GF MSA 160 User manual

GF Piping Systems
Instruction manual
Manuale d'uso
Instruction d’utilisation
Betriebsanleitung
MSA 160 Electrofusion Unit
MSA 160 Saldatrice per Elettrofusione
MSA 160 Machines d’électrofusion
MSA 160 Elektroschweißgerät

Operating instructions MSA 160 Index
Index
Page
I General Information 3
•
Warning notice
3
•
Other symbols and notices
3
• Abbreviations 3
1. Introduction
4
1.1
Product Description
4
1.2
Components description
5
1.2.1
Operation Controls
5
1.2.2
D
isplay
5
1.2.3
Electrical switch
5
1.2.4
Input/output interface for bardcode reader or
5
data transfer
1.2.5
Ambient temperature sensor
5
1.2.6
Power Cable
6
1.3
Barcode Scanner (optional)
6
1.4
Extension Cables for Power Supply
6
1.5
Fitting coding 6
2.
Fusion process
7
2.1
Overview of operating procedure
7
2.2
Power On
8
2.3
Fusion data entry
8
2.3.1
Bar code data input (optional)
8
2.3.2
Manual data entry
10
2.4
Fusion cables removal
11
2.5 Welding check 11
3. Settings 12
3.1
Language
12
3.2
Calendar and Time
12
3.3
Brightness
12
4. Data Management 13
5. Error messages 14
6. Technical characteristics 15
6.1
Standards
15
7. Safety and Maintenance 16
7.1
Cleaning
16
7.2
Fusion cables and check
-
up
16
7.3
Accident Prevention
16
7.3.1
Operating the Unit
16
7.3.2
Check before Operation
17
7.3.3
Protection of the Unit
17
7.3.4
Defect Unit
17
7.3.5
Opening the Unit
17
7.3.6 Working with safety in mind 17
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Operating Manual MSA 160
8. Disposal 18
9. Transport and assembly 18
9.1
Packaging
18
9.2
Intermediate storage
18
9.3 Scope of delivery 19
10. About this manual 19
10.1
General statements
19
10.2
Copyright 19
11.
Customer Service
19
2

Operating instructions MSA 160 Index
I General Information
Symbols are frequently used to allow an easy understanding of the
manual and point out duties of the operator. The following tables
contain the explanation of all symbols used in this manual.
• Warning notice
Warning notices are used in this manual 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.
Dangerous situation!
Caution
Failure to comply could lead to injury or damage to
property.
• Other symbols and notices
Symbol Meaning
Attention Mandatory: you must comply this regulation
Advise Suggestion: This notice contains important information
• Abbreviations
Abbreviation Meaning
MSA 160 MSA 160 electrofusion unit
PE Polyethylene
PP Polypropylene
dn Pipe outer diameter (nominal)
3

Operating Manual MSA 160
1. Introduction
Dear Customer,
Thank you for choosing this product. The electrofusion unit MSA 160 is
designed according to the current technology standards. Using it for
purposes other than those described in this manual may cause injury to
the operator or to others. It may also cause damage of the machine or
other equipments.
Therefore:
• The machine should only be used when integral.
• Always follow the safety instructions.
• Complete documentation should be kept nearby the machine.
1.1 Product Description
The MSA 160 is an electrofusion control unit for the electrofusion jointing
of PE, PERT and PP-R fittings up to d160.
Fusion parameters input can be accomplished with a fusion barcode
Interleaved 2/5 – 24 characters or manually.
The internal microprocessor controls the values of welding parameters,
set the power output accordingly and the messages of the LCD display,
guides the operator to successfully execute all the necessary
operations.
In addition, the MSA 160 is tracking and storing in the internal memory
up to 500 welding protocols, that can be transferred to a PC via USB
stick.
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.
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Operating instructions MSA 160
1.2 Components description
1.2.1 Operation Controls
The four buttons allow the input of the data needed for configuring the
machine.
Button
Description
– Decreases set values, scrolls characters in reverse order,
allows specific selections
+ Increases set values, scrolls characters, allows specific
selections
STOP Stops any operation and the process; goes back to previous
(O) point
START Confirms inserted data and starts welding
( I )
1.2.2 Display
The display, a graphical LCD 2 rows x 16 characters each, is the visual
user interface of the welding machine, showing the steps to be
executed, the fusion data, the possible errors and alarm messages.
1.2.3 Electrical switch
The electrical switch powers on/off the electrofusion machine and is the
ultimate command to be activated in case of emergency or internal
fault of the welding machine itself. The machine includes a thermal
protection, to automatically disconnect the machine from the power
supply source in case of potential hazards.
1.2.4 Input/output interface for bardcode reader or data transfer
The USB connector is acting as input for barcode scanner as well as
communication port to transfer, via USB memory stick, the welding
protocols stored within the internal memory to an external personal
computer.
1.2.5 Ambient temperature sensor
The sensor measures the ambient temperature, to adjust the fusion time
according to the external conditions.
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Operating Manual MSA 160
1.2.6 Power and Welding Cables
The power cable is delivered with a Schuko plug for being connected
to power supply.
The low voltage cables shall be connected to the fitting pins.
As standard they are supplied with female connectors, Ø4mm.
1.3 Barcode Scanner (optional)
When connected to the machine, it enables a quick insertion of
welding parameters by reading the related bar code.
The scanner operates keeping it near to the barcode and pushing
the button. The successful read is confirmed by an acoustic tone and
a change of the information on the LCD.
If the bar code data is not identified immediately, repeat the
reading, for instance at a different distance or select the other
barcode on the fitting label.
After use, protect the barcode reader, storing it into the case.
1.4 Extension Cables for Power Supply
To avoid excessive number of brownouts and dissipation, on extension
cables, use cables with section:
• 2.5mm² for cables ≤ 10m full-run;
• 4mm² for cables ≤ 30m full-run.
1.5 Fitting coding
In the table below are summarized the symbols used to identify the
the fitting type. This is useful mainly for manual data entry.
Symbol Description
Ι Coupler
† Tapping Tee or saddle
Τ Tee
Υ Reducer
C Elbow
[ Single socket
< Electro-thermo-retractable sleeve
J (TDW) Tapping Tee
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Operating instructions MSA 160
2. Fusion process
Attention Before connecting the MSA 160 to the power source, the operator must
have read the chapter “Technical characteristics”!
2.1 Overview of operating procedure
The sequence of the information provided by the machine during the
welding procedure is shown at glance in the following picture for the
two possible operating mode (with barcode reader or manual data
input).
MSA 160 Ver. 1.00
SN: “128Z456001”
230V 50Hz
01/04/17 12:12
Start Welding
Bar Code
PEEL & CLEAN?
YES=START
ENTER FUSION
DATA
GF I 110 mm
40 V 210 sec
40V 210s
OK=START
40V 210s 12s
N°12 22°C
FUSION CYCLE
COMPLETE
Cooling Time
20 min
Manual
PEEL & CLEAN?
YES=START
V.=40 22°C
sec=210
TYPE=I GF
D=110mm
40V 210s
OK=START
39.5V 210s 12s
N° 12 22°C
FUSION CYCLE
COMPLETE
DISCONN. FITTING
PRESS START
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Operating Manual MSA 160
MSA 160 Ver. 1.00
SN: S182Z6605010
230V 50Hz
01/04/17 12:12
2.2 Power On
Connect the machine to the power mains or power generator, already
started, and switch on the machine. The display shows the information
concerning the installed software and the serial number of the
machine.
Then it shows the input voltage and frequency
At this time you may change some settings of the unit: date/time,
language or brightness of the display itself (see “Settings” paragraph).
Make sure that the frequency value is in the range 50 – 60 Hz and the
voltage is between 205 – 255 V. Then press START to go ahead.
PEEL & CLEAN?
YES=START
Advise
ENTER FUSION
DATA
GF I 110 mm
40 V 210 sec
2.3 Fusion data entry
The MSA 160 allows the manual insertion of the parameters or the
automatic acquisition, if the scanner is used, by reading the barcode
data of the fitting.
If the scanner is available and connected to the USB port, the MSA 160
will switch to barcode mode.
If not, it will allow the input of values manually (see next paragraphs for
the detailed explaination).
2.3.1 Bar code data input (optional)
 Pipes preparation
If the pipes are scraped and cleaned press START; otherwise get
back and do the fusion preparations.
The preparation of the pipes according to guidelines (scraping, cleaning,
alignment) is essential to ensure the quality of the welding.
 Data entry
If the scanner is connected, the next message will ask to ENTER FUSION
DATA, coded on the sticker of the connected fitting.
Only fittings with a diameter ≤ 160 will be accepted by the MSA160. For
larger diameters a message will pop up on the display, alerting the user.
When the data are captured, the display will switch automatically to a
different view, summarizing the parameters printed in the barcode.
If the barcode is not read, try once again, taking care of the
suggestions mentioned in the previous chapter.
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Operating instructions MSA 160
Warning
V= 40 SEC= 375
YES=START
E9 – RESISTANCE
TOO LOW
E10 – RESISTANCE
TOO HIGH
Warning
40V 210s 12s
N°12 19°C
Note
E4 – INTERR. WITH
STOP BUTTON
Please check the data read by the scanner are those of the fitting going
to be welded
To move forward, press START, while to get back to a previous window,
press STOP.
 Voltage and time values
In case all the preps are done and the fitting barcode is scanned, the
MSA 160 will summarize the data used for the welding. The user shall
now connect the fusion cables and press START once again
 Fitting check
This will enable the unit to check the fitting resistance against the
parameters read from the barcode.
In case of consistent data, the MSA 160 will start automatically the fusion
process. If the fusion cables will not be connected to the fitting the MSA
160 will ask to connect the fitting.
If the fitting is properly connected but the resistance of the coil differs
too much from the supposed value, read from the barcode, the display
will show the corresponding error message.
If the fusion cables are properly connected, double check the fitting
and the barcode, and then repeat the entire procedure (press STOP to
restart it). If the problem still remains, the fitting and the barcode shall be
replaced.
To avoid error messages, it is essential to check regularly the integrity of
the fusion cables and the connectors.
If all the steps above are not solving the issue, it is recommended to get
assistance from a Regional service Center or send the machine to Georg
Fischer for a more detailed check up
 Welding execution
As soon as the fitting check is passed, the MSA 160 will start the welding
cycle.
During the fusion process, the MSA 160 shows the applied voltage, the
expected fusion time, the time to completion, the welding number and
the ambient temperature.
The MSA 160 tunes the fusion time according to the external temperature.
Therefore the final fusion time might be slightly different from the
nominal value, collected from the barcode.
To stop a welding cycle, because of incorrect data or actions, press the
STOP button. An error message will be shown and the indication will be
reported in the welding protocol as well.
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Operating Manual MSA 160
Warning
FUSION CYCLE
COMPLETE
Cooling time
20 min
PEEL & CLEAN?
YES=START
Warning
V.=40 22°C
sec=210
TYPE=I GF
D=110mm
Stopping the on-going fusion process will result in a suspicious welding:
the responsability will be in charge of the operator
If the fusion process is ended successfully, the user will be informed with
a message, while in case of issues a specific error indication will appear
on the display.
After the fusion cycle, the user may be informed about the cooling time
to wait, before applying pressure to the fitting or removing the clamps.
2.3.2 Manual data entry
When the scanner is not present, or recognized, the MSA 160 works in
manual entry mode.
 Pipes preparation
If the pipe ends are scraped and cleaned press START; otherwise get
back and do these activities.
The preparation of the pipes according to guidelines (scraping, cleaning,
alignment) are essential to ensure the quality of the welding.
 Data input
Using “+” and “-”, it is possible to insert the fusion voltage (in the range 8-
42V) and the fusion time (up to 399”). Confirm the values with the START
button. The MSA160 will summarize the fusion data, the user shall confirm
them and start the fusion pressing the START button, or press (+) button
to insert more details, like the fitting type, the diameter (up to d160) and
the manufacturer.
 Connectivity check
CONNECT
FITTING
Warning
The next step will be the connectivity check ensure the fitting is
connected to fusion cables.
In case nothing is connected, the machine will ask to connect the
fitting.
After the connection has been finally made, press START to repeat the
check.
 If the check is still failing, it is recommended to get assistance
from a Regional service Center or send out the machine to Georg
Fischer for a more detailed check up


Welding execution
As soon as the connectivity check is passed, the MSA 160 will begin the
40V 210s 12s
N° 12 19°C welding cycle.
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Operating instructions MSA 160
E4 – INTERR. WITH
STOP BUTTON
Warning
FUSION CYCLE
COMPLETE
Warning
During the fusion process, the MSA 160 shows the applied voltage, the
expected fusion time, the time to completion, the welding number and
the ambient temperature.
To stop a welding cycle, because of incorrect data or actions, press the
STOP button. An error message will be shown and the indication will be
reported in the welding protocol as well.
Stopping the on-going fusion process will result in a suspicious welding:
the responsability will be in charge of the operator
If the fusion process is ended successfully, the user will be informed with
a message, while in case of issues a specific error indication will appear
on the display.
Press START to move forward.
At the end of the fusion cycle the user has to wait the end of the cooling
time, before applying pressure to the fitting!
DISCONN. FITTING
PRESS START
Danger
Warning
2.4 Fusion cables removal
When the fusion cycle has ended, the user can detach the fusion
cables from the fitting and move ahead with the next welding.
Pay attention during the fusion cables removal, since the fitting is still in a
melted status
The fitting area is hot, pay attention not to burn yourself!
To execute the next welding cycle press START, going back to the initial
menu item.
2.5 Welding check
Often the electrofusion fittings are equipped with fusion indicators,
giving evidence of the heating process occurred: double check if they
are sticking out.
This indication is not enough to ensure the quality of the welding, but
just confirming the heating has occurred!
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Operating Manual MSA 160
230V 50Hz
01/04/17 12:12
LANGUAGE (GB)
DD/MM/YY hh:mm
3. Settings
As soon as the electrofusion machine is switched on, several
configuration options are possible.
• “-“ button selects the language
• “+” button selects the date/time
• STOP button selects the LCD brightness
• START button moves on to the welding process
3.1 Language
The MSA 160 allows the selection of the display language. It is possible to
choose English, Italian, Spanish, French and Chinese languages.
For selecting the language, press the botton “-” : the message
‘LANGUAGE’ is shown on the display. Then pressing “-“ you can select
your specific language and confirm with START.
3.2 Calendar and Time
Date and time are shown in the format:
Day / Month / Year hour : minutes
Pressing the “+” button you can go in edit mode and change the
values using “+” or “-” buttons. To confirm the modified values and
move to the next field, press the START button as well as to exit the
menu.
3.3 Brightness
To change the display brightness in case of visibility issues due to
weather conditions, keep pressed the “STOP” button on the main
screen for 5 seconds, the display will start blinking. Then using the “+”
and “-“ button change the brightness. Save permanently the new value
pressing the START button.
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Operating instructions MSA 160
Attention
PROTOCOLS SAVE
OK = START
DELETE MEMORY?
OK = -
4. Data Management
The electrofusion unit MSA 160 saves up to 500 welding protocols in the
internal memory. Data are saved till the operator deletes them or the
memory is full.
As consequence of a welding cycle, each protocol contains the
following information:
Serial number of the MSA 160 and software version
Fusion cycle number
Date/time of welding cycle
Ambient temperature (in °C)
Fusion data entry mode (barcode/manual)
Fitting Manufacturer
Fitting type
Fusion voltage applied
Diameter
Nominal welding time
Actual welding time, following the temperature adjustment
Fusion Energy
Preparation done
Error Code (0 in case of good welding)
Next Revision Date
When the memory is full it is not possible to save data protocols
anymore. During the last 50 welding processes, to announce the run out
of the memory, a periodic message is shown to point out the remaining
free space and suggest to transfer all stored data.
If the internal memory is full, it will be automatically deleted and all
recorded welding protocols will be lost!
The protocols stored in the internal memory of the MSA 160 can be
copied in a memory stick for being analysed in a PC in a later stage,
both in CSV and PDF format.
Just insert the USB stick on the USB connector available on the machine,
when the scanner is not connected. Then, switch on the electrofusion
unit and wait for the message asking for data transfer request.
Push the START button to enable the transfer.
Then, delete the internal memory pressing “-“ button or ignore it pressing
STOP button.
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Operating Manual MSA 160
5. Error messages
In case of anomalies or errors, the MSA 160 will pop up with a specific
message useful to identify the possible issue. The related number will be
even tracked within the welding protocol, to give evidence of the
accident.
The table below summarizes all the messages managed by the MSA
160, with a brief explaination of the possible causes.
MESSAGE POSSIBLE REASONS
E1: MAINS VOLTAGE TOO LOW Generator voltage/freq. below the threshold
E2: MAINS VOLTAGE TOO HIGH Generator voltage/freq. above the threshold
E3: OUTAGE DURING LAST FUSION Power cord disconnected during last fusion
E4: FUSION INTERRUPTED WITH STOP
Fusion stopped by the user
BUTTON
E5: AMBIENT TEMP. TOO LOW Temp. sensor detected a value below the threshold
E6: AMBIENT TEMP. TOO HIGH Temp. sensor detected a value above the threshold
E7: INTERNAL TEMP. TOO LOW EF unit cannot fuse, since it is too cold
E8: INTERNAL TEMP. TOO HIGH EF needs to cool down, since it is too hot
E9: FITTING RESISTANCE TOO LOW Fitting faulty or wrong barcode
E10: FITTING RESISTANCE TOO HIGH Fitting faulty or wrong barcode
E11: FUSION VOLTAGE TOO LOW Not enough power from mains
E12: FUSION VOLTAGE TOO HIGH Internal circuit not calibrated or faulty
E13: FUSION CIRCUIT INTERRUPTED Power cord or output cables detached during welding
E14: FUSION CURRENT TOO HIGH Fitting broken or circuitry not calibrated or faulty
E15: FITTING OUT OF RANGE Fitting is not in the right range: either the voltage or the
diameter are not allowed.
E16: SYSTEM ERROR Electronic faults. Switch off the unit.
WRONG DATA WRITE Potential issues during data writing in the internal memory
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Operating instructions MSA 160
6. Technical characteristics
Mains voltage and frequency
Power consumption
Recommended generator
performance
Welding technique
Fusion voltage
Operating temperature
Temperature sensor resolution
Diameter Max
Fusion data input mode
Capacity of internal
protocols memory
Communication port
Barcode reader port
Protection factor
Dimensions W x D x
H Weight
Fusion cable
Power cord
Mains plug
230 V 50/60 Hz
2.7 kW
3 KW
Voltage control
8-42 V AC
- 10 °C / +45°C
± 1°C
160 mm
Bar code, manual
500 welding cycles
USB
USB
IP 54
480 x 380 x 180 mm
13 kg
3 m, 4.0mm straight plugs
4 m, 3x1,5mm2 -Single phase
Schuko type
6.1 Standards
• ISO 12176-2
• ISO 13950
• EN 60335-1 (Safety)
• EN 61000-3 and others (EMC)
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Operating Manual MSA 160
WARNING
7. Safety and Maintenance
7.1 Cleaning
Clean the unit regularly with a slightly damp cloth. The front plate and
other plates can be cleaned with industrial alcohol if necessary (no
solvents or Trichlor products).
Under no circumstances should the unit be sprayed or immersed in
water nor cleaned with compressed air.
7.2 Fusion cables and check-up
Regular control of the fusion cables is necessary. Damaged cables must
be replaced.
Regular functional check-ups and readjustments are required. These
must be carried out by a Georg Fischer authorized service agent.
7.3 Accident Prevention
7.3.1 Operating the Unit
Do not let unauthorized or untrained personnel or children use the unit.
When the unit is not in operation, avoid unauthorized use by keeping it
in a dry, locked room.
Safe operation of the fusion unit can only be ensured when the
following criteria are fulfilled:
• appropriate transport
• appropriate storage
• appropriate installation
• operation for the correct purpose
• careful handling and operation
• periodic maintenance
16

Operating instructions MSA 160
The unit may only be used under surveillance.
Every person who is involved in the installation and operation of the
fusion unit must be properly qualified and should follow these Operating
Instructions exactly.
Use of the unit can be dangerous, if the Operating Instructions are not
followed. The unit may not be used in surroundings having a high risk of
explosion.
7.3.2 Check before Operation
Before each operation, check the unit for damage and whether it is
able to function properly. All components must be mounted correctly to
ensure proper operation.
7.3.3 Protection of the Unit
Keep the mains lead and secondary cables away from sharp edges.
Make sure damaged cables are immediately replaced by an
authorized service agent. Do not subject the unit to heavy mechanical
loads. The unit is water spray resistant.
7.3.4 Defect Unit
Arrange that damaged housings or other parts are replaced or repaired
by an authorized service agent. If the unit is not functioning properly it
must be repaired by an authorized service agent without delay.
WARNING
Warning
Only authorized and properly qualified personnel are allowed to make
repairs on the unit. Such specialized technicians must be fully aware of
all the safety guidelines, maintenance measures and possible dangers
described in this manual!
7.3.5 Opening the Unit
The unit may only be opened by an authorized service agent. If not, the
warranty will cease immediately.
When the unit has been opened or the housing removed, parts of the
fusion unit are exposed which may have a dangerous electrical charge!
7.3.6 Working with safety in mind
“Make your contribution to safety in the workplace."
17
Warning

Operating Manual MSA 160
• Report any deviations from normal operation immediately to the
person in charge.
• Always keep safety in mind while working.
• Take care of all standard and regulations applied in your country
For your own personal safety as well as for the safe and optimal handling of
the machine, the MSA 160 must be installed correctly.
Connect and disconnect the fitting only when the power supply is
switched off.
8. Disposal
After the joining preparation the plastic shavings should be disposed
properly.
Separate collection of electronic and electrical waste (from the
equipment) has to be ensured through appropriate systems.
Note:
The here below symbol indicating separate collection for electrical and
electronic equipment according to WEEE directive (Waste Electrical
and Electronic Equipment)
9. Transport and assembly
9.1 Packaging
A decisive factor in the choice of packaging is the means of transport.
Usually the machine and all the accessories are delivered in a
cardboard box on a pallet or wooden case upon request.
Special care must be taken when transporting the machine in order to
prevent damage from impact or improper loading and unloading.
All movable parts must be fixed in place.
Transport insurance should be provided for according to the type and
duration of transport. Condensation due to large temperature
fluctuations and sharp jolts during shipment should be avoided.
Please handle the machine with care.
9.2 Intermediate storage
If the machine is not used immediately upon delivery, the machine must
be stored in a safe place and properly covered.
18