GF MSA 2.0 User manual

Instruction manual
Bedienungsanleitung
Manuel d‘utilisation
GF Piping Systems
MSA 2.0 /MSA 2.1
Polyvalent Electrofusion Units
MSA 2.0 /MSA 2.1
Polyvalentes Elektroschweissgerät
MSA 2.0/MSA 2.1
Unité d‘électrosoudage polyvalente

Operating Instructions MSA 2 General Information
1
Index
Page
I General Information 3
 Warning notice 3
1 Introduction 4
1.1 Product description 4
1.2 Components description 5
1.2.1 Operation Controls 5
1.2.2 Display 6
1.2.3 Ambient Temperature Sensor 6
1.2.4 USB Interface 6
1.2.5 Power Cable 6
1.2.6 Welding Cable 7
1.3 Barcode Reader Scanner 7
1.4 Extension Cables for Power Supply 7
1.5 START/STOP Card 8
2 Fusion process 9
2.1 Overview of operating procedure 9
2.2 Switching On 10
2.3 Connect fitting 10
2.4 Enter operator code/job number (MSA 2.1 only) 11
2.5 Enter fusion data 12
2.6 Preparation check (MSA 2.1 only) 13
2.7 Fusion process 14
2.7.1 Welding phase 14
2.7.2 Cooling time 15
2.8 Welding check 15
3 Configuration settings 16
4 Data Management 17
4.1 Protocol view 18
4.2 Protocol export (MSA 2.1 only) 19
5 Error messages 20
6 Technical characteristics 21
6.1 Standards 21
7 Maintenance 22
7.1 Cleaning 22
7.2 Fusion Cables 22
7.3 Function Check-up 22
7.4 Spare parts 22
8 Accident Prevention 23
8.1 Operating the Unit 23
8.2 Check before Operation 23
8.3
Protection of the Unit 23
8.4 Defect Unit 24
8.5 Opening the Unit 24

General Information Operating Instructions MSA 2
2
8.6
Wo
rking with safety in mind
24
8.7 Other disposal 24

Operating Instructions MSA 2 General Information
3
I General Information
Dear Customer,
Thank you for choosing this product. The electrofusion unit MSA
2.0 is designed according to newest technology. Using it for
purposes other than those described in this manual may cause
injury to the operator or to other people. It may also cause
damage of the machine or other equipments.
To prevent problems, the machine should only be used when in
perfect working conditions; following the safety instructions;
keeping on hand the technical documentation.
Anyway, the manufacturer reserves the right to make technical
changes to MSA 2.0 which may result in differences from the
pictures and information contained in this manual.
To point out relevant aspects operating this electrofusion unit,
symbols are frequently used. The following table contains their
explanation.
Warning notice
Warning notices are used to inform about possible injuries or
damage to properties. Please read carefully and always consider
these warnings!
Symbol
Meaning
Danger
Imminent danger!
Failure to comply could result in
death or extremely serious injuries.
Warning
Possible danger!
Failure to comply could result in serious injuries.
Caution
Dangerous situation!
Failure to comply could lead to injury or damage to
property.

Introduction Operating Instructions MSA 2
4
1 Introduction
1.1 Product description
The MSA 2.0 is an electrofusion control unit for the electrofusion
jointing of PE (PolyEthylene) and PP (PolyPropylene) pipes.
Fusion parameters input can be accomplished with a fusion
barcode according to ISO/TR 13950 standard or manually.
The internal processor controls the values of welding
parameters, set the power output accordingly and, thanks to the
messages shown in the graphical display, guides the operator
to successfully execute all the necessary operations.
In addition, the MSA 2.0 is tracking and storing in the internal
memory up to 350 welding protocols, (500 for MSA 2.1) that can
be browsed by the user even days or months after the welding
execution.
To ensure high quality fusion cycles, depending on the ambient
temperature, the machine is adjusting automatically the welding
time, for the correct distribution of the energy to the fitting.

Operating Instructions MSA 2 Introduction
5
1.2 Components description
1.2.1 Operation Controls
There are seven buttons the user can press to operate the
machine. START (green button) and STOP (red button) are the
most important, used to get a confirmation or a stop for all the
actions. The remaining (blue) are auxiliary buttons used for
menu navigation and data entry.
Button Description
()
Moves the cursor to previous field,
increases set values, scrolls characters
()
Moves the cursor to next field, decrement
set values, scrolls characters in reverse
order
()
Moves the cursor to the left
()
Moves the cursor to the right
MENU
Enters into additional menus
STOP/ESC
(O)
Stops any operation and the process; goes
back to previous step
START/OK (
I)
Confirms inserted data and starts welding

Introduction Operating Instructions MSA 2
6
1.2.2 Display
The graphical display is the main user interface of the welding
machine. It shows the steps to be executed in sequence, the
fusion data, possible errors and alarm messages.
It is possible to change its brightness using the andbuttons
and then save permanently the new value pressing the 
button, in case of limited visibility due to weather conditions. The
operation can be done only when the display shows the fitting
icon
1.2.3 Ambient Temperature Sensor
The outside sensor measures the ambient temperature, to check
the temperature is in the permitted range (between -20° C and
50° C) and adjust the fusion time according to the external
conditions.
1.2.4 USB Interface
The USB type-A interface available on the rear of the machine is
the interface used to upgrade the software version, perform the
calibration of the unit and (MSA 2.1 only) export the protocols.
The connector is protected against dust and water by a cap,
which ensures an IP67 protection factor when properly fixed.
1.2.5 Power Cable
The power cable is delivered with an earthed plug for being
connected to power supply at 230V/50Hz.
The power source can be either the mains or a generator. In the
latter case there are no deterministic rules to select the right
generator output power. Requirements will vary depending on
the efficiency of the generator as well as other factors, like the
power needed by the fitting.

Operating Instructions MSA 2 Introduction
7
1.2.6 Welding Cable
The fusion cable shall be connected to the fitting pins. As
standard the terminals are supplied with straight female
connectors, Ø4mm.
1.3 Barcode Reader Scanner
The barcode scanner allows a quick reading of welding
parameters by reading the related barcode, pointing the barcode
(at a distance of 10-15 cm) and pressing its button.
The successful reading is confirmed by special acoustic tones
and a display change. In case of drawbacks, to check if the
barcode reader is damaged, you can try to read for test purpose
the code printed below, when the machine shows the barcode
symbol.
If this code is read successfully, the issue is not on the barcode
reader. After usage, remember to place the barcode scanner
into its protective case.
1.4 Extension Cables for Power Supply
To avoid excessive dissipation or brown out, on Extension
cables, use cables with section:
•4mm² for cables ≤ 10m full-run;
•6mm² for cables ≤ 30m full-run.

Introduction Operating Instructions MSA 2
8
1.5 START/STOP Card
START / STOP card can be used as alternative to the buttons
on the keypad. For instance, you can confirm the commands or
start the welding process by scanning the START bar code on
the card.
The STOP barcode can be used instead to go back to the
previuos step.

Operating Instructions MSA 2 Fusion process
9
2 Fusion process
2.1 Overview of operating procedure
The welding workflow is shown in the picture below
t =
----
s
Vo= --.-V
R = --.--Ω
12/06/12 15:50 25°C
t =
----
s
Vo= --.-V
R = 07.45Ω
------
------
12/06/12 15:50 25°c
t = 0040s
Vo= 39.5V
R = 07.45Ω
12/06/12 15:50 25°C
t = 0020s
Vo= 39.7V
E = 003.1kJ
N 150
t = 0040s
Vo= 39.6 V
E = 007.5kJ
N 150
 = 10’
N 150
Prepare the
welding and
connect the fitting
Read the fusion
parameters
barcode
Start the fusion
Fusion in progress
Fusion completed
automatically
Cooling time

Fusion process Operating Instructions MSA 2
10
Next paragraphs describe step by step the interactions with the
electrofusion unit.
2.2 Switching On
Before connecting t e mac ine to t e power source, please read t e
c apter 6 ‘Tec nical c aracteristics‘ and c eck t e input voltage. If a
generator is used, t is as to be started before connecting t e electro-
fusion unit and must supply a constant output voltage! Any sudden
c anges could compromise t e correct welding result and/or damage
t e control unit.
Connect the machine to the power mains or generator when the
generator is already started. At power on the display shows the
machine information: machine type, software version and serial
number.
2.3 Connect fitting
The next step consists of connecting the fitting to the machine by
the operator. The MSA 2.0 asks this with a prolonged sound.
The LED of the barcode scanner blinks to inform the operator it
has to do it.
Awaiting for that, the display shows the icon of a fitting and the
information about ambient temperature and current date/time.
t =
--
--
s
Vo= --.-V
R = --.--Ω
12/06/12 15:50 25°C
Attention
MSA 2.0
V 2.06
S156A6308001

Operating Instructions MSA 2 Fusion process
11
As soon as a fitting presence is recognized, the MSA 2.0 moves
automatically forward, asking for the fusion parameters.
This is also pointed out by a double short tone of the MSA 2.0
and the barcode scanner. The scanner LED switches off too, to
alert the operator that it is ready to accept commands.
2.4 Enter operator code/job number (MSA 2.1 only)
At the beginning the user can add some work site information,
like the operator code and the job number for the next welding.
The reading of the operator code can be set as mandatory or left
optional.
When the leads are properly connected to the fitting, the control
unit checks the fitting resistance and displays it to the user.
In the MSA 2.1, before the acquisition of the fusion parameters,
the user can read with the scanner the operator badge (ISO
12176-3 compliant) and the job number.
t =
----
s
Vo= --.-V
R = 07.45Ω
------
------
12/06/12 15:50 25°C
The information will be shown above the barcode icon, in place
of the dash (‘-‘) symbols
t =
----
s
Vo= --.-V
R = 07.45Ω
JSMITH
A116…
12/06/12 15:50 25°C
In case the operator code is mandatory the first row ‘----‘ will
blink and the MSA 2.1 will not move forward, blocking the
acquisition of the fusion parameters.

Fusion process Operating Instructions MSA 2
12
2.5 Enter fusion data
After that, the user can insert the fusion parameters:
•Either reading the barcode information with the scanner,
•or, if the barcode cannot be read with a scanner for any
reason, entering manually fusion time and voltage by
pressing the START/OK ( I ) button to go in “edit” mode
and then using () and () to select the required digits
and () () to change field. Once the values are entered,
must be pushed START/OK ( I ).
At this stage, to ensure a reliable jointing, pipes and fitting have
to be already prepared: pipes must have been scraped, cleaned,
aligned following the instructions of the fitting manufacturers.
If fusion parameters are not acquired, there might be several
reasons:
•The barcode reader may be operated in a wrong way: try to
put it closer to the barcode
•The barcode may be damaged
•The data are not the expected ones (prolonged tone
generated by the machine): the barcode read does not
contain fusion parameters
As soon as the data are correctly read from the barcode, the
machine confirms with a double acoustic tone and show on the
display a summary of the captured fusion parameters: time,
voltage and expected coil resistance.
t = 0040s
Vo= 39.5V
R = 07.45Ω
12/06/12 15:50 25°C

Operating Instructions MSA 2 Fusion process
13
When the operator confirms his intent of starting the fusion
process, pressing the START/OK ( I ) button, the unit will start to
weld.
If the barcode is not correct the machine and the scanner give
both a prolonged tone to ask for the correct one. In case of
inconsistency between measured versus scanned parameters
the machine shows instead a message screen, with the proper
error like the following one (fitting resistance too high in respect
to the nominal value).
E
-
10

12/06/12 15:50 25°C
2.6 Preparation check (MSA 2.1 only)
Before starting the fusion process, the MSA 2.1 shows a
reminder to the operator, to ensure the preparation activities
have been properly carried out.
12/06/12 15:50 25°C
As soon as the operator confirms with the START/OK button, the
fusion process starts.

Fusion process Operating Instructions MSA 2
14
2.7 Fusion process
2.7.1 Welding phase
During the fusion process, the display shows the information
concerning the output voltage, the remaining fusion time and the
applied energy.
t = 0020s
Vo= 39.7V
E = 003.1kJ
N 150
T e mac ine adjusts t e fusion time according to t e external
temperature and barcode information. T erefore t e final fusion time
values mig t be slig tly different from t e nominal values, captured
from t e barcode.
The fusion process can be stopped at any time by the operator
by pushing STOP/ESC (O). Then the fusion process
immediately stops and an error message occurs (see ‘Error
Messages’ chapter).
Stopping t e on-going fusion process will result in a suspicious
welding: t e responsability will be in c arge of t e operator.
When the fusion operation is going to finish, a repeated acoustic
signal alerts the user that the process is near to complete. As soon
as the fusion process is correctly concluded, the display shows
briefly the information concerning the real fusion time, the average
voltage and the total energy applied to the jointing. These data will
be part of the welding protocol stored intothe internal memory.
t = 0040s
Vo= 39.6 V
E = 007.5kJ
N 150
Note
Warning

Operating Instructions MSA 2 Fusion process
15
2.7.2 Cooling time
After the completion of the process, the fusion summary and the
remaining cooling time, if defined in the barcode, are displayed
alternately. Messages are active till the user will press the
STOP/ESC (O) button, to proceed with the next welding.
 = 40’
N 150
Remove t e external clamp only w en t e cooling time is expired!
Danger of burning!
T e fitting area is ot! Pay attention during t e removal of t e cables.
When the cooling time is going to finish or finished, an acoustic
signal alerts the user the process is near to complete.
2.8 Welding check
The electro-fusion fittings are equipped with pins, giving evidence of
the heating process occurred: double check if they are sticking out.
T is indication is not enoug to ensure t e quality of t e welding, but
just confirming t e eating as occurred! T erefore please follow t e
instructions of t e fitting manufacturer.
Warning
Danger
Attention

Configuration settings Operating Instructions MSA 2
16
3 Configuration settings
The MSA 2.0/2.1 does not need any setting. Only possible
change is the date/time adjustment, to adapt to different time
zones.
To enter into this menu, press twice the MENU button. The
calendar menu allows date and time modification.
They are shown in the format: Day / Month / Year hour:minutes

:

13/06/12
17:46
MENU
START/OK ( I ) must be pressed to go in “edit mode”. Then the
desired values can be selected by ()()while the cursor
position can be changed by ()(). When insertion is
completed, press
START/OK ( I ) to confirm the setting. To cancel instead the
operation press STOP/ESC (O).
Since the MSA 2.0/2.1 has to be calibrated regulary, the user
can check in advance the expiring revision date. Just pressing
three times the MENU button the user can access such
information (mm/yy).

08/12
MENU

Operating Instructions MSA 2 Data Management
17
4 Data Management
The electro-fusion unit saves the welding protocols for each
fusion cycle in the internal memory. These data can be saved in
a PDF/BINARY file too (only for MSA 2.1).
When the memory is full, the oldest protocol is overwritten by the
most recent.
To conform to different standards, the welding machine saves
(and provides for a later analysis) the following data:
MSA Type & Serial Number
Fusion cycle number
Date/time of fusion cycle
Error number
Fitting size
Fitting type
Fitting manufacturer
Fusion voltage nominal (MSA 2.1)
Fusion time nominal (MSA 2.1)
Fusion preparation verified (MSA 2.1)
Fusion voltage actual
Fusion time actual
Energy
Mains voltage
Ambient temperature
Operator code (MSA 2.1 only BINARY file)
Job number (MSA 2.1 only BINARY file)

Data Management Operating Instructions MSA 2
18
4.1 Protocol view
To view the saved protocols, press MENU once: the most recent
protocol appears as first.

123 E
-
0
d110 [
+ F+
12/06/12 15:54 25°C

123
Vo=39.5V
t =1000s
E = 200kJ P=215V
The buttons ()() allow to scroll up and down the list of
protocols, while the ()() ones allow to see all the information
related to each single protocol. the Pressing STOP/ESC (O) the
user can go back to main menu again.
In the table below are summarized the symbols used to identify
the fitting type.
Symbol Description
C Elbow 45° - 90
Τ Tee 90°
[ Single socket
Ι Coupler
‡ Saddle and coupler
Υ Reducer
J Tapping Tee
< Electro-thermo-
retractable sleeve