Rothenberger ROWELD ROFUSE Sani 160 User manual

www.rothenberger.com/manuals
ROWELD ROFUSE Sani 160
®
5.4230

ppa. Arnd Greding
DEUTSCH Seite 3
ENGLISH page 16
FRANÇAIS page 29
NEDERLANDS bladzjde 42
Bedienungsanleitung bitte lesen und aufbewahren! Nicht wegwerfen!
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Please read and retain these directions for use! Do not throw them away! The warranty does not cover
damage caused by incorrect use of the equipment! Subject to technical modifications!
Lire attentivement le mode d’emploi et le ranger à un endroit sûr! Ne pas le jeter! La garantie est
annulée lors de dommages dûs à une manipulation erronée! Sous réserve de modifications techniques!
Lees de handleiding zorgvuldig door en bewaar jaar goed! Niet weggooien! Bij schade door
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CE-KONFORMITÄT/
CE-CONFORMITY/
CONFORMITÉ/
EC-KONFORMITEIT
Andere Normen/
Other Standards/
Autres normes/
Andere standaarden
EG Richtlinie 89/336 EWG
EG Niederspannungsrichtlinie 73/23 EWG
EN 292/1
EN 292/2
EN 60242
CE-KONFORMITÄTSERKLÄRUNG
EC-DECLARATION OF CONFORMITY
DECLARATION CE DE CONFORMITÉ
Wir erklären in alleiniger Verantwortung, dass
dieses Produkt mit den angegebenen Normen
und Richtlinien übereinstimmt.
We declare on our sole accountability that this
product conforms to the standards and guidelines
stated.
Nous déclarons sous notre propre responsabilité
que ce produit est conforme aux normes et directives
indiquées.
Wij verklaren in eigen verantwoordelijkheid dat dit
product overeenstemt met de van toepassing zijnde
normen en richtlijnen.
EC-KONFORMITEITSVERKLARING
2

ENGLISH 17
Introduction
Dear Customer:
Thank you very much for purchasing our product. We are confident that it
will meet your expectations.
The ROWELDROFUSE Sani 160 welding unit for electrofusion fittings is
designed exclusively for joining PE discharge lines equipped with electro-
fusion fittings.
The ROWELDROFUSE Sani 160 was manufactured and checked according
to state-of-the-art technology and widely recognized safety regulations
and is equipped with the appropriate safety features.
Before shipment, it was checked for operation reliability and safety. In the
event of errors of handling or misuse, however, the following may be
exposed to hazards:
- the operator’s health,
- the ROWELD®ROFUSE Sani 160 and other hardware of the operator,
- the efficient work of the ROWELDROFUSE Sani 160.
All persons involved in the installation, operation, maintenance, and
service of the ROWELDROFUSE Sani 160 have to
- be properly qualified,
- operate the ROWELDROFUSE Sani 160 only when observed,
- read carefully and conform to the User’s Manual before working
with the welding unit.
Thank you.

18 ENGLISH
1Safety Instructions
When using the ROWELDROFUSE Sani 160 welding unit, comply with the
following safety instruction to protect yourself from electrocution, injuries,
and fire. Read and respect these instructions entirely before using the unit
and keep the safety instructions in good order.
1.1 Keeping Your Work Area Orderly
Keep the area you work in orderly and tidy. If you do not have a proper
overview or if it is not orderly, this is in itself a potential cause for acci-
dents.
1.2 Paying Attention to Your Work
When working, monitor your actions and do not use the unit if you do
not feel perfectly well. Pay attention to what you are doing at all time.
1.3 Securing the Pieces to Be Welded
Use appropriate clamps to secure the fitting and the joint mechanically.
By doing so, you also have your hands free to control the welding unit.
1.4 Ensuring a Compatible Environment
Do not use the unit in a humid or wet environment or while it is raining.
Do not use it close to flammable materials, such as liquids and gases.
Avoid any contact with acids and other corrosive chemicals.
1.5 Cleaning the Welding Unit
The ROWELDROFUSE Sani 160 must not be sprayed with or immersed in
water. Use a dry piece of cloth to remove dirt from the unit.
1.6 Checking the Welding Unit for Damage
Each time before operating the welding unit, check safety features or
possibly existing parts with minor damage for proper function. Make sure
that the push-on connection terminals work properly, that contact is fully
established, and that the contact surfaces are clean. All parts have to be
installed correctly and properly conform to all conditions in order to be
sure the unit works as intended.
1.7 Repairing the Unit
Damaged safety features or functional parts should be properly repaired
or changed by a qualified after-sales service. Therefore, the unit must
never be repaired if not by a qualified and licensed specialist. Home-made
repairs are strictly prohibited, as they may put you at a high risk of danger.

ENGLISH 19
1.8 Opening the Unit
Do not remove the cover from the welding unit. It may be opened only by
specialized staff of Rothenberger or another, properly authorized partner
company.
1.9 Using Suitable Accessories
Use only approved and properly labelled accessories (e.g., extension ca-
bles).
1.10 Using Genuine Parts
On any rate, use only – if available – genuine and original accessories and
spare parts.
1.11 Using the Appropriate Unit
Make sure you use the unit that is appropriate for the intended work, and
weld only fittings that are intended for this kind of application. The weld-
ing unit is suited exclusively for indoor installation applications. Use for
buried pipeline construction applications is prohibited.
1.12 Unplugging the Power Supply Cord
To avoid unnecessary risk, unplug the power supply cord from the mains
socket when the unit is not used.
1.13 Storing the Welding Unit Safely
Store the unit in a safe locale. Dry, lockable locales located at some height
are particularly suited, the more so if they are out of the reach of children.
1.14 Protecting Yourself from Electrocution
Connect the unit only to power supply socket equipped with an equip-
ment grounding contact. In an environment that is humid or otherwise at
risk of ground loops, the unit has to be operated with ground-leakage
circuit breaker (30 mA false intensity threshold).
1.15 Only Qualified Operators
The unit must be operated exclusively by properly trained specialized staff
or by trainees if supervised by a competent person entitled to train others.
Adolescents younger than 16 years of age may in no event be qualified to
operate the unit.
1.16 Avoiding Unwanted Start of Operation
Make sure that the unit is switched off before connecting it to the power
supply. Carry it in such a way the none of the two buttons can be pressed
inadvertently.

20 ENGLISH
1.17 Improper Use of the Welding and Power Supply Cables
Do not carry the ROWELDROFUSE Sani 160 by its cord and do not pull
the cord to unplug the unit from the socket. Protect cord and cables from
heat, oil, and cutting edges.
1.18 Mains Power Supply
EVU wiring regulations, VDE provisions, regulations for prevention of
accidents, DIN / CE regulations, and applicable national codes have to be
respected. Mains power fuse protection should be max. 10 A. Power sup-
ply to the unit has to be connected through a leakage current switch
(earth-leakage circuit breaker rated at 30 mA false intensity).
1.19 Protecting Yourself from High Temperatures in the Fitting
Caution! Be careful not to touch the fitting being welded or its immedi-
ate vicinity while welding is in progress and after it was finished. Tem-
peratures in these pieces may be as high as up to 200 °C.
1.20 Protecting Yourself from the Electrical Voltage in the Fit-
ting
Caution! The voltage at the contact terminals of the fitting may be as
high as up to 230 V during welding. Therefore, ensure at all times that
neither the terminals nor the welding cables of the fitting are defective.
While welding, never touch the contact terminals and their vicinity, and
never remove the welding cable before having completely finished the
welding process.
1.21 Keeping Pipes and Fittings Dry
Never weld a fitting or pipes that are wet or filled with water.

ENGLISH 21
2Service and Repair
As the unit is used in applications that are sensitive to safety considera-
tions, it may be serviced and repaired only on our premises or by partners
who were specifically trained and authorized by us. Thus, constantly high
standards of operation quality and safety are maintained.
IMPORTANT!
Non-compliance with this provision will dispense the manufacturer from
any warranty and liability claims for the unit and any consequential dam-
age.
When serviced, the unit is automatically upgraded to the technical specifi-
cations with which the product is currently shipped, and we grant a three-
month functional warranty on the serviced unit.
We recommend having the device serviced at least every twelve months.
In Germany, keep in mind the follow-up check under BGV A2!
Transport, Storage, Shipment
The ROWELDROFUSE Sani 160 is shipped in a cardboard box. Store the
ROWELDROFUSE Sani 160 in the box dry and protected from humidity.
When shipped, the welding unit should be placed into the box at any
time.
3Principle of Operation
The ROWELDROFUSE Sani 160 allows joining with electrofusion fittings,
discharge lines made of PE / PP and routed indoor, of the following makes:
Geberit, Akatherm-Euro, Coes, Valsir, Wavinduo, and Vulcathene-Euro.
The microprocessor-controlled welding unit ROWELDROFUSE Sani 160
- controls and monitors the welding process in a fully automated
fashion,
- determines welding duration depending on the ambient tempera-
ture,
- shows all information with three LEDs and a seven-segment display
screen.
Further Optional Accessories
- Transport Case
- Handheld Scraper

22 ENGLISH
4Operation
4.1 General Information on the Applied Procedure
Electrofusion welding is characterized by thermal fusion of the outer
surface of the pipe and the inner surface of the weld fitting by heating
the heater coil incorporated into the fitting. In this process, the weld
fitting shrinks and thereby creates the contact pressure needed to carry
out the fusion of pipe and fitting surfaces. The automatic welding unit
provides the electrical energy needed to perform this and control the
energy supply according to certain parameters, such as ambient tempera-
ture.
4.2 Preparing the Welding Process
In all cases, the relevant information supplied by the manufacturer of the
pipes and the fittings have to be respected. First, both pipe butt have to
be cut at right angles and level using appropriate tools. Then, using a
chamfering and peeling tool or a handheld scraper, chamfer the edge and
smoothen the pipe surface up to the length it will be inserted into the
fitting. Then, the weld surface that is achieved by this process has to be
de-fatted using an appropriate solvent (non-fibrous paper, spirit or suit-
able alcohol). Make sure nobody touches the cleansed surface and secure
pipe and fitting for the welding operation.
4.3 Turning the Welding Unit On
After connecting the power supply cord to 230V mains power, turn the
welding unit on using the main switch. The unit then performs an auto-
test. All three LEDs are on briefly simultaneously to indicate that the unit
is ready for operation. Furthermore, the seven-segment characters show
the welding mode H0 for approximately 1 second. After this, both the
LEDs and the screen characters change back to off.
4.4 Connecting the Electro fusion Fitting
Connect the connection terminals to the fitting and check for proper
contact. The contact surfaces of the connection terminals and the fitting
have to be clean. Dirty contacts may lead to improper welding and also to
overheated and fused connection terminals.
After the fitting was connected, the yellow LED (Fitting connected) is on.
At the same time, the screen displays the welding time. By pressing the
START key, the welding process can now be started.
The welding time is counted down from about 80 s. To determine the
welding duration that will be needed, the ambient temperature is taken
into consideration to some extent, which may result in a welding time
slightly longer or shorter than 80 s.
H0
80

ENGLISH 23
4.5 Welding Process
The welding process is monitored for its entire duration applying the
welding parameters computed for the fitting.
4.6 End of Welding
The welding process was completed successfully if the actual welding time
shown on the screen is 0, the green LED (End) is on, and at the same time
the audible signal can be heard twice.
4.7 Welding Aborted
The welding process has caused errors if the red LED (Fault) is on and the
audible signal buzzes intermittently. Additionally, an error code is dis-
played on the screen.
An error has to be reacted to by pressing the STOP key.
4.8 Cooling Time
The cooling time as given in the fitting manufacturer’s instructions has to
be respected. Note that during that time, no external forces must be
applied to the pipe fitting joint which is still warm.
4.9 Returning to the Start of Welding
After welding is finished, disconnecting the welded fitting from the weld-
ing unit will cause the unit to return to the start of welding. An additional
safety feature prevents a given electro fusion fitting from being welded
twice inadvertently: after a properly completed or an aborted welding
operation, the welding unit first has to be disconnected from the fitting
to be ready for the next welding.

24 ENGLISH
5Self-Monitoring Functions Overview
5.1 System Error
CAUTION!
The welding unit has to be disconnected immediately from the power
supply and the fitting. The auto-test has found an error in the system. The
unit must no longer be operated and has to be turned in for check and
repair.
5.2 Power Supply Failure
The last welding is incomplete. The welding unit was disconnected from
the power supply. This error has to be acknowledged by pressing the
STOP key.
5.3 No Contact
There is no properly established electric contact between the welding unit
and the fitting (check push-on terminal on fitting), or the heater coil is
defective.
5.4 Low Voltage
The input voltage is below 180 V. Adjust generator output voltage.
5.5 Overvoltage
The input voltage is above 280 V. Adjust generator output voltage.
5.6 Temperature Error or Temperature Sensor Defective
The measured ambient temperature is outside the operating range of the
welding unit, i.e., below – 5 °C or over + 40 °C.
If this error is displayed during the unit’s auto-test, the temperature sen-
sor is defective.
5.7 Frequency Error
The frequency of the input voltage is out of tolerance (40 Hz - 70 Hz).
5.8 Low or Excess Current
The message is displayed if the there is a momentary current failure or if
the current regulator is defective.
5.9 Emergency Off
The welding process has been interrupted by pressing the STOP key.
E2
E3
E4
E5
E6
E7
E0
E8
E1

ENGLISH 25
5.10 Fitting Already Welded
After welding was finished, the fitting was not disconnected from the
welding unit, and the user attempted to weld the same fitting a second
time. E9

26 ENGLISH
6Troubleshooting
6.1 Nothing happens after unit was turned on, it does not
execute the auto-test
Possible causes:
· The unit is not connected to a mains power outlet.
· The switch is defective.
· The power supply line is faulty.
· The unit is defective.
· There is a general problem with the power supply.
6.2 After connecting the fitting, the yellow check LED does not
light up, welding is impossible
Possible causes:
· The contact terminals are not properly connected.
· The contact terminals are dirty.
· The welding cable is faulty.
· The weld fitting is defective.
· The weld fitting is unsuitable.
· The unit is defective.

ENGLISH 27
7ROWELD® ROFUSE Sani 160 Technical Speci-
fications
Nominal Voltage 230 V
Frequency 40 Hz - 70 Hz
Power 1200 VA, 80 % ED
Protection Index IP 44
Primary Current max. 10 A
Ambient Temperature – 5 °C to + 40 °C
Max. Output Current 5 A
Measuring Tolerance:
Temperature ± 5 %
Curent ± 2 %
Unit Dimensions L = 120 mm, W = 160 mm, H = 77 mm
Welding Cable Length 3 m
Power Supply Cord Length 2.5 m

28 ENGLISH
8Service and Repair Contact
ROTHENBERGER Werkzeuge Productions GmbH
Lilienthalstrasse 71 - 87 Phone: [phone]
D 37235 Hess. Lichtenau Fax: [phone]
Germany Web: www.rothenberger.com
9Accessories and Spares for ROWELD® RO-
FUSE Sani 160
Aluminium Carrying Case
ROWELD®ROFUSE Sani 160 User’s Manual
Manual Scraper
10 Disposal
Parts of the machine are reusable materials and can be recycled. Ap-
proved and certified recycling companies are available for this. For the
environmentally friendly disposal of the non-recyclable parts (e.g. elec-
tronic scrap) please ask your responsible waste authority.