FRIATEC FRIAMAT User manual

37
Operating Instructions
FRIAMAT®Fusion Units
Technical Equipment FRIALEN®/FRIAFIT®

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Contents Page
1. SAFETY 4
1.1 Dangers 4
1.2 Safety hints and tips 4
1.3 Use in accordance with the requirements 5
1.4 Sources of Danger 6
1.5 Permitted users 6
1.6 Dangers from electrical power 6
1.7 Emissions 7
1.8 Safety precautions on site 8
1.9 Signal equipment 8
1.10 Emergencies 8
2. TECHNICAL DATA / TRANSPORT / COMMISSIONING 9
2.1 Technical data 9
2.2 Transport / storage / despatch 10
2.3 Setting up / connection 10
2.4 Putting into service 10
3. BASIC SETTINGS 11
3.1 Explanation of the function buttons 11
3.2 Date and time 12
3.3 Setting the signal volume 12
3.4 Setting the language 13
4. OPERATION 14
4.1 Construction / components 14
4.2 Functional principles 14
4.3 Fusion operating procedure 14
4.4 Preparation 14
4.5 Reading in the bar code 15
4.6 Starting the fusion process 16
4.7 Display voltage and frequency 17

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5. AUXILIARY FUNCTION (ONLY FOR DOCUMENTATION UNITS) 18
5.1 Documentation 18
5.1.1 Switching on 18
5.1.2 Switching off 18
5.2 Operator’s Pass 19
5.3 Commission Numbers 20
5.3.1 Specifying and saving a commission number 20
5.3.2 Selecting saved commission numbers 21
5.3.3 Deleting saved commission numbers 21
5.3.4 Altering currently set (activated) commission numbers 22
5.3.5 Deactivating commission numbers 22
5.4 Info-text 22
5.5 Fusion Report 23
5.5.1 Print / delete the whole content of the memory 23
5.5.2 Printing out and deleting individual commission numbers 24
5.5.3 Deleting data without printing out the logs. 25
6. MAINTENANCE / TAKING OUT OF SERVICE 25
6.1 Warranty 25
6.2 Care and Maintenance instructions 25
6.3 Checking the reader wand 26
6.4 Taking out of service 26
7. OPERATING FAULTS 26
7.1 Faults when reading in the bar code 26
7.2 Emergency Input 26
7.3 Overheating 27
7.4 Fusion interruption 27
7.5 Fault messages / Warning messages 28
8. APPENDIX 30
8.1 Recommended accessories (options) 30
8.2 Authorised Service Centres world-wide 31

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1. Safety
1.1 Dangers
The fusion units of the FRIAMAT®Family are constructed using state of the
art technology and in accordance with recognised safety rules, and are fitted
with the appropriate protective equipment. In addition to this the fusion units
of the FRIAMAT®Family are entitled to carry the TÜV GS Test Symbol as a
result of tests in line with the German Equipment Safety Law.
The fusion units of the FRIAMAT®Family have been checked for function and
for safety before being delivered. Incorrect operation or misuse, however,
can mean potential danger to
- the health of the operator,
- your FRIAMAT®model or other property of the user,
- the efficient operation of your FRIAMAT®model
All personnel who are in any way involved with the commissioning, operation,
maintenance or repair of the FRIAMAT®must
- be suitably qualified and
- comply precisely with these operating instructions.
This affects YOUR safety !
1.2 Safety hints and tips
This operating instruction employs the following SYMBOLS with WARNING
NOTES:
DANGER ! Describes an impending threat of danger !
Non-compliance with this instruction can result in severe damage to health
and property.
WARNING ! Describes a dangerous situation !
Non-compliance with this instruction can cause slight injuries or damage to
property
IMPORTANT ! Designates user tips and other useful information

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1.3 Use in accordance with the requirements
The fusion units of the FRIAMAT®Family are exclusively for use in the fusion
of
- FRIALEN Safety Fittings with HD-PE pressure pipes (SDR 17-7)
and
- FRIAFIT Sewage Fittings with HD-PE sewage pipes (SDR 17 - 32)
Your FRIAMAT®model can also be used with fittings from other manufacturers
as long as they have been provided by the manufacturer with a bar code 2/5
interleaved to ANSI HM 10.8 M - 1983 or ISO CD 13950/08.94.
Using in according with the requirements also includes observing
- all the directions in this Operating Instruction and also
- the guidelines from the DVGW Code of Practice, from the DVS, the UVV
and the appropriate national and local regulations.
IMPORTANT ! Any other usage does not comply with the requirements !
FRIATEC AG accepts no liability for use which does not comply with the
requirements:
- Modifications or alterations are not permitted for safety reasons
- The fusion units of the FRIAMAT®Family must only be opened by an
electrical specialist
- Fusion with fusion units of the FRIAMAT®Family whose lead seals are
broken will render all claims for warranty and liability null and void.
Other examples of uses which contravene the requirements:
- use as a battery charger
- use as a power supply for heaters of any type

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1.4 Sources of Danger
- Damaged connection leads and extension cables must be replaced
immediately
- Do not either remove safety devices or put them out of action
- Eliminate known faults immediately
- Do not leave your FRIAMAT®model unattended
- Keep away from flammable liquids / gases
- Do not operate in an Ex-environment
1.5 Permitted users
Only trained personnel may work with your FRIAMAT®model. The operator is
responsible for third parties in the working area The user must:
- make the operating instruction available to the operator and
- satisfy himself that the latter has read and understood them
1.6 Dangers from electrical power
- Do not use any damaged connecting cables
- Check the connection leads for damage
- Pull out the power supply plug before all care and maintenance work !
- Only have servicing, maintenance and repairs carried out by authorised
service centres
- Only connect the fusion units of the FRIAMAT®Family to the supply
voltage stated on the rating plate
WARNING ! Distribution points on the construction site: Comply with
the regulations on circuit breakers
Outdoors (on construction sites) sockets must be fitted with earth leakage
circuit breakers. If using generators the DVGW Work Sheet GW 308 and
VDE 0100 Part 728 must be complied with. The generator output rating
required is dependent on the power requirements for the largest fitting being
used, on connection conditions, ambient conditions and the actual generator
type (its control characteristics). Since generators from different model ranges
exhibit very different control characteristics the suitability of a generator
cannot always be guaranteed by the specified rated output alone.

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In the event of doubt (e.g. when purchasing new) ask the authorised service
centre or request the “Positive Generator List” from FRIATEC AG.
Only use generators whose operating frequency lies within the range from
45 - 66 Hz.
First start the generator and let it run for half a minute. Set the off-load voltage
if necessary and limit it to the voltage specified in the technical data. !
Generator (mains) fuse max. 16 A (slow acting)
IMPORTANT ! Before starting the fusion process always check the input
voltage for your FRIAMAT®model from the Technical
Data (See Section 2.1 and 4.7)
If using an extension cable make sure the cross section is adequate:
- 2.5 mm2up to 50 m and
-4mm
2up to 100 m length.
Always unroll the cable fully before use. ! Do not connect any other equipment
to the same generator whilst fusion is taking place ! At the end of the fusion
operation first disconnect the power cable to the generator and then shut off
the generator.
DANGER ! Risk to life ! Never open your FRIAMAT®model whilst it is
connected to the power supply !
The fusion units of the FRIAMAT®Family are must only be opened by
specialist personnel from a recognised service centre !
1.7 Emissions
The (equivalent) continuous noise level from all fusion units of the FRIAMAT®
Family is below 70 dB(A). When working in a quiet environment the effect of
the signal tone on the “Loud” setting is very loud. For this reason the signal
tone is adjustable (loud / quiet)

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1.8 Safety precautions on site
IMPORTANT ! All the fusion units of the FRIAMAT®Family are splash
proofed. They must not be, however, dipped in water.
1.9 Signal equipment
The fusion units of the FRIAMAT®Family confirm certain operating processes
with an acoustic signal tone (1, 2, 5 tones or a continuous tone). These
signals have the following meanings:
Signal tone x 1 means: Confirmation of reading in a bar code
Signal tone x 2 means: Fusion process ended.
Signal tone x 3 means: Supply voltage too low / too high.
Signal tone x 5 means: Warning - Fault. Look at the display !
1.10 Emergencies
In an emergency switch the master switch to “OFF” immediately and
disconnect your FRIAMAT®model from the power supply ! The fusion units of
the FRIAMAT®Family can be stopped by:
- operating the master switch
- pulling out the power supply plug

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2. Technical data / Transport / Commissioning
2.1 Technical data
FRIAMAT
®
FRIAMAT
®
E FRIAMAT
®
L FRIAMAT
®
LE
Input voltage range AC 200 V.-. 260 V AC 200 V.-. 260 V AC 200 V.-. 260 V AC 200 V.-. 260 V
Frequency range 44 Hz... 66 Hz 44 Hz... 66 Hz 44 Hz... 66 Hz 44 Hz... 66 Hz
Current consumption AC 16 A max. AC 16 A max. AC 16 A max. AC 16 A max.
Power 3.5 kW 3.5 kW 3.0 kW 3.0 kW
Generator rated output 1~
d20 - d160 AC 2.4 kW AC 2.4 kW AC 2.4 kW * AC 2.4 kW *
d180 - d630 AC 4.0 kW AC 4.0 kW
(mechanical governor)
d180 - d630 AC 4.0 kW AC 5.0 kW
(electronic governor)
Equipment fuse 16 A slow acting 16 A slow acting 16 A slow acting 16 A slow acting
Casing Enclosure class Enclosure class Enclosure class Enclosure class
IP 54 DIN 40 050 IP 54 DIN 40 050 IP 54 DIN 40 050 IP 54 DIN 40 050
Protection class I Protection class I Protection class I Protection class I
DIN 57 700 DIN 57 700 DIN 57 700 DIN 57 700
Connection cable 5 m with 5 m with 5 m with 5 m with
contoured plug contoured plug contoured plug contoured plug
Fusion cable 4 m with Ø 4 mm 4 m with Ø 4 mm 4 m with Ø 4 mm 4 m with Ø 4 mm
fittings plug fittings plug fittings plug fittings plug
Bar code Code 2/5 Code 2/5 Code 2/5 Code 2/5
interleaved to interleaved to interleaved to interleaved to
ANSI HM 10.8M - ANSI HM 10.8M - ANSI HM 10.8M - ANSI HM 10.8M -
1983, ISO CD 1983, ISO CD 1983, ISO CD 1983, ISO CD
13950/08.94 13950/08.94 13950/08.94 13950/08.94
Working temperature range -20 °C ... +50 °C** -20 °C ... +50 °C** -20 °C ... +50 °C** -20 °C ... +50 °C**
Fusion current monitoring Short circuit 110 A Short circuit 110 A Short circuit 110 A Short circuit 110 A
Open circuit Open circuit Open circuit Open circuit
0.25 x I
N
0.25 x I
N
0.25 x I
N
0.25 x I
N
Printer interface Parallel - Parallel -
(D-Sub 25) (D-Sub 25)
Fusion voltage max. AC 48 V max. AC 48 V max. AC 48 V max. AC 48 V
Dimensions 370x280x480 mm 370x280x480 mm 350x260x450 mm 350x260x450 mm
W x D x H
Weight 19 kg 19 kg 14 kg 14 kg
Weight with transport box 23 kg 23 kg 18 kg 18 kg
*: The FRIAMAT®L / LE is only suitable for domestic connections and distribution pipes up to
d110, plus saddle components of all sizes
** : When fusing fittings from other manufacturers always take heed of the details given on the
working temperature range.

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2.2 Transport / storage / despatch
Your FRIAMAT®model is delivered in a transport box. There are no particular
requirements for unpacking, or for (temporary) storage in the transport box.
Storage temperature - 20 °C to + 70 °C
WARNING ! Do not damage the front face of your FRIAMAT®model !
Always despatch in the transport box.
2.3 Setting up / connection
If protected from rain and wet your FRIAMAT®model can be set up and
operated out of doors.
- Set up the FRIAMAT®on level ground (as near horizontal as possible).
- Ensure that generator is fused with a 16 A minimum (slow acting) fuse.
- Plug the mains plug into the mains socket or connect to the generator.
- If necessary use an extension cable, ensuring that the cross section is
adequate (see section 2.1 “Technical Data”).
- Always comply with the operating instructions for the generator.
WARNING ! Always unroll the cable before use
2.4 Putting into service
WARNING ! Charring ! Dirty contacts can char the plug.
The contact surfaces of the fitting and the fusion plug must always be clean.
- Remove any existing deposits thoroughly
- Protect the plug from contamination, replacing it if necessary
- Check the fusion plugs and contact sockets on the fitting for dirt, and only
then make the connection

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3. Basic Settings
3.1 Explanation of the function buttons
The fusion units of the FRIAMAT®Family have 6 function buttons. Please take
note of the diagram below and the basic explanation of the buttons,
START: The START button is green in colour. It is used to start a fusion
process, to confirm messages and to call up / select menu functions.
The START button also moves the cursor in the display to the left
when entering characters (e.g. entering notes, date).
STOP: The STOP button is red in colour. It is used to cancel a fusion
process, in some menus to select menu functions and generally to
end menu functions. The STOP button also moves the cursor in the
display to the right when entering characters (e.g. entering notes,
date).
INFO: The INFO button is yellow or grey in colour depending on the
model. It is used to call up current information (voltage / frequency,
date / time, ambient temperature, fusion operator, language) or to
scroll through the individual menus. When entering characters (e.g.
entering notes, date) the setting of the required character is made
with the INFO button.
SET: The SET button is grey in colour. It is used to save settings.
MENU: The MENU button is yellow or grey in colour depending on the
model. It is used to call up the main menu and to scroll through the
individual menus. When entering characters (e.g. entering notes,
date) the setting of the required character is made with the MENU
button.
RES: The RES button is grey in colour. It is used to cancel an input
process.
START STOPINFO
SET RESMENU

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3.2 Date and time
There are two ways of setting date and time.
1. Through the main menu:
Go into the main menu by pressing the MENU button. Now press the
MENU button as many times as it takes for the “Set Date / Time” setting
menu to appear in the display. To set the date / time press the START
button. “FRIAMAT” and the designation of your model will appear in the
top line of the display, whilst the date and time will appear in the bottom
line. The first character will flash. With the INFO / MENU button you can
move one day forward / back. With the START / STOP button you can
move left or right. With the SET button you can confirm and save the new
Date / Time, and with the RES button you can break off without saving.
After pressing the SET or RES button, press the STOP button at the end to
cancel the menu selection.
2. Reading in the TIMER bar code
“FRIAMAT” and the designation of your model will appear in the top line of
the display, whilst the date and time will appear in the bottom line. The first
character (Day) will flash. With the INFO / MENU button you can move one
day forward / back. With the START / STOP button you can move left or
right. With the SET button you can confirm and save the new Date / Time,
and with the RES button you can break off without saving.
FRIAMAT
01.Jul 1999 14:34
3.3 Setting the signal volume
Go into the main menu by pressing the MENU button. Now press the MENU
button as many times as it takes for the “Signal Volume” setting menu to
appear in the display. To set the signal volume press the START button.
“Signal Volume” will appear in the top line of the display, whilst “loud” will
appear on the left in the bottom line and “quiet” on the right. By pressing the
START / STOP button you can adjust the signal volume to loud / quiet. Press
the STOP button at the end to cancel the menu selection.

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3.4 Setting the language
Go into the main menu by pressing the MENU button. Now press the MENU
button as many times as it takes for the “*Language *” setting menu to
appear in the display (Meaning of the star : See IMPORTANT note in this
section). To set the language press the START button. “*Language *” will
appear in the top line of the display, whilst the actual language set will appear
in the bottom line. Two stars will flash on the right and left to show that you
are in the language setting menu. To change the language select the language
you require with the INFO / MENU button. Press the SET button to end and
save the settings. You can press the RES button to end without saving. Press
the STOP button at the end to end the menu selection.
Signal volume
loud quiet
IMPORTANT ! The setting of the language only refers to the one shown
in the display. The language of the documentation
(Report) remains English
IMPORTANT ! In the language setting menu two stars appear, left and
right, in the upper line. These are used to allow the
language setting menu to be recognised when for
example the language has accidentally been set wrongly.
* Language *
* German *
* Language *
yes continue End
Signal volume
yes continue End

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4. Operation
4.1 Construction / components
The electronics in your FRIAMAT®model are housed in a splash-proof
casing. The carrying frame is also used to hold the cables. The fusion units of
the FRIAMAT®Family are designed for a maximum fusion voltage of 48 V. The
supply and fusion voltage are isolated from each other by a safety transformer.
4.2 Functional principles
Only electrofusion fittings with a bar code can be fused with the fusion units
of the FRIAMAT®Family : Each fitting is assigned a sticker with a bar code.
This contains the information to ensure that fusion is carried out properly. The
computerised command system of your FRIAMAT®model:
- is completely automatic in regulating and checking the metering of the
electrical power
- determines the fusion time depending on the ambient temperature. The
temperature probe in the fusion cable continuously determines the ambient
temperature.
4.3 Fusion operating procedure
So that the FRIALEN Safety Fittings and the FRIAFIT Sewage Fittings will be
properly processed it is essential to adhere to the FRIALEN operating
instructions.
The same applies to fittings from other manufacturers.
4.4 Preparation
IMPORTANT ! Unroll the cable completely !
This applies to mains, fusion and, if applicable, extension
leads. The contact surfaces of the fitting and of the
fusion plugs must be clean; dirty contacts can cause
overheating and charring of the plug. If necessary remove
any existing deposits cleanly

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Always protect the plug from contamination. If there is a
deposit which cannot be completely removed, the fusion
plugs must be replaced.
- Prepare the fitting and pipes for fusion in accordance with the assembly
instructions
- Ensure that the contact pins on the fitting are accessible for connection of
the fusion plugs
- Connect up the power supply (mains or generator)
- If using a generator start it up first and allow to warm up for 30 seconds
- Switch on the master switch (1)
- Connect the fusion plugs to the contact pins on the fitting
4.5 Reading in the bar code
IMPORTANT ! It is not acceptable to read in the bar code label from
another sort of fitting instead. After ending the read-in
process the reader wand must be replaced in the reader
wand pouch immediately to avoid damage and contami-
nation to the tip of the wand.
If there is a bar code label stuck onto the fitting this should always be used.
If the bar code label on the fitting being fused is illegible due to damage,
an identical fitting from the same manufacturer with a legible bar code
label should be used.
Hold the reader wand slightly slanting and slightly inclined (like a pencil) and
place it on the fitting in front of the bar code. Now move the reader wand
quickly across the whole label and a little beyond. The reading can be done
from left to right or from right to left. When this has been done correctly the
machine will confirm it with a signal tone. If the reading in is not successful
first time try again, if necessary at a different angle or speed.

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4.6 Starting the fusion process
IMPORTANT ! If there is a malfunction in the fusion process hot molten
PE can be expelled in rare cases.
So:
Keep at a safe distance of at least 1 m from the fusion
point during the fusion process ! Do not connect any
other equipment during the fusion process !
The fusion process can be broken off at any time by pressing the STOP
button. When the fused area has cooled down (and the source of the fault
eliminated if necessary) the fusion process can be repeated (depending on
the fitting manufacturer; please comply with the instructions for use from the
fitting manufacturer in question).
Operating steps: (see also the visual representation on the next page):
1. Press the START button to initiate the fusion process
2. If applicable confirm the display “Pipe processed ?” with the START
button. Next there will be an automatic display of the ambient temperature
and a resistance check on the connected fitting. The fusion process will
start. In the display you can follow the duration of the fusion process (the
complete fusion time will be displayed and counted down to zero in
seconds).
3. Display “End of fusion” means: fusion process finished, ready for the next
fusion. The displays “t:” and “tc:” mean required and actual fusion time
and these must agree.
4. Make a note of the fusion parameters onto the pipe / fitting. This will also
avoid fusing twice
5. To initiate a new fusion process press the START button.

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4.7 Display voltage and frequency
Before or after the fusion: To display the voltage and frequency press the
INFO button. The STOP button will take you back to the basic setting.
During fusion: Pressing the INFO button will display the voltage and frequency,
after 3 seconds the unit will automatically go back to the basic setting.
WARNING ! Your FRIAMAT®model is designed for an input voltage
range of 200 - 260 volts. If you are working in the range
from 150 - 200 volts or 260 - 320 volts the actual voltage
and frequency will automatically appear on the display.
You can ignore this warning note by pressing the STOP
button and carry on working but there is a risk that
you will damage the electronics of your FRIAMAT®model.
If the input voltage range is under 150 volts or above
320 volts the actual voltage and frequency will likewise
appear on the display. In this case, however, the warning
indication will remain until you have regulated the input
voltage back into the recommended range and have
acknowledged with the STOP button.
Voltage: 221.3 V
Frequency: 50.01 Hz
End of fusion
t: 53 s tc: 53 s
FRIA MON 63 mm
Pipe processed ?
FRIA MON 63 mm
START Infotext

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5. Auxiliary function (only for documentation units)
5.1 Documentation
Your FRIAMAT®model is supplied with the documentation deactivated
(switched off). The “Documentation” function is used to save the technical
fusion parameters. These can in each case be assigned to a commission
number and/or to an operator pass.
5.1.1 Switching on
This function is activated or deactivated by reading in a DOCUMENTATION
bar code (see plastic card in the accessories pouch). When the function is
activated the display will show the sequential number on the left and the
number of fusions which can still be stored on the right (and if applicable,
above these the appropriate commission number.)
5.1.2 Switching off
The DOCUMENTATION function can be deactivated by reading in the
DOCUMENTATION bar code again. The safety question of whether this is
required can be acknowledged by pressing the START button or rejected by
pressing the STOP button (breaking off with the STOP button will bring about
a return to the previous state).
FRIAMAT
2➔Code 499
Switch off
documentation ?

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5.2 Operator’s Pass
IMPORTANT ! The operator pass can only be read in with the documen-
tation switched on
Your FRIAMAT®model can be set for use with an operator pass by reading in
the bar code from an operator pass. The operator pass can be ordered from
FRIATEC. When a user code has been read in for the first time all fusions
which are then carried out will be saved under the code for this operator
pass. If another operator pass is read in your FRIAMAT®model will be
switched over to suit.
Your FRIAMAT®model can be cleared for use without an operator pass by
reading in the USER OFF bar code (see plastic card in the accessories
pouch). The question “Deactivate operator?” then appears. This can be
confirmed by pressing the START button or the process can be broken off by
pressing the STOP button.
IMPORTANT ! By means of the operator pass your FRIAMAT®model
can be blocked to protect it from unauthorised use. .
After reading in the current operator pass again the
query will appear “Block the unit?”. This can be confirmed
by pressing the START button or the process can be
broken off by pressing the STOP button. Your FRIAMAT®
model will be automatically blocked when the code for an
operator pass is on file and time-wise a change of date
takes place i.e. your FRIAMAT®model will be blocked on
the next day.
Deactivate
operator ?
Block the
unit ?
Read in
operator

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In both cases (manual or automatic blocking) the note “Read in Operator” will
appear in the display. Your FRIAMAT®model can be cleared for use by
reading in an operator pass
5.3 Commission Numbers
For simple administration of up to 20 different commission numbers your
FRIAMAT®model has a commission number specification menu.
5.3.1 Specifying and saving a commission number
Go into the main menu by pressing the MENU button. Now press the MENU
button as many times as it takes for the “commission no.” setting menu to
appear in the display. To get into the “Change/Specify commission nos.”
setting menu press the START button. By pressing the STOP button you will
go into the specification setting menu in which you can enter and save up to
20 commission nos. If you press the START button the current commission
no. will appear. The first character of the commission no. will flash. This can
be increased by pressing the INFO button or decreased by pressing the
MENU button. With the START / STOP button you can move left or right
within the commission no. With the SET button the commission no. set will be
saved and taken into the Specification Menu, and with the RES button you
can break off the process without saving.
Another method for getting into the “Change/Specify Commission Nos.”
setting menu is to read in the COMMISSION CODE (see plastic card in the
accessories pouch).
Commission No.
12 Dossenheimer Way
Commission No.
New Selection Delete
Commission No.
Change Specification