APOLLO 160 Universal Electrofusion Welding Machine

he APOLLO 160 universal electrofusion welding machine is built for installers who require consistent, safe and reliable fusion joints in demanding applications such as gas distribution, water supply systems and sprinkler fire-protection installations.

With 2500 W output power and a variable voltage range from 10 to 55 V AC (including the 39.5 V required by PP-R electrofusion fittings), the machine delivers stable performance across PP-R, HDPE and PP materials. An integrated memory capable of storing up to 3200 weld cycles enables traceable documentation, improving both quality control and compliance with project standards.

Complete Professional Kit

The APOLLO 160 is supplied with:

• The welding machine with power cable

• A rugged carrying bag

• A barcode scanner for automatic parameter entry

• A printer for instant weld documentation

• A scraper for proper surface preparation

This ensures operators have everything needed for professional electrofusion work in the field or workshop.

About Electrofusion Welding (Rewritten Educational Section)

Electrofusion welding is a joining method for thermoplastic pipe systems, most commonly used with HDPE, PP-R and PP. Instead of applying external heat, specially designed fittings contain embedded heating coils. When electrical current flows through these coils, the surrounding polymer softens and fuses, forming a strong, homogeneous, leak-resistant joint.

Because the process is controlled electronically, electrofusion provides uniform results and minimizes operator-dependent variability. This makes it suitable for installations where safety, durability and compliance are essential, including utilities and industrial systems.

Where Electrofusion Is Most Commonly Used

Electrofusion welding is widely applied across sectors that require dependable pipeline connections:

1. Drinking Water Networks

Forms clean, pressure-resistant joints that protect water quality.

2. Gas Distribution Systems

Creates sealed, high-integrity joints that reduce the risk of leaks.

3. Industrial Piping

Suitable for chemical transport thanks to excellent corrosion resistance.

4. Mining Operations

Withstands abrasion and heavy-duty conditions for slurry and water transport.

5. Wastewater and Sewer Systems

Prevents infiltration and exfiltration, ensuring system reliability.

6. Landfill Leachate Collection

Provides secure, long-term connections that protect soil and groundwater.

7. Irrigation Lines

Supports reliable water delivery in agricultural systems.

8. Geothermal Installations

Delivers leak-free loops for heating and cooling applications.

9. Aquaculture Systems

Ensures safe water flow in fish farms and water recirculation systems.

10. Pipe Rehabilitation

Suitable for repairing existing pipelines without full replacement.

11. Renewable Energy Infrastructure

Supports fluid transport in solar thermal and other energy systems.

Benefits of Electrofusion Welding

• Produces strong, uniform, repeatable joints

• Resistant to corrosion and chemical degradation

• Suitable for a wide range of pipe diameters and wall thicknesses

• Requires no solvents or mechanical couplings

• Less dependent on operator skill compared to other welding methods

• Supports complete traceability when used with data-logging machines such as APOLLO 160

To ensure consistently high-quality results, operators should follow training guidelines, use approved materials and adhere strictly to manufacturer instructions.

Equipment Requirements (Rewritten & Integrated)

A professional electrofusion setup generally includes:

• Electrofusion welding machine with clamps and electronic control (APOLLO 160)

• Electrofusion fittings with embedded heating wires

• Scanner for importing fusion parameters

• Scrapers and rounding tools for pipe preparation

• Calipers and measurement gauges for alignment

• Marker for reference markings

• Stable power supply or generator

• Personal protective equipment (gloves, goggles, protective clothing)

• Documentation system for weld records

• Cooling timer for controlled joint solidification

• Ventilation equipment when working in enclosed areas

• Repair kit with spare parts or fuses

• Transport equipment such as trolleys or lifting tools for large pipes

The APOLLO 160 package covers most of these needs straight out of the box.

Electrofusion Welding Procedure (Rewritten Overview)

A typical welding sequence involves:

1. Preparation
   Pipes and fittings are cleaned, scraped and marked to ensure correct insertion depth and alignment.

2. Fitting Placement
   Electrofusion fittings containing heating wires are positioned on the pipe ends.

3. Clamping
   Pipes are held securely to avoid movement during heating and cooling.

4. Fusion Cycle
   The welding machine sends a controlled electrical current into the fitting’s coils, melting the surrounding polymer.

5. Material Fusion
   Molten material from the fitting and the pipe intermix, creating a uniform molecular bond.

6. Cooling Phase
   The joint is left untouched until fully solidified to achieve maximum strength.

7. Inspection
   The weld is checked visually and dimensionally for uniformity.

8. Data Logging
   Machines like the APOLLO 160 store weld parameters for traceability and quality assurance.