HAYES Manual Butt Fusion Machines

Welcome to the Hayes Family!

The Hayes manual COMBAT PROX series butt fusion machines are designed to provide many years of service when operated and maintained carefully and correctly.

• The COMBAT PROX series is suitable for butt fusion of pipes and fittings made of HDPE and other types of thermoplastic pipes.
• The machine comprises a pipe alignment carriage, insert sets, a Teflon-coated heating plate, an electric trimmer, and an electric stand.
• Designed and manufactured according to the American international standard (Inches) ASTM F2620.
• This machine is rugged, reliable, and manually operated, capable of fusing pipe consistently with high-quality results.
• It requires only one operator and minimal maintenance.
• Additional DIPS and Metric pipe inserts are available and sold separately.

Do not operate this machine until you have carefully read and understand all sections of this manual.

About this manual

This manual serves as a manufacturer's guide and does not replace proper training by qualified instructors. The information provided is operational and may not cover all field situations. This guide is intended to supplement, not replace, professional experience.

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IMPORTANT Safety Information

Hazards are identified by the "Safety Alert Symbol" followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION".

Signal words "NOTICE" and "IMPORTANT" are used to draw attention to specific information:

• "NOTICE": Alerts to actions that might damage the machine or property, or warns against unsafe practices.
• "IMPORTANT": Provides helpful tips to improve job performance or ease.

California Proposition 65 Label

The California Office of Environmental Health Hazard Assessment (OEHHA) amended regulations related to "clear and reasonable" Proposition 65 warnings, effective August 30, 2018. For HAYES machines sold or operated in California, the included label must remain attached. Proposition 65 informs the public about potential exposures to chemicals that the state has determined can cause cancer, birth defects, or other reproductive harm. While HAYES machines are safe under normal conditions, they may contain trace amounts of listed compounds from manufacturing processes. For more information, visit www.P65warnings.ca.gov.

[WARNING] Cancer and Reproductive Harm - www.P65warnings.ca.gov

Notice

All data in this Operator's Manual is offered in good faith as typical values, compiled from vendor data and believed to be accurate. It is the user's responsibility to determine the safety, potential hazard, toxicity, and suitability of the machine for their specific use. HAYES INDUSTRIAL SOLUTIONS INC. makes no guarantee, expressed or implied, regarding the effects of use, results obtained, or safety, hazard, and toxicity of the product. The information is intended solely to assist in the safe handling of this machine.

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Industrial Safety RISK MATRIX

Avoid serious injury: This unit must be operated by trained personnel only. Skill and knowledge are required for proper use. Improper operation, maintenance, or repair can be dangerous and could result in injury or death.

Be alert and report anything unusual or unsafe.

[DANGER] Both the heater element and the trimmer with electric motor are NOT EXPLOSION PROOF. If operating in an explosive atmosphere, the heater should be brought up to temperature in a safe environment, then unplugged before entering the explosive atmosphere for fusion. Operation in an explosive atmosphere without necessary safety precautions can result in serious injury or death.

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Parts of the butt fusion machine

Teflon-coated heating plate: The heater is coated to reduce polymer adhesion. Its temperature is controlled by a microprocessor in the electric box located in the stand.

[Image description: A flat, circular heating plate with a black Teflon coating, designed to be inserted between pipes.]

Electric Trimmer: This is a heavy-duty trimmer with a robust electric motor. It creates clean, parallel mating surfaces perpendicular to the pipe centerline.

[Image description: A powerful electric tool with a circular blade, designed to shave the ends of pipes for a precise fit.]

Pipe alignment carriage: Pipe support stands are used to support the pipe at both ends of the butt fusion machine, assisting with pipe loading and alignment.

[Image description: The main body of the fusion machine, featuring clamps that hold the pipes in place and allow for precise alignment.]

Stand for heating plate and trimmer: This stand holds the heater and trimmer, and also connects them to control the heater's temperature.

[Image description: A sturdy metal stand with designated spots for the heating plate and trimmer, featuring control panel elements.]

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Specifications

Other available inserts

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Instruction of use

Before operation make sure of the following:

• Skill and knowledge are required to obtain a good quality joint.
• The machine should be placed on a stable and dry plane to operate.
• Check field generator for adequate power supply and fuel sufficient to complete the fusion joint.
• Make sure the blades of the trimmer are sharp and the Teflon in the heating plate is in good condition.
• Ensure you select the proper temperature according to the pipe manufacturer's recommendation. A pyrometer or other surface temperature measuring device should be used periodically to ensure proper surface temperature of the heating tool plate.
• Place the appropriate inserts for the pipe OD or the fitting being fused.
• Pouring water or applying wet cloths to the joint to reduce cooling time is not acceptable.

IMPORTANT NOTES

Non-stick coating:

Coated surfaces have been treated to reduce polymer adhesion. If polymer adheres to the heating plate, wipe lightly with a clean cotton cloth. Do not use a wire brush or abrasive material.

Welding parameters:

Pipe manufacturers have established qualified fusion procedures that must be followed precisely. Obtain a copy of the pipe manufacturer's procedures or the appropriate joining standard for the pipe being fused.

Heater temperature:

To meet pipe manufacturer's temperature specifications, the heating plate's surface temperature should be measured with a surface pyrometer prior to initial use and at reasonable intervals thereafter.

[Image description: A view of the butt fusion machine assembled, showing the heating plate and trimmer positioned between the pipe clamps.]

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Temperature controller setting

Switch on

• Press “SET” for more than 4 seconds until “Sd” is shown in the upper window.
• Press “▲” or “▼” key to enter the setting temperature.
• Press "SET" to confirm.

Deviation correction of temperature control instrument

Switch on

[Image description: A digital temperature controller display showing '220' in the PV window and '220' in the SV window.]

• Press “SET” for more than 3 seconds until “SI” is shown in the upper window.
• Press “SET” until “SC” is shown in the upper window.
• Press “▲” or “▼” key to enter the temperature correction value.
• Press "SET" key to confirm.

[Image description: A digital temperature controller display showing '8.8.8' in the PV window and '8.08' in the SV window.]

[Image description: A digital temperature controller display showing '8.8.8' in the PV window and '220' in the SV window.]

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Welding procedure

Description of Method

The principle of Butt fusion is to heat two surfaces to a designated temperature, then fuse them together by application of a sufficient force. This force causes the melted materials to flow and mix, thereby resulting in fusion.

The butt fusion procedure has 4 stages:

1. Stage #1: Pipe Preparation
   • Cut and Clean
   • Trim
   • Align
2. Stage #2: Heating cycle
   • Preheat
   • Heating up
3. Stage #3: Welding
   • Welding time
   • Cooling time
4. Stage #4: Removing Pipe
   • Inspecting

Stage #1: Pipe Preparation

Cut and Clean

Cut the pipe and clean the inside and outside of both ends of the pipes with a clean lint-free dry cloth. Remove all dirt from the clamps surfaces where the pipes will be clamped in the butt fusion machine.

[Image description: Close-up of a pipe end being cleaned with a lint-free cloth.]

Trimming pipes

Face the pipe ends until the trimmer bottoms out on the stops and is locked between the clamps to establish clean, parallel mating surfaces between the pipe ends. Open the clamps, remove the trimmer and clean the inside and outside of both ends of the pipes with a clean lint-free dry cloth.

[Image description: A pipe end being trimmed by the electric trimmer, showing the blade making contact.]

Alignment

Check the pipe ends for high/low alignment and out-of-roundness. If adjustment is needed, adjust the high side down by tightening the high side clamp. Do not loosen the low side clamp or slippage may occur during fusion. Re-face the pipe ends if excessive adjustment is required and remove any dirt with a clean, lint-free cotton cloth. The maximum OD high-low misalignment allowed in the butt fusion procedure must be less than 10% of the pipe minimum wall thickness.

[Image description: Two pipe ends held in the machine's clamps, showing the alignment guides and adjustment mechanisms.]

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Stage #2: Heating cycle

Preheat: Verify that the heater surface temperatures are in the specified range according to the standard. Follow pipe manufacturer's procedure. A pyrometer or other surface temperature measuring device should be used before the first joint of the day and periodically throughout the day to ensure proper temperature of the heating tool plate. The thermometer on the electric box indicates the internal temperature of the heater, which varies from the actual surface temperature.

Place the Heater: Place the heating tool in the butt fusion machine between the pipe ends. The heater must be clean and its Teflon coating must be in good condition.

[Image description: The heating plate being inserted between two pipe ends held in the machine's clamps.]

NOTICE: Incorrect heating temperature can result in questionable fusion joints.

Stage #3: Welding

Bring the pipe ends into full contact with the heating tool at fusion force.

After the heating cycle is completed and a slight melt is observed around the circumference of the pipe, maintain contact without force, while a bead develops between the heater and the pipe.

Remove the heater and quickly apply fusion force with the lever handle in accordance with the pipe manufacturer's recommended fusion procedure or appropriate joining standard. The quicker this process can be safely done, the better.

A torque wrench can be used when a specified Interfacial Pressure is required. Hold this force for at least 10 seconds. After 10 seconds, the locking cams will assist by maintaining jaw position during the cooling cycle.

An interfacial pressure of 60 to 90 psi (0.41 to 0.62 Pa) is used to determine the force required to butt fuse the pipe components. Multiply the interfacial pressure by the pipe area to calculate the required fusion force (lb). For manually operated fusion machines, apply enough force to roll the bead back to the pipe surface. A torque wrench may be used to apply the proper force. Manual fusion without a torque wrench has been used successfully by many gas utilities.

NOTICE: Failure to follow pipe manufacturer's heating time, pressure, and cooling time may result in a bad joint.

[Image description: Two pipe ends being fused together, showing the application of force and the formation of a melt bead.]

Stage #4: Removing Pipe

After the pipe has cooled sufficiently, apply closing force on the lever handle and push the locking cams down into the unlocked position. Unscrew the clamp knobs enough that they can be swiveled outward.

Inspecting: Visually check the entire joint. The joint should be smooth and symmetrical. The bottom of the groove between the beads should not be lower than the pipe surface. The misalignment of two beads should not exceed 10% of the wall thickness.

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Reference Welding Standard

According to the ASTM F 2620

Pipe and fitting manufacturers have established qualified fusion procedures that should be followed precisely. Obtain a copy of the pipe manufacturer's fusion procedures or appropriate joining standard for the pipe being fused. Follow the procedure carefully and adhere to all specified parameters.

[Diagram description: An illustration showing the butt fusion process, with labels for Melting Zone, Hot Plate, Butt Fusion, and Pipe/Fitting.]

[Diagram description: A schematic showing a pipe being fused, with labels for HEATER, PIPE or FITTING, and a note about "A Minimum Melt Bead Size Needed Before Removing Heater".]

NOTICE: Avoid high stress such as pulling, installation, or rough handling for an additional 30 min or more after removal from the fusion machine (only 10 minutes additional cooling time is required for IPS 1 in. and smaller pipe sizes). Do not apply internal pressure until the joint and surrounding material have reached ambient air temperature.

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Terminology

[Diagram description: An illustration showing a pipe cross-section with labels OD (Outside Diameter) and ID (Inside Diameter), and T (Thickness).]

F

IFP*Ap + DRAG

Ap

(OD – T) * T * π

SDR

OD/SDR

T

OD/T

F

Force

Ap

Pipe area

SDR

Standard dimensional ratio

T

Thickness

OD

Outside diameter

ID

Inside diameter

B

Bead size

π

3.14

t

time

DRAG

Drag Pressure 30 PSI

IFP

Interfacial Pressure = 75 PSI = (Min 60 PSI – Max 90 PSI)

Temperature

204 – 232 °C | (400 – 450 °F)

HDPE Thermoplastic pipe sizes IPS DIPS mm Chart Conversion

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Butt fusion visual appearance guideline

Reference: ASTM F 2620

ACCEPTABLE VISUAL APPEARANCE

[Image description: A pipe joint showing a proper double roll-back bead and good alignment.]

UNACCEPTABLE VISUAL APPEARANCE

[Image description: A pipe joint with incomplete face-off, showing an uneven cut surface.]

[Image description: A pipe joint with improper alignment in the fusion machine, appearing as a mitered joint.]

[Image description: A pipe joint exhibiting "high-low" pipe alignment, visually appearing as a mitered joint.]

[Image description: A pipe joint showing contamination within the fused area.]

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Preventative Maintenance

STORE

To ensure optimum performance, the machine must be kept clean and well maintained. Store the machine indoors, in a dry covered area, protected from the weather.

CLEAN AND DRY

Clean the machine body with soap and water, wash as needed, and keep it dry. Remove the heater and trimmer from the spray area before cleaning. When cleaning the heating tool, do not use an abrasive pad or steel wool. Use a non-synthetic cloth that will not damage or scratch surfaces.

REMOVE DIRT AND LUBRICATE

Remove oily dirt buildup from guide rods and use WD-40 to lubricate them, then wipe dry. Do not leave the cleaning agent on the guide rods. Lubricate guide rod bushings with SAE 10W-40 motor oil through the oil holes on the movable jaw. Occasionally add a drop of oil to pivot pins and shafts. Wash and clean bearings and threads in kerosene or solvent and keep them lubricated.

KEEP EVERYTHING NICE AND TIGHT

Check all nuts, bolts, and snap rings to ensure they are secure and in place.

ADJUSTING TEMPERATURE

Allow the heater to stabilize at the new temperature (5 to 10 minutes) after adjusting.

Inspection

Make as many copies of this page as you need.

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Warranty

LIMITED WARRANTY

Hayes warrants all products distributed. All products have a 12-month warranty against manufacturer's defects from the date of purchase directly from Hayes or Hayes authorized dealers. This warranty only covers factory defects.

RETURN OF GOODS

Buyers must receive written authorization directly from Hayes or a Hayes authorized dealer before any returns. Goods must be in the same condition as received. Buyers have 15 days to request a return of goods after the date of purchase. Buyers are responsible for return freight for any reason other than manufacturer's defects.

IMPROVEMENT

Hayes reserves the right to make any changes or improvements to its products without incurring any liability or obligation to update or change previously sold machines and/or accessories.

PROPRIETARY RIGHTS

All proprietary rights pertaining to the design, colors, and branding are exclusively the property of Hayes.

DISCLAIMER OF LIABILITY

Hayes accepts no responsibility for fusion joints. Operation and maintenance of the product are the responsibility of operators. Qualified joining procedures are recommended when using Hayes fusion equipment. Hayes makes no further warranty of any kind, express or implied; all implied warranties of merchantability and fitness for a particular purpose that exceed this obligation are hereby disclaimed by Hayes.

Remember your product information to activate your warranty.

Model No: ____________________ Serial No.: ________________________

Inspector: ____________________ Date of the purchase: _______________

Distributor: ___________________

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HAYES Quality Certificate

Dear Customer,

Your machine has been fully tested and inspected for quality assurance by our technical department.

COMBAT4PROX # __________________

COMBAT6PROX # __________________

COMBAT8PROX # __________________

This welding machine meets the HAYES quality standards and is released for field use.

Date: _________________________

Signature: ______________________

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