Hayes COMBAT6 Operator's Manual
  1. Manuals
  2. Brands
  3. Hayes Manuals
  4. Welding System
  5. COMBAT6
  6. Operator's manual

Hayes COMBAT6 Operator's Manual

Manual butt fusion machines
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Revision 02/21/24
Welcome to the Hayes Family!
The HAYES® manual COMBAT series butt fusion machines will give many years of service if operation procedures
and maintenance are followed carefully and correctly.
✓ The HAYES® COMBAT series is suitable for butt fusion pipes and fittings made of HDPE and any other kind
of thermoplastic pipes from 2" to 6".
✓ This machine is rugged, reliable and manually-operated. This unit is designed to make the fusion process
easier when welding small diameter pipes. It requires only one operator and minimal maintenance.
✓ Machine consists of pipe alignment carriage, insert sets, Teflon-coated heating plate, electric trimmer and
electric stand.
✓ The portable manually operated alignment will simplify the job on site. The compact electric trimmer and
the heater work with 220V and they only need 700 watts of power each. It will save you time and money
while fusing pipe consistently with high-quality results.
✓ Designed and manufactured according to the American international standard (Inches) ASTM F2620.
✓ Additional DIPS and Metric pipe inserts are available and sold separately
Do not operate this machine until you have carefully read, and understand all the sections of this manual.
About this manual
This manual is only a manufacturer´s guide. It does not take the place of proper training by qualified instructors. The
information in this manual is operational and cannot cover all the situations that may appear in the field. This guide
does not exceed the experience of a professional.
www.hayesfusion.com
4901 Whiskey Rd. Aiken, SC 29803 USA | (803) 200 - 2093
Manual Butt Fusion Machines
Operator's
Manual
P A G E
| 1
COMBAT6 220V
COMBAT 6 220V

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the COMBAT6 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Hayes COMBAT6

Summary of Contents for Hayes COMBAT6

  • Page 1 The HAYES® manual COMBAT series butt fusion machines will give many years of service if operation procedures and maintenance are followed carefully and correctly. ✓ The HAYES® COMBAT series is suitable for butt fusion pipes and fittings made of HDPE and any other kind of thermoplastic pipes from 2” to 6”.

  • Page 2: Table Of Contents

    P A G E Table of content Safety information Industrial safety (Risk Matrix) Manual Butt fusion machines (Introduction) Application What is Butt fusion? When to use Butt fusion ? Benefits of Butt fusion Butt fusion procedure Parts of the hydraulic Butt fusion machine Datasheet Specifications Machine operation Things to know before operating this machine...

  • Page 3: Safety Information

    California has determined can cause cancer, birth defects, or other reproductive harm. The list now includes more than 900 chemicals. HAYES FUSION machines are safe, stable and non-toxic under normal condition and when handling correctly, but may contain a trace amount of listed compounds as a result of our manufacturing processes.

  • Page 4: Industrial Safety Risk Matrix

    P A G E Industrial Safety RISK MATRIX Avoid serious Injury: This unit must be operated by trained personnel only. Skill and knowledge are required to proper use this equipment. Improper operation, maintenance or repair of this product can be dangerous and could result in injury or death. Be alert and report anything that you see, feel, smell or hear differently than expected, or that you think is unsafe.

  • Page 5: Manual Butt Fusion Machines (Introduction)

    Introduction Application The HAYES Manual Butt fusion machine is used for welding thermoplastic pipes and fittings made of HDPE (Polyethylene), PPR (Polypropylene), PB (Polybutene) and PVDF by heat fusion and manually controlled force. This method plays a crucial role in joining pipes and fittings, ensuring leak-proof connections and long-lasting joints when maintaining the integrity of fluid transportation networks.

  • Page 6: Parts Of The Hydraulic Butt Fusion Machine

    P A G E Parts of the Manual butt fusion machine Teflon-coated heating plate Electric Trimmer/Facer A trimmer or facer is a rotating cutting device used to square-off the pipe or fitting ends to obtain properly mating fusion surfaces. Included! The heater is coated to reduce polymer adhesion.

  • Page 7: Datasheet Specifications

    P A G E COMBAT 6 220V 2” – 6” IPS PRODUCT SPECIFICATIONS COMBAT6 MODEL 220 V Pipe ranges 2” IPS – 6” IPS Complete set of inserts 2” 3” 4” 5” + 6” Master Working temperature 0-518 °F Displayed...

  • Page 8: Machine Operation

    P A G E Machine Operation 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 surface to operate. ✓ Check field generator for adequate power supply and fuel sufficient to complete the fusion joint.

  • Page 9: Setting Up The Unit

    P A G E Setting up the unit Connect the trimmer and the heater to the electric unit with the special connectors as shown in the image. Connect the Electric Unit (Support) To the right power source and turn both switches on. The green light is the desired temperature and the red light Is the reached temperature.

  • Page 10: Temperature Controller Setting

    P A G E | 10 Temperature controller setting ► Switch on ► Press “SET” for more than 4 seconds until “Sd” is shown in the upper window ► Press “△” or “▽”key. Enter the setting temperature. Press "SET" to confirm Deviation correction of temperature control instrument Switch on Press “SET”...

  • Page 11: Welding Procedure

    P A G E | 11 Welding procedure Description of Method The principle of Butt fusion is to heat to a designated temperature the ends of two thermos plastic pipes until a bead is formed, then fuse them together by application of a sufficient force or pressure. This force or pressure causes the melted materials to flow and mix, thereby resulting in fusion that is stronger that the pipe itself.

  • Page 12: Stage #1: Prepare, Trim And Align The Pipe

    P A G E | 12 Step by step welding procedure Stage #1: PREPARE, TRIM AND ALIGN THE PIPE Place pipe support stands at both ends of the butt fusion machine and adjust the support stands to align the pipe with the fusion machine centerline.

  • Page 13: Stage #3: Joining The Pipe (Fuse / Cool)

    P A G E | 13 Stage #3: JOINING THE PIPE (FUSE / COOL) Fuse pipe together Cooling with pressure Cooling Without pressure Close the clamps by bringing the Keep the pipes joined on the carriage Once the cooling time with force has pipe ends together.

  • Page 14: Optional Use Of Torque Wrench

    Make sure you convert your units before using it to set any bearing preloads. How to use a torque wrench? Hayes has designed a special torque adapter for the machine. Place the adapter into the handle socket and tighten it with the screw provided.

  • Page 15: Reference Welding Standard

    P A G E | 15 HOW TO CALCULATE FUSION FORCE – ASTM F 2620 (Manual Machine) HAYES COMBAT 6 110V Welding ranges: 2" 3" 4" 5” 6” 1 Mpa= 145 PSI = 10 Bar = 1 N/mm² Torque Wrench: 16.33"...

  • Page 16: Glossary Of Terms

    P A G E | 16 Glossary of terms Welding terminology T = Time P = Pressure B = Bead size Pipe terminology ND = Nominal Diameter DIN = Internal Diameter OD = Outside Diameter T = Thickness PN = Nominal Pressure SDR = Standard Dimensional Ratio Relation between the Outside diameter and Thickness of the wall Temperature terminology...

  • Page 17: American Standard Astm F 2620

    P A G E | 17 Reference Welding Standard According to the ASTM F 2620 (United States) Pipe and fitting manufacturers have established qualified fusion procedure which should be followed precisely. You should obtain a copy of the pipe manufacturer's fusion procedures or appropriate joining standard for the pipe being fused.
  • Page 18 P A G E | 18 Reference Welding Standard According to the DVS 2207-1 (European Standard) TEMPERATURE: (200 – 220 °C) (392 – 428 °F) IFP: 0.15 N/mm² = 21.76 PSI = 0.15 MPa = 15 Bar DRAG: 0.01 N/mm² BEAD UP HEAT UP HEAT SOAK...

  • Page 19: Hdpe Thermoplastic Pipe Sizes Ips Dips Metric Chart Conversion

    P A G E | 19 HDPE Thermoplastic pipe sizes IPS DIPS mm Chart Conversion Nominal Pipe Size Real Size Outside Real Outside Closer Metric Real Size Outside Diameter (OD) Diameter (OD) (mm) Pipe size or (mm) Diameter (OD) (Known as Inches) (Inches) 1 Inch = 25,4 mm (Not the same)

  • Page 20: Cold Weather Procedures

    P A G E | 20 Cold weather procedures ✓ When the ambient temperature becomes colder, it will require a longer heating time to develop an indication of melt and the final bead size. The pipe wall thickness and pipe diameter are primary factors to consider when determining the necessary heating cycle time.

  • Page 21: Butt Fusion Visual Appearance Guideline

    P A G E | 21 Butt fusion visual appearance guideline Reference: ASTM F 2620 ACCEPTABLE VISUAL APPEARANCE Proper double roll-back bead. Proper alignment. UNACCEPTABLE VISUAL APPEARANCE Incomplete face-off. Improper alignment in fusion machine–mitered joint. Improper Contamination in joint. “high-low” pipe alignment. Visually mitered joint.

  • Page 22: Recommendations Preventative Maintenance

    | 22 Recommendations Preventative Maintenance The Hayes manual COMBAT series butt fusion machines will give many years of service if operation procedures and maintenance are followed carefully and correctly. PROPERLY HANDLE ELECTRICAL CORDS ✓ Yanking or pulling on the cord instead of gently unplugging it can strain the cord’s connections, leading to frayed wires, loose connections, or even short circuits.

  • Page 23: Machine Maintenance And Inspection

    P A G E | 23 Machine Maintenance and Inspection Satisfactory or needs Part Serial # Details repair Inspect the trimmer blades for damage and sharpness Check cord, plug and sockets Electric trimmer / Facer Trimmer does not wobble when trapped between jaws Check for loose pieces, screws and mechanical connections Check cord, plug and sockets Heater surface is clean and the PTFE coat is in good...

  • Page 24: Warranty

    IMPROVEMENT Hayes Industrial Solutions, Inc. reserves the right to make any changes in or improvements on its products without incurring any liability or obligation to update or change previously sold machines and/or the accessories. PROPRIETARY RIGHTS All proprietary rights pertaining to the design, colors, and branding, are exclusively the property of Hayes Industrial Solutions, Inc.

  • Page 25: Quality Certificate

    □ COMBAT6PROX # __________________ □ COMBAT 6 220V # __________________ □ COMBAT8PROX # __________________ This welding machine meets the Hayes Industrial Solutions, Inc. quality standards and is released for field use. Date: Signature: www.hayesfusion.com COMBAT 6 220V 4901 Whiskey Rd. Aiken, SC 29803 USA | (803) 200 - 2093...

Table of Contents