is expected in combination with the devices CQ-01 and CQ-02 specifically dedicated to the
positioning of the thermoplastic round belts.
With W-01 are indistinctly indicated the models:
W-01/6 for 120V power voltage
W-01/8 for 230V power voltage
1 General information
1.1 Application
The welder W-01 was specifically designed for a rapid and safe welding of thermoplastic round belts up to a
diameter of 15 mm / 0,6 in. in combination with the positioning devices CQ-01 and CQ-02.
The welder W-01 is manufactured according to recognized engineering principles and state of art
technology, and complies with applicable regulations.
These operating instructions imply that all assembly, maintenance, and repair work, as
well as operation of the welding device, be carried out by SKILLED/QUALIFIED
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.
1.2 Important safety terms
Symbols WARNING and INDICATION were included in this manual.
These symbols indicate hazards or special instructions to be observed.
WARNING Serious injury and/or serious material damages may ensue if ignored.
INDICATION Indicates important technical information that may not be known to even
expert personnel.
1.2.1 General warnings
Read all hazard warnings and operating instructions.
Failure to observe the hazard warnings and operating instructions may lead to electrical shock, fire and/or
serious injury hazards.
The tool power plug must be suited to the socket. Strictly avoid modifying the plug. Do not use adapter plugs.
Unmodified plugs and sockets suited for the purpose reduce electrical shock risks.

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Store the tool away from rain or humidity. Water penetration in the tool increases electrical shock risk.
Do not use the cord for purposes other than those intended and, specifically, do not use it to transport or
hang the tool and do not pull on it to unplug the tool.
Keep the cord away from heat, oil, sharp corners and machine parts in motion. Damages and tangled cords
increase electrical shock risks.
1.2.2 Personnel safety
Never use the tool when tired or under the influence of drugs, alcohol or prescription medicine.
Always wear personal safety devices as well as protective gloves.
When the tool is not used, keep out of reach of children. Do not allow untrained personnel or personnel who
have not read these instructions use the tool.
1.2.3 Improper use
The welder W-01 was exclusively designed for the applications described in this user manual. In particular,
the welder W-01 was developed to join Habasit fabric belts made of technopolymers (TPU, PA, PVC,
TPO…) without metal.
An improper use and an application for different purposes than those described in the instructions are not
allowed.
Habasit declines any responsibility for the consequences of an improper use.
Observe all assembly, operation and maintenance indications of the machine, as well as all technical data!
This will avoid any problem/damage to persons or objects.
The term QUALIFIED PERSONNEL refers to persons authorized to carry out the required work.
These persons must be adequately trained and have such an experience in their field to be able to reckon
and prevent danger. They are aware of the relative dispositions and safety regulations.

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1.3 EC declaration of conformity
Habasit Italiana Spa has included the EC Declaration of Conformity with the machine as per European
Directives 2014/35/UE –APPENDIX IV and 2014/30/UE –APPENDIX IV :

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1.4 EC plates
The EC plate was affixed to the device:
2 General description
Figure 1: General overview
Pos.
Description
1
HEATING PLATE
1

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3 Technical data
Characteristics
UM
Value
ELECTRICAL DATA
-Nominal power voltage
Vac
1x230 Vac 50-60 Hz (W-01/8)
1x120 Vac 50-60 Hz (W-01/6)
-Overall installed power
W
70
PRODUCTION
-Round belt diameter
mm [inc]
2÷15 [0,08 ÷0,6]
-Max temperature
°C [°F]
270 [519]
-Max plate temperature deviation
°C [°F]
± 10 [± 18]
-Preheating time
[min]
10
DIMENSIONS
-Dimensions(length x height x depth)
mm [inc]
270L x 150W x 40H [10,6L x 5,9W x 1,6H]
WEIGHT
-Net weight
kg [lbs]
0,31 [0,68]
4 Operating mode
The welder W-01 operates according to the hot blade principle; to weld the belts, make contact between the
belt ends and the hot plate of the welder.
The heating power and the electronic regulator of the welder W-01, in combination with the heating plate are
optimally adapted to the energy requirement for butt-end welding of thermoplastic round belts

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5 Getting started
Make sure the voltage specified on the specifications plate corresponds to connected mains voltage.
A tool marked 230 V can also be connected to the 220 V mains.
Similarly, for the 120 V version, 110 V power is tolerated.
Make sure the heating plate [1] is clean.
Connect the welder W-01 to mains and place it on the support or on a sufficiently flat surface. Respect
preheating time of 10 min.
Check temperature of the heating plate. The temperature is preset at the factory at 270 °C / 519 °F.
WARNING
Do not touch the hot zone of the welding tool!
Keep device away from water and meltable substances.
Make sure the heating plate do not touch surfaces or objects when the welder is placed on the support or on
the workbench.
Do not suspend the welder W-01 from its cable with the heating plate swinging. The
heat rising from the heating plate [1] may damage the welder W-01.
During pauses in work, place the welder, if it is still connected to the mains, on the
supplied support or on a level surface

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6 Welding of round belts
Procedure: refer to the user manual of the CQ positioning device used.
7 Maintenance
Always keep the welding device clean. Clean the heating plate [1] regularly and remove all material residues.
Clean the heating plate [1] while heated with a cotton cloth
For cleaning with a cloth moistened with water or solvent, the welder must be
disconnected from the power supply.
Do not reconnect to the power supply until the welder is completely dry.
Burning hazard! Fold cotton cloth in several layers to assure good insulation!. Do not
touch hot surfaces
Never clean heating plate [1] with hard objects (such as screwdrivers, spatulas etc.)!
This will damage the Teflon coating
Periodically inspect the power supply cable and connector plug for defects (insulation damage, etc.) and
rectify or replace with the correct type where necessary.
7.1 Measuring of the plate temperature on the welder W-01/6 or W-01/8
Check the operating temperature of the welding device once a month.
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 the welder for at least 10 minutes.
Insert a precision temperature probe into the hole [2] of the
heating plate [1].
The temperature gauge ought to indicate 270 °C ± 10 °C / 519
°F ± 18 °F and it must be comparable (± 5 °C / ± 9,5 °F) with
the value shown on the display of the welder.
Should the measured temperature deviates from 270 °C ± 10
°C / 519 °F ± 18 °F, adjust with a screwdriver, increasing or
decreasing gradually, the set temperature. When you generate
a rotation of the adjustment spindle of the temperature set, the
display shows the “flashing” value of the current temperature
set. After each change of the set, leave for a few minutes to
stabilize the platen temperature on the new value and then
check the real value of the plate temperature on the display and
on the measuring thermometer. In case of failure to reach the
temperature value, replace the welder.

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7.2 Replacement of the power cord on welder W-01/6 or W-01/8
Check power cord periodically. In case of damage replace with the same type (imprinted on the cable). To
make sure only skilled staff will do this repair, special tools are required for this operation.
All work on the hot-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.
7.3 Accessory/spare parts orders
Spare parts and accessories can be directly ordered from the manufacturer at the following address:
Please clearly specify ordered part codes.
Enter codes based on Drawings (see chapter “SPARE PARTS”) and, if possible, the power voltage required
for mains connection.
The use of other branded spare parts that do not meet Habasit specifications is prohibited.
Habasit is not liable for the use of non-original Habasit spare parts.
7.4 Warranty
All tools are subject to attentive final inspection. They are guaranteed free of material and factory defects for
1 year provided they are used correctly.
7.5 Technical consulting
Our experts are available for all consultations. For technical questions concerning welding device operations
and conditions, contact the manufacturer at the address listed above.
Habasit Italiana S.p.A.
Via del Lavoro, 50.
31016 CORDIGNANO (TV) - ITALY
Tel.: [phone]
Fax: + 39 0438 912374
E_mail : [email protected]
Internet : www.habasit.com

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8 Dismantling and scrapping
The welder must be uninstalled by HABASIT Assistance Service technicians or authorized HABASIT
technicians with experience in:
Machine assembly/disassembly
Assembly/disassembly of the electrical, pneumatic and hydraulic plant, consulting the corresponding
diagrams.
Generally the machine is decommissioned and dismantled when replaced.
This operation may be performed by specialized companies or the owner; in any case, current regulations
must be observed.
If demolished by the user’s personnel, the various parts must be separated by type and specialized (and
authorized) companies employed for the disposal of the various products.
We would like to remind you that the most important materials used in machine construction are:
Steel
Aluminum
Electric wires
Plastic materials
Rubber
Habasit Italiana Spa has adopted suitable measures to reduce the disposal of RAEE
generated by the use of AEE incorporated in its machines in order to reduce RAEE as
mixed solid waste to a minimum, to ensure the correct processing and high level of
RAEE separate waste collection.
Habasit collects the RAEE generated by its production, maintenance and customer
service activities as per Directive 2012/19/EU article 13.
In order to reduce the presence of hazardous substances when recycling new AEE,
Habasit requests suppliers comply with Directive 2012/19/EU and accompany AEE
with an explicit declaration of conformity to Directive 2002/95/EC (RoHS).
This machine was designed and constructed with recyclable materials and
components.
If demolished by the customer’s staff, the various components must be separated by
type.
RAEE must be collected separately (art. 3-h) and discarded according to art. 6 in
directive 2012/19/EU.
WARNING!
Before carrying out any kind of work on the machine it is essential to ensure that the plant (electrical,
pneumatic and water) is disconnected from energy supplies, that the pneumatic and water plant is properly
depressurized and that there is no remaining potential energy in the moving parts.

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9 Spare parts
10 Customer service
For any further clarifications, contact Habasit Italiana S.p.A. customer service at the following address:
Product liability, application considerations
The proper selection and application of Habasit products, including the related area of product safety, is 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.
This use and maintenance manual and its attachments are translated from original language (Italian).
Habasit Italiana S.p.A.
Via del Lavoro, 50.
31016 CORDIGNANO (TV) - ITALY
Tel.: [phone]
Fax: + 39 0438 912374
E_mail : [email protected]
Internet : www.habasit.com
H08D013502

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11 A1 - Preventive maintenance checklist
Job positions: A: Machine operator
B: Maintenance technician
Work to be performed
Frequency
Spare part code
(for additional information and reference numbers, see user manual)
Periodic (monthly)
Evaluation criteria
Daily
1
6
Note
1. Cleaning
1.1 Clean the machine after use removing residue deposits
A
2. Inspect the power cord
2.1 Inspect the cord and plug to ensure there are no defects
B
Insulation damaged,
Defective connections
3. Measure heating plate temperature
3.1 Proceed as thoroughly indicated in user manual chapter “MAINTENANCE”
B
Observations and notes:

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12 A2 - Preventive maintenance summary sheet
Machine type:
Machine nr.: Start date:
Actions –see checklist
check
completed
check
completed
check
completed
check
completed
(daily unrecorded work)
next
approv
al
date
next
appro
val
date
next
appro
val
date
next
appro
val
date
2.1 Check for cord damages
3.1 Measure heating plate temperature
Observations, repairs: