Hayes CG Series User manual

Socket Fusion Pipe Welder
CG Series - Commercial Grade
DESCRIPTION
The HAYES CG Series is our commercial-grade heating iron line. These tools are derived
from the best quality materials and parts on the market. The heating plate itself is formed
from the highest-grade aluminum alloy which allows the heating plate to give optimal
performance for heat preservation.
The inside components are made using the latest technology. The internal board delivers
more accurate and sensitive heat transference between the outside heating plate and the
digital board.
With special instructions you can switch the temperature mode between Fahrenheit and
Celsius. The digital display is very simple and easy to operate. This makes for a very smart
piece of equipment.
The HAYES CG is suitable for joining a variety of thermoplastic pipes and fittings for different
applications in the industry. This machine can weld HDPE (Polyethylene), PP-R
(Polypropylene), PB (Polybutene).
Our heating tool is designed and manufactured according to the American international
standard ASTM F2620. Our line of ancillary accessories such as heating adapters, cold ring
pliers and chamfer/depth gages are manufactured to ASTM F1056 guidelines, which will
assist in completing a quality fusion consistently if the pipe manufacturer's procedures are
followed carefully.
We offer a variety of options for all our customer’s needs. Our goal is to deliver world class
guaranteed plastic pipe fusion tools with fast shipping for a very competitive price.
Refer to the pipe manufacturer’s recommended procedures for the welding parameters.

P A G E | 2
www.hayesfusion.com | HAYES FUSION
PROCEDURE / APPLICATION
Definition according to the ASTM F2620: The socket fusion technique consists of
simultaneously heating both the external surface of the pipe end and the internal surface of
the socket fitting to a designated temperature, then fuse them together by application of a
sufficient force. Thereby resulting in fusion.
Socket fusion tools consist of a heating tool, heating adapter, cold rings pliers and
chamfer/depth gages.
TECHNICAL INFORMATION
✓Heating tool features
•Heat resistant aluminum plate
•Digital screen with adjustable temperature control
•Accurate heating temperature
•Automatic adjustable environment temperature
•Ergonomic handle
•Durable and efficient to maximize the pipe fusion
•Voltage protection
•Different working pipe sizes
You can purchase all socket accessories at www.hayesfusion.com
Heating Tool
CG2
CG4
Working range (Inches)
½” –2” IPS
½” –4” IPS
Power
800W
1400W
Voltage range
110V
110V
Frequency
50 / 60Hz
50 / 60Hz
Display Temperature
Fahrenheit / Celsius
Fahrenheit / Celsius
Temperature setting range
356°F - 536°F
356°F - 536°F
Factory Setting
500 ± 10°F
500 ± 10°F
Socket temperature range
500 ± 10°F
500 ± 10°F
Warning Temperature
>550°F
>550°F
Environment temperature
-68°F - 140°F
-68°F - 140°F
Relative humidity
45% - 95%
45% - 95%
Insurability Resistance
≥1MΩ
≥1MΩ
Leakage Current
≦5Ma
≦5Ma
Weight
4.2 LB (7”x 2”x 15”)
7.2 LB (7”x 2”x 15”)

P A G E | 3
www.hayesfusion.com | HAYES FUSION
Socket Fusion Pipe Welder
(Before use, please read the manual carefully)
ABOUT THIS MANUAL
This manual is only a manufacturer´s guide. It does not take the place of proper training by
qualified instructors and does not exceed the experience of a professional. The information in
this manual is operational and cannot cover all the situations that may occur in the field such
as environment temperature, pipe material, thickness, selected welding standard, etc.
BEFORE THE WELDING PROCESS
A. Cut and chamfer the pipe.
B. Place the cold ring at the proper depth on the pipe as determined by the depth gauge.
C. Attach the coated heating adapters to the heating tool when the tool is cold.
D. Connect to a 110V grounded power source only and begin operating the welding machine.
Permit enough preheating to stabilize the temperature.
MACHINE SET UP
•Once the unit is connected to proper power source it will automatically turn on and begin
to heat to the last temperature that was set. If you need to turn on and off the heating
tool hold down the to activate the On/Off mode.
•Set the desired temperature by holding the button to activate the Set mode and then
using the “up/down” buttons you can choose the proper temperature.
•Allow a few seconds for the heating tool to show the temperature that it is currently at
and permit enough time to reach and stabilize the desired temperature.
WELDING PROCESS
Put the pipes and fittings into the heating adapters, remove pipes and the fittings from the
heating adapters when they reach the proper heating time. Connect the pipes and fittings
together until the bead is formed.

P A G E | 4
www.hayesfusion.com | HAYES FUSION
IMPORTANT NOTES
Welding procedure
✓Skill and knowledge are required to obtain a good quality joint.
✓Ensure you select the proper temperature according to the pipe manufacturer’s
recommendation.
✓It is important to know the technical information before you use your heating tool.
Heating adapters: You can purchase all socket accessories at www.hayesfusion.com
Welding parameters: Pipe and fitting manufacturers have established qualified fusion
procedures which should be followed precisely. You should obtain a copy of the pipe
manufacturer's procedures or appropriate joining standard for the pipe being fused.
Heating iron temperature: To meet pipe manufacture’s temperature specifications,
the surface temperature of the heating adapters should be measured with a surface
pyrometer prior to initial use and at reasonable time intervals thereafter.
Ensure you test the temperature on the surface of the heating adapters and not on the heating
plate itself. The heater’s built-in thermometer indicates internal temperature and should only
be use for reference.
Show temperature in Celsius: Connect the machine to the proper power source,
then press for a few seconds until the code 000 is shown and then press 6 times
until the code 006 is shown and then press to select Fahrenheit °F or Celsius °C, allow a
few seconds for the heating tool to read the selected temperature mode and start to heat to
the last temperature that was set. If you need to set a new temperature hold the button
to activate the Set mode and then you can choose the proper temperature. Allow a
few seconds for the heating tool to show the temperature that it is currently at and permit
enough time to reach and stabilize the desired temperature.
CAUTION
Heating iron
✓The heater is to be used with AC power only. Check heater to confirm correct power
requirements and only use a power source with the correct voltage and current capacity.
✓Connect heating tool to power and permit sufficient preheating to stabilize the
temperature before the welding process.
✓When welding, if temperature adjustment is needed, please turn off the heating tool first
and turn it on again to adjust the new temperature. Adjustment of the temperature when
it is already set will damage the temperature control components.
✓It is recommended to use an insulated heater bag to store the heating tool when it is hot.

P A G E | 5
www.hayesfusion.com | HAYES FUSION
¡WARNING!
Avoid Injury
This unit must be operated by trained personnel only.
Industrial Safety
RISK MATRIX
Be alert and report anything that you see, feel, smell or hear differently than expected, or that
you think is unsafe.
SOURCE: Heating tool and heating adapters
Do not adjust temperature above 575 °F. This can result in damage to the heater components
and the non-stick surfaces.
HAZARD
RISK
RISK CONTROL
ELECTRICAL
Electrocution
•Make sure to use a power source with the
correct voltage and current capacity.
•Connect to a 110V grounded power source
only.
•Keep the cables away from chemical agents
or water.
THERMAL
Risk of fire
•Do not use the machine in atmospheres with
explosion risk, due to the presence of gases,
flammable vapors, etc
•Wear protective gloves. Never touch the
surface of the heating tool or heating
adapters when they are hot.
•Move the heating plate cautiously when it is
hot and carefully remove the heating
adapters.
Burn Risk

P A G E | 6
www.hayesfusion.com | HAYES FUSION
SOCKET FUSION TIME CYCLES
American National Standard - ASTM F2620
Polyethylene (PE)
Temperature: 490 - 510 °F / 254 - 266 ℃
PIPE SIZE
PE80 MDPE
Medium Density Polyethylene -
PE 2406/PE 2708
PE100 HDPE
High Density Polyethylene - PE
3408/PE 3608/PE 4710
Pipe Size
Heating
Time
Fusion
Time
Cooling
Time
Heating
Time
Fusion
Time
Cooling
Time
Inches
mm
Sec.
Sec.
Sec.
Sec.
1/2"CTS
16
6-7
Immediate
30
6-10
Immediate
30
1/2"IPS
20
6-7
Immediate
30
6-10
Immediate
30
3/4"
25
6-7
Immediate
30
6-10
Immediate
30
1"
32
10-12
Immediate
30
15-17
Immediate
30
1 1/4"
40
12-14
Immediate
45
18-21
Immediate
60
1 1/2"
50
14-17
Immediate
45
20-23
Immediate
60
2"
63
16-19
Immediate
45
24-28
Immediate
60
2 1/2"
75
18-20
Immediate
45
24-28
Immediate
60
3"
90
20-24
Immediate
60
28-32
Immediate
75
4"
110
24-29
Immediate
60
32-37
Immediate
75
* Allow the joint to cool an additional five (5) minutes before exposing the joint to any type of
stresses.
NOTE: Some recommend using a 50-60 grit emery or garnet cloth to roughen the outside of
the pipe and inside of the fitting as a means of minimizing any possible skin interface when
making the fusion. Sandpaper is not recommended for this purpose, as it might disintegrate
and contaminate the joint interface.
Pipe chamfer(c) and Insert depth (d)
Pipe Size (s)
Pipe Chamfer
Insert depth
Inches
mm
(c)
(d)
1/2"CTS
16
2 mm
13 mm
1/2"IPS
20
14 mm
3/4"
25
15 mm
1"
32
17 mm
1 1/4"
40
18 mm
1 1/2"
50
20 mm
2"
63
3 mm
26 mm
2 1/2"
75
29 mm
3"
90
32 mm
4"
110
35 mm

P A G E | 7
www.hayesfusion.com | HAYES FUSION
HEAT FUSION VISUAL APPEARANCE GUIDELINE
American National Standard - ASTM F2620
Acceptable Visual Appearance
✓Melt bead flattened by cold ring.
✓No gaps or voids.
✓Good alignment between pipe and
fitting.
Unacceptable Visual Appearance
✓Melt bead not flattened against the
fitting/cold ring.
✓Improper insertion depth; no cold
ring.
✓Excessive heating.
✓Misalignment.

P A G E | 8
www.hayesfusion.com | HAYES FUSION
WARRANTY CERTIFICATE
LIMITED WARRANTY
Hayes warrants all products distributed. All products have 12 months warranty against
manufacturer's defects from the date of purchase directly from Hayes or Hayes authorized
dealers. Furthermore, this warranty only covers factory defects.
RETURN OF GOODS
Buyer must receive written authorization directly from Hayes or Hayes authorized dealer
before any returns. The goods must be in the same condition as received. The buyer has 15
days to request a return of goods after the date of the purchase. Buyer is responsible for
return freight for any reason other than manufacturer's defects.
IMPROVEMENT
Hayes 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.
HEATING TOOL INSPECTION
Heating Tool Model No:____________________ Inspector: _______________________
Heater Serial No.: ________________________ Date Tested: _____________________
Factory Setting:____________________