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Mecmesin Multitest 0.5d Service And Repair Manual

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Number 022-005
Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Issue Number: 08
Page 1 of 58
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Summary of Contents for Mecmesin Multitest 0.5d

  • Page 1 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 1 of 58 PDF copy stored in approved Paper copy printed from approved PDF source by: location by: (click on signature for validation) Name Signature...

  • Page 2: Table Of Contents

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 2 of 58 1. Contents Contents .................... 2 Change History ................. 3 Warnings and Cautions ..............4 Latest firmware version: - I : V1.01-03 M : V1.01-02 ....... 5 Firmware release notes ..............

  • Page 3: Change History

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 3 of 58 2. Change History Iss. Date Effective Author Document / Mechanical Change S.No. clarification Change 06/08/08 Initial Draft Instruction 13/03/09 Various 09/04/10 1700 Additions to spare parts list &...

  • Page 4: Warnings And Cautions

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 4 of 58 3. Warnings and Cautions General anti static precautions should be observed whilst following this service instruction. Anti-static precautions must be taken when performing any...

  • Page 5: Latest Firmware Version: - I : V1.01-03 M : V1.01-02

    4. Latest firmware version: - I : V1.01-03 M : V1.01-02 The version of software is displayed on the stand start-up screen. Mecmesin Limited recommends that instruments have the latest version of firmware installed. Multitest-d software can be upgraded to the latest version (see section 5 for firmware history) using the following: 022-006: MULTITEST-d Programming Work Instruction.

  • Page 6: Visual Identification Of Motor Type

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 6 of 58 340-104 – MultiTest-d LCD firmware. Implemented in version 1.01-03 (DCR1971) June 2012 ------------------------- 1) MultiTest-d sends corrupted data with AFG/BFG. (Flyspray ID681) - Data transmission routines modified to prevent corrupted data packets being sent to Emperor Lite when used with AFG/BFG.

  • Page 7: Preparation For Working Inside The Base Casting

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 7 of 58 7. Preparation for working inside the base casting Ensure that the test stand is switched-off and disconnected from the mains supply Support the test stand safely in an...
  • Page 8 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 8 of 58 Lift the base panel clear of the base casting – access to all components within the base casting is now available. Refitting of the Base-Plate is the reverse of the above procedure...

  • Page 9: Transformer Removal And Replacement Parvalux

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 9 of 58 8. Transformer removal and Replacement Parvalux Remove the base plate as per 7, Instructions 2 to 5 Locate the transformer as identified in the photograph...

  • Page 10: Transformer Removal And Replacement Dunker

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 10 of 58 9. Transformer removal and Replacement Dunker 13. Remove the base plate as per 7, Instructions 2 to 5 14. Remove the M3x10...

  • Page 11: Rear Panel & Mains Filter Replacement Parvalux

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 11 of 58 Rear Panel & Mains Filter Replacement Parvalux 19. Remove the base plate as per 7, Instructions 2 to 6 20. Locate the rear panel as identified in the photograph 21.
  • Page 12 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 12 of 58 23. The rear panel can now be lifted partially clear of the base casing. This gives sufficient access for replacement of the mains filter,...

  • Page 13: Mains Filter Replacement Dunker

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 13 of 58 Mains Filter Replacement Dunker 25. Remove the base plate as per 7, Instructions 2 to 6 26. Locate the rear panel as identified in the photograph 27.

  • Page 14: Rear Panel Replacement Dunker

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 14 of 58 Rear Panel Replacement Dunker 30. Remove the base plate as per 7, Instructions 2 to 6 31. Locate the rear panel as identified in the photograph.
  • Page 15 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 15 of 58 36. Disconnect rear panel RS232 loom (352-193) from J19 on the control board. 37. Disconnect the communications loom (352-190) rear panel (I/O) from J6 on the control board 38.

  • Page 16: Motor Replacement Parvalux

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 16 of 58 Motor Replacement Parvalux 39. Remove the base plate as per 7, Instructions 2 to 6 40. The motor/gearbox unit, complete with an encapsulated encoder (also known as the ‘tachometer’),...
  • Page 17 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 17 of 58 45. Disconnect the motor encoder loom (brown/yellow/blue/orange) from the motor’s encapsulated encoder (tachometer). 46. Remove the 3-off M6x12 socket cap head motor retaining screws 47.

  • Page 18: Motor Replacement Dunker

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 18 of 58 Motor Replacement Dunker 49. Remove the base plate as per 7, Instructions 2 to 6 50. The motor/gearbox unit, complete with an encapsulated encoder (also known as the ‘tachometer’), is...
  • Page 19 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 19 of 58 55. Disconnect motor encoder loom (352- 191-V01) from J2. 56. Remove the 3-off M6x12 socket cap head motor retaining screws 57. Lift the motor out of the base casing.

  • Page 20: Pcb Replacement

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 20 of 58 PCB Replacement Warning: General anti-static precautions should be observed whilst handling the PCB 59. Remove the base plate as per 7, Instructions 2 to 6 60.

  • Page 21: Front Panel Replacement

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 21 of 58 Front Panel Replacement 68. Remove the base plate as per 7, Instructions 2 to 6 General anti-static precautions NOTE: should be observed.
  • Page 22 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 22 of 58 73. Remove front panel components as described in the following instructions. 74. Re-assemble with replacement parts as necessary. Refitting of the Front Panel...

  • Page 23: Emergency Stop Replacement

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 23 of 58 Emergency Stop Replacement General anti static precautions should be observed. NOTE: 75. Depress the release lug on rear of Emergency Stop button to release loom connection - take care - excessive force can break the lug.

  • Page 24: Front Panel & Lcd Screen Replacement

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 24 of 58 Front Panel & LCD Screen Replacement General anti static precautions should be observed. - To ensure the correct NOTE: ‘readability’ a 300-164-V01 MT-d FRONT PANEL PCB ASSY and 301-032-V01 MT-d LCD MODULE ASSY are replaced.

  • Page 25: Speed Potentiometer/Encoder Replacement

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 25 of 58 Speed Potentiometer/Encoder Replacement. NOTE: The speed pot can also be replaced by removing the base, the front panel assembly can be left in situ.
  • Page 26 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 26 of 58 87. Replace the 4-off 9mm spacers and reconnect the front panel PCB assembly – TAKE CARE, ENSURE THE PINS ON THE LCD MODULE AND ENCODER SEAT WITHIN THEIR SOCKETS.

  • Page 27: Shroud Removal And Replacement

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 27 of 58 Shroud Removal and Replacement 89. Remove the base plate as per 7, Instructions 2 to 6 90. Remove the 3-off plastic snap action rivets retaining the top cap to the shroud and lift off the cap.
  • Page 28 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 28 of 58 93. Lift the shroud until it comes clear of the columns/crossheads Refitting of the Shroud is the reverse of the above procedure...

  • Page 29: Ballscrew Coupling Replacement

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 29 of 58 Ballscrew Coupling Replacement 94. Remove the shroud as per Section 20. 95. Remove M8 x 20 socket cap head screws retaining top crosshead to columns 96.
  • Page 30 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 30 of 58 97. For Multitest 2.5-d remove coupling Locate new coupling onto the bottom of the ball screw, and ensuring that the long screw locates on the machined flat lightly, tighten it.
  • Page 31 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 31 of 58 100. Retighten both M8 x 20 socket cap head screws using Loctite 101. Set the vertical position of the coupling such that it is fully inserted into the lower portion of the coupling and retighten the grub screws.

  • Page 32: Ballscrew, Top And Moving Crosshead Assembly Replacement

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 32 of 58 Ballscrew, Top and Moving Crosshead Assembly Replacement 102. Remove the shroud as per Section 20. 103. Slacken fixed top collet on Microswitch rod (note the relative positions of the fixed collet) 104.

  • Page 33: Limit Switch Assembly Replacement

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 33 of 58 Limit Switch Assembly Replacement General anti static precautions should be observed. NOTE: 106. Remove the base plate as per 7, Instructions 2 to 6 107.
  • Page 34 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 34 of 58 111. Slacken grub screws retaining top and bottom fixed collets (note the relative positions of all four collets) 112. Unplug limit switch from PCB 113.
  • Page 35 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 35 of 58 114. Withdraw the limit switch/rod assembly from the test stand Refitting of the Limit Switch is the reverse of the above procedure 115.

  • Page 36: Technical Bulletin 24-09-14

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 36 of 58 Technical Bulletin 24-09-14 Further info. We found that the membrane keypads ribbon tail protective purple coating can be removed which in turn exposes the silver conductor tracks and allows shorts to...
  • Page 37 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 37 of 58 The flexible cable consists of a plastic sheet on to which is printed silver conductors. The conductors are over printed with a purple insulating coating. Only one side of the cable is vulnerable to abrasion –...

  • Page 38: Fault Finding And Cure

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 38 of 58 Fault finding and cure. For explanation of the RS232 loom and SPI loom please refer to section titled What are the SPI and the RS232 looms?

  • Page 39: Lcd Fails To Illuminate

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 39 of 58 2) LCD fails to illuminate: i. Check for power as 1) Stand won’t turn on: ii. Check loom connections are correctly wired to front panel PCB and the motor control PCB.
  • Page 40 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 40 of 58 Low mains power Error 02 can be displayed if the stand is run at maximum from start-up and the mains voltage power supply is at the bottom end of the tolerance allowed for our systems (230V +-10%).

  • Page 41: Error 06 Is Displayed On Screen

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 41 of 58 5) Error 06 is displayed on screen: i. Upgrade to latest versions of firmware. See 4 ii. Replace front panel PCB. If the fault persists iii.

  • Page 42: Crosshead Fails To Move

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 42 of 58 i. Check that the limit switch rod moves freely. ii. If the limit switch rod doesn’t move freely then remove base from stand and check that the micro switch spacer closest to the base casting hasn’t rotated causing it to catch on the base casting.

  • Page 43: Stand Fails Load Test

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 43 of 58 i. Check that all the bolts securing the columns and crosshead assembly have been correctly tightened and that the motor mounting bolts are tight.

  • Page 44: Error 09 Is Displayed On Screen

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 44 of 58 Later PCB with capacitors added Replace front panel PCB if the two capacitors are missing. Replace 331-076 MECHANICAL ROTARY ENCODER (SPEED POT).

  • Page 45: Stand Resets Itself. (Switches On And Off)

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 45 of 58 v. If all of the above are ok then replace the limit switch. 16) Stand resets itself. (Switches on and off). i. Check Motor Control PCB fuse is held securely within its holder, if necessary squeeze the fuse holders contacts together slightly.

  • Page 46: Error Codes & Messages

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 46 of 58 Error codes & messages For explanation of the RS232 loom and SPI loom please refer to section titled What are the SPI and the RS232 looms? Error codes: The duration the stand was running before an error message is displayed below the error message.
  • Page 47 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 47 of 58 Error 05 – Internal communication fault. - SPI reception incorrect, check the SPI and RS232 looms. Error 06 – Firmware upgrade required / Motor Control PCB EEPROM Write error.

  • Page 48: What Are The Spi And The Rs232 Looms

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 48 of 58 What are the SPI and the RS232 looms? On the right a photo of the SPI loom (352-189) from the build instructions.
  • Page 49 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 49 of 58 The RS232 loom 352-192 in the photos, also referred to as RS232 Front, connects between the Front Panel PCB to the Motor PCB.

  • Page 50: Checking Firmware With Hyperterminal / Funterm

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 50 of 58 Checking firmware with HyperTerminal / FUNterm. It the stand is not functioning correctly, the firmware can be checked for corruption using HyperTerminal.

  • Page 51: Note Regarding Hyperterminal/Funterm

    Ensure that the stand is set as 9600 baud, send the command ‘gp’, the stand will return its settings Return this information to the Mecmesin Support Team to decipher. Note regarding HyperTerminal/FUNterm: When the system is correctly setup a '?' from HyperTerminal gives a response of 'load' 'displacement', e.g.

  • Page 52: Technical Bulletin - Cpa0126 - Data Spike & Emperor Lite

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 52 of 58 Technical Bulletin – CPA0126 – Data spike & Emperor Lite A data spike may appear when using an AFG/BFG, Multitest-d/Vortex-d and Emperor-Lite if the Multitest-d/Vortex-d front panel PCB firmware is pre I: V1.01-03 The cause of the issue has been identified as the test stands front panel PCB and is corrected by the latest firmware I : V1.01-03 The stands data transmission routines...

  • Page 53: Dimensions - Mk2 Stand

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 53 of 58 Dimensions - Mk2 Stand. Mk2 test stands have a blue base casting. Dimensions - Mk1 Stand Mk1 test stands had a grey base casting.

  • Page 54: Dimensions - Anvil Plate

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 54 of 58 Dimensions - Anvil plate 408-477-F ANVIL PLATE Further information;...

  • Page 55: Rear Connector Pin-Outs

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 55 of 58 Rear connector pin-outs Parvalux Stand Dunker Stand The pin-out for the 25 way I / O connector on the back of the MultiTest-d is:-...

  • Page 56: Spare Parts List

    Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 56 of 58 Spare Parts List PCB’s supplied will not be accepted back for credit due to obvious handling and storage problems. Req’d Part No.
  • Page 57 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 57 of 58 413-021 RUBBER FOOT 420-229 NUT SELF CLINCHING M4 (For above). 412-023 DUST COVER 25 WAY D SOCKET 412-027 DUST COVER 9 WAY D SOCKET...
  • Page 58 Number 022-005 Multitest 0.5d, 1d & 2.5d Service and Repair Manual Issue Number: 08 Page 58 of 58 420-039 WASHER M3. 0.5. ZINC 420-053 SCREW GRUB SKT M4x10 420-063 SKT GRUB SCREW M4x4MM 420-236 M12x1 NUT LOCKING PITCH 420-246 WASHER FLAT M12 (1.5mm THK)

This manual is also suitable for:

Multitest 1dMultitest 2.5d

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