GF MSA 2 CF User manual

Instruction manual
GF Piping Systems
MSA 2 CF
Electrofusion Unit

Operating Instructions MSA 2 CF General Information
1
Index
Page
I General Information 3
Warning notice 4
1 Introduction 5
1.1 Product description 5
1.2 Components description 6
1.2.1 Operation Controls 6
1.2.2 Display 7
1.2.3 Emergency Stop Switch 7
1.2.3 Ambient Temperature Sensor 7
1.2.4 USB Interface 7
1.2.5 Power Cable 8
1.2.6 Welding Cable 8
1.3 Barcode Reader Scanner 8
1.4 Extension cords and pigtails 9
1.5 START/STOP Card 9
2 Fusion process 10
2.1 Overview of operating procedure 10
2.2 Switching On 11
2.3 Material selection 11
2.4 Connect fitting 13
2.5 Enter operator code/job number 14
2.6 Enter fusion data 15
2.7 Preparation check 17
2.8 Fusion process 18
2.8.1 Welding phase 18
2.8.2 Cooling time 19
2.9 Welding check 19
3 Configuration settings 20
4 Data Management 21
4.1 Protocol view 22
4.2 Protocol erase 23
4.3 Protocol export 23
5 Error messages 25
6 Technical characteristics 26
6.1 Standards 26
7 Maintenance 27
7.1 Cleaning 27
7.2 Fusion Cables 27
7.3 Function Check-up 27
7.4 Spare parts 27
8 Accident Prevention 28
8.1 Operating the Unit 28
8.2 Check before Operation 28

General Information Operating Instructions MSA 2 CF
2
8.3
Protection of the Unit
28
8.4 Defect Unit 29
8.5 Opening the Unit 29
8.6 Working with safety in mind 29
8.7 Other disposal 29
9 Configuring the unit 30
9.1 Temperature scale set-up 30

Operating Instructions MSA 2 CF General Information
3
I General Information
Dear Customer,
Thank you for choosing this product. The electrofusion MSA 2
CF 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.
Safety
Please read and understand this instruction manual before using
the MSA electrofusion processor.
Safety standards and precautions should be followed at all
times.
Do not use or store the MSA electrofusion processor where
volatile gas concentrations may be present.
Only properly trained and qualified personnel should use the
MSA electrofusion processor.
Treat electrical equipment as a potential source of ignition and
follow proper practices for working in an explosive atmosphere.
The electrofusion Processor must be located out of the trench.
For protection against the risk of electric shock, connect the
MSA electrofusion processor only to properly grounded outlets.
Use only up-to-date fusion information supplied by the
manufacturer of the fitting when fusing in manual mode.
To point out relevant aspects operating this electrofusion unit,
symbols are frequently used. The following table contains their
explanation.

General Information Operating Instructions MSA 2 CF
4
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
The manufacturer reserves the right to make technical changes
to MSA 2 CF which may result in differences from the pictures
and information contained in this manual.
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.

Operating Instructions MSA 2 CF Introduction
5
1 Introduction
1.1 Product description
The MSA 2 CF is an electrofusion control unit for the
electrofusion jointing of COOL-FIT PE (PolyEthylene) 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 COOLFIT is tracking and storing in the
internal memory up to 1000 welding protocols, 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.

Introduction Operating Instructions MSA 2 CF
6
1.2 Components description
1.2.1 Operation Controls
There are seven buttons you 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

Operating Instructions MSA 2 CF Introduction
7
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 Emergency Stop Switch
Pushing the E-stop switch instantly shuts off the power to the
processor
1.2.3 Ambient Temperature Sensor
The outside sensor measures the ambient temperature, to check
the temperature is in the permitted range (between 0° F and
120° F) 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 export the protocols. The connector is
protected against dust and water by a cap, which ensures an
IP67 protection factor when properly fixed.

Introduction Operating Instructions MSA 2 CF
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1.2.5 Power Cable
The power cable is delivered with an earthed plug for being
connected to power supply at 115V/60Hz.
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.
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.

Operating Instructions MSA 2 CF Introduction
9
1.4 Extension cords and pigtails
Due to the high amperage draw of electrofusion fittings, the use
of an extension cord is not encouraged. In the event such usage
is necessary, the following lengths and wire gauges are
recommended:
Cord Length Wire Gauge
25 ft. # 10/3 (6 mm2)
50 ft. # 8/3 (10 mm2)
Extension cords should not be used on large couplers.
A pigtail is an adapter for converting from a 30 amp twist-lock to
a 15 amp straight blade plug. Its purpose is for powering the
processor where a NEMA L5 socket is not available, especially
while downloading. Its use is not recommended in field
applications with electrofusion fittings over 63mm in diameter.
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.

Fusion process Operating Instructions MSA 2 CF
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2 Fusion process
2.1 Overview of operating procedure
The welding workflow is shown in the picture below
t = ----s
Vo= --.-V
R = --.--Ω
12/06/19 15:50 70°F
t = ----s
Vo= --.-V
R = 07.45Ω
------
------
12/06/19 15:50 70°F
t = 0040s
Vo= 39.5V
R = 07.45Ω
12/06/19 15:50 70°F
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

Operating Instructions MSA 2 CF Fusion process
11
Next paragraphs describe step by step the interactions with the
electrofusion unit.
2.2 Switching On
Before connecting the machine to the power source, please
read the chapter 6 ‘Technical characteristics‘ and check the
input voltage (100V-130V). If a generator is used, this has to be
started before connecting the electro-fusion unit and must
supply a constant output voltage! Any sudden changes could
compromise the correct welding result and/or damage the
control unit.
Connect the machine to the power mains or generator (100v-
130V) when the generator is already started. At power on the
display shows the machine information: machine type, software
version and serial number.
2.3 Material selection
As soon as the scanner is enabled during the power on, select
the plastic material: the MSA 2 CF can weld PE, PP-R,
PP/PVDF or PB INSTAFLEX fittings. As the fusion parameters
change depending on the material, the user has to set the
proper one. This shall be done reading with the scanner the
desired barcode, out of the 4 shown below
Attention
MSA 2 CF
V 2.01
S156H6908011

Fusion process Operating Instructions MSA 2 CF
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As soon as the MSA 2 CF has captured the code, it will change
the icons accordingly. For PE:
t = ----s
Vo= --.-V
R = --.--Ω
25°C
12/06/12 15:50
For INSTAFLEX BIG
t = ----s
Vo= --.-V
R = --.--Ω
INSTAFLEX
25°C
12/06/12 15:50
For SEADRAIN
t = ----s
Vo= --.-V
R = --.--Ω
SeaDrain
25°C
12/06/12 15:50
For PP-R
t = ----s
Vo= --.-V
R = --.--Ω25°C
12/06/12 15:50
If the machine is switched off, the last setting will be shown at
the next power-on.
P
B
PE
P
P
PP
-
R

Operating Instructions MSA 2 CF Fusion process
13
2.4 Connect fitting
The next step consists of connecting the fitting to the machine
leads. The MSA 2 CF asks this with a prolonged sound. The
LED of the barcode scanner blinks to inform you have 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
12/06/19 15:50 70°F
As soon as a fitting presence is recognized, the MSA 2 CF
moves automatically forward, asking for the fusion parameters.
This is also pointed out by a double short tone of the MSA 2 CF
and the barcode scanner. The scanner LED switches off too, to
alert the operator that it is ready to accept commands.
In case of PP, as there may be multiple coils connected in
parallel, the MSA 2 CF will show roughly how many are present:
to do that, the user has to connect the coils one after the other,
and the unit will add a bullet, on the screen to report the coil is
ok (connected properly, no short or open circuit) or not.
t = ----s
Vo= --.-V
R = 07.45Ω
------
------
12/06/12 15:50

25°C

Fusion process Operating Instructions MSA 2 CF
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2.5 Enter operator code/job number
At the beginning you may 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.
Before the acquisition of the fusion parameters, you can read
with the scanner the operator code (ISO 12176-3 compliant) and
the job number.
Alternatively, you can enter operator code and job number
manually, pressing the STOP button for 2” to enable the “edit”
mode, and then inserting the characters using () and () and
() () to change field. Once the data are entered, you can
confirm with the START button.
t = ----s
Vo= --.-V
R = 07.45Ω
------
------
12/06/19 15:50 70°F
The information will be shown above the barcode icon, in place
of the dash (‘-‘) symbols
t = ----s
Vo= --.-V
R = 07.45Ω
JSMITH
A116…
12/06/19 15:50 70°F
In case the operator code is mandatory the first row ‘----‘ will
blink and the MSA 2 CF will not move forward until the operator

Operating Instructions MSA 2 CF Fusion process
15
code is entered, blocking the acquisition of the fusion
parameters.
2.6 Enter fusion data
After that, you can insert the fusion parameters reading the
barcode information with the scanner.
If the barcode cannot be read with a scanner for any reason, the
data can be entered manually.
In case of manual mode, the machine works in different ways,
depending on the material selection.
If the material selection is PE or PP-R, then time and voltage
values must be entered, 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 )
If the mode is PP, the manual mode is based on a list of
selectable items the user can see pressing the START button.
With () and () he can choose the fitting, confirming with the
START/OK button.
SeaDrainplus
d= 1. 5” x4
12/06/12 15:50
If the mode is PB (INSTAFLEX), then the manual mode is also
based on a list of selectable items the user can see pressing the
START button. With () and () he can choose the fitting type,
confirming with the START/OK button.
INSTAFLEX
d125
12/06/12 15:50

Fusion process Operating Instructions MSA 2 CF
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As soon as the data are correctly read from the barcode or
selected manually, 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
When the operator confirms his intent of starting the fusion
process, pressing the START/OK ( I ) button, the unit will start to
weld.
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
12/06/19 15:50 70°F

Operating Instructions MSA 2 CF Fusion process
17
When you confirm the intent of starting the fusion process,
pressing the START/OK 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

12/06/19 15:50 70°F
2.7 Preparation check
Before starting the fusion process, the MSA 2 CF shows a
reminder, to ensure the preparation activities have been properly
carried out.
12/06/19 15:50 70°F
As soon as you confirm with the START/OK button, the fusion
process starts.

Fusion process Operating Instructions MSA 2 CF
18
2.8 Fusion process
2.8.1 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
The machine adjusts the fusion time according to the external
temperature and barcode information. Therefore the final fusion
time values might be slightly different from the nominal values,
captured from the barcode.
The fusion process can be stopped at any time by pushing
STOP/ESC. Then the fusion process immediately stops and an
error message occurs (see ‘Error Messages’ chapter).
Stopping the on-going fusion process will result in a suspicious
welding: the responsibility will be in charge of the operator.
When the fusion operation is going to finish, a repeated acoustic
signal alerts you 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 into the internal memory.
t = 0040s
Vo= 39.6 V
E = 007.5kJ
N 150
Note
Warning