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Multitest 0.5d, 1d & 2.5d

Service and Repair Manual

Number 022-005

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 ..................................................................... 5

Visual Identification of Motor Type .................................................... 6

Preparation for working inside the base casting ................................ 7

Transformer removal and Replacement Parvalux ............................. 9

Transformer removal and Replacement Dunker ............................. 10

10.

Rear Panel & Mains Filter Replacement Parvalux .......................... 11

11.

Mains Filter Replacement Dunker ................................................... 13

12.

Rear Panel Replacement Dunker .................................................... 14

13.

Motor Replacement Parvalux .......................................................... 16

14.

Motor Replacement Dunker ............................................................ 18

15.

PCB Replacement ........................................................................... 20

16.

Front Panel Replacement ................................................................ 21

17.

Emergency Stop Replacement ........................................................ 23

18.

Front Panel & LCD Screen Replacement ........................................ 24

19.

Speed Potentiometer/Encoder Replacement. ................................. 25

20.

Shroud Removal and Replacement................................................. 27

21.

Ballscrew Coupling Replacement .................................................... 29

22.

Ballscrew, Top and Moving Crosshead Assembly Replacement .... 32

23.

Limit Switch Assembly Replacement............................................... 33

24.

Technical Bulletin 24-09-14 ............................................................. 36

25.

Fault finding and cure. ..................................................................... 38

26.

Error codes & messages ................................................................. 46

27.

What are the SPI and the RS232 looms? ........................................ 48

28.

Checking firmware with HyperTerminal / FUNterm. ........................ 50

29.

Note regarding HyperTerminal/FUNterm: ........................................ 51

30.

Technical Bulletin

– CPA0126 – Data spike & Emperor Lite ........... 52

31.

Dimensions - Mk2 Stand. ................................................................ 53

32.

Dimensions - Mk1 Stand ................................................................. 53

33.

Dimensions - Anvil plate .................................................................. 54

34.

Rear connector pin-outs .................................................................. 55

35.

Spare Parts List ............................................................................... 56

Содержание Multitest 0.5d

Страница 1: ...d 2 5d Service and Repair Manual Number 022 005 Issue Number 08 Page 1 of 58 PDF copy stored in approved location by click on signature for validation Paper copy printed from approved PDF source by Name Signature Date ...

Страница 2: ...tor Replacement Dunker 18 15 PCB Replacement 20 16 Front Panel Replacement 21 17 Emergency Stop Replacement 23 18 Front Panel LCD Screen Replacement 24 19 Speed Potentiometer Encoder Replacement 25 20 Shroud Removal and Replacement 27 21 Ballscrew Coupling Replacement 29 22 Ballscrew Top and Moving Crosshead Assembly Replacement 32 23 Limit Switch Assembly Replacement 33 24 Technical Bulletin 24 0...

Страница 3: ... section to explain what the SPI and RS232 looms are V1 01 02 04 13 06 12 1971 TF Added detail for tachometer to highlight which it is Add reference to 840 214 d PROGRAMMING UPGRADE KIT LCD FP PCB Test points during fault finding I V1 01 03 05 23 11 12 2043 TF 0 5d parts and identification added title changed Technical bulletin CPA0126 Anvil plate dims Mk1 Mk2 dims Rear connector pin outs 06 30 07...

Страница 4: ...Number 022 005 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 repairs to electronic equipment ...

Страница 5: ...NG UPGRADE KIT which includes a 351 078 cable to connect between 9W and 25W PLEASE NOTE When you have completed the reprogramming of the test stand Mecmesin Limited recommends verification of the product to confirm correct instrument operation 5 Firmware release notes 340 101 MultiTest d motor firmware Implemented in version 1 01 02 DCR1855 June 2011 Motor now put into hold mode when stopped inste...

Страница 6: ...eviously unused addresses Implemented in version 1 01 01 DCR 1574 April 2009 Communication corruption when E Stop engaged Flyspray ID 123 Configuration commands now do not cause communication failure when E Stop engaged Separate error codes for motor control and front panel PCB s Flyspray ID 124 Eeprom error codes changed to be different from motor control eeprom error codes Official release of Vo...

Страница 7: ...e that the test stand is switched off and disconnected from the mains supply 3 Support the test stand safely in an inverted position 4 Remove 4 off rubber feet 22mm dia x 10mm retained by countersunk screws 5 Remove base plate retained by 4 off M4x12mm pan pozi taptite screws into the base casting and 2 off M4x6mm pan pozi screws into the rear panel ...

Страница 8: ...Repair Manual Number 022 005 Issue Number 08 Page 8 of 58 6 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 ...

Страница 9: ...Remove the yellow orange transformer connections to the PCB NOTE record the connections before removing 11 Using a 5mm ball ended allen key remove the 2 off M6x12 socket cap screws retaining the transformer mounting plate to the base casing 12 Lift out the transformer Unscrew nylon nut Remove transformer from plate NOTE The transformer must be insulated from its mounting plate An insulating gasket...

Страница 10: ...t the grey blue brown Mauve transformer connections to the inlet filter 16 Remove transformer leads Yellow J13 Orange J12 17 Remove the four M4 x10 screw csk skt holding the transformer bracket in position 18 Lift out the transformer Unscrew nylon nut Remove transformer from plate NOTE The transformer must be insulated from its mounting plate An insulating gasket is supplied with the transformer f...

Страница 11: ...lter 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 Disconnect grey blue brown mauve connectors from transformer to mains inlet filter 22 Using a 2 5mm allen key remove the 3 off screws retaining the Rear Panel to the base casing ...

Страница 12: ...ined in the rear panel by 2 off M3x12 countersunk screws and 2 off M3 Nyloc nuts 24 For the complete removal of the rear panel for replacement as an assembly or the replacement of any of the parts disconnect the earth loom from the back panel cut the cable ties retaining the rear panel looms unplug looms from the PCB NOTE record the connections before removing Refitting of the Rear Panel and Mains...

Страница 13: ...ograph 27 Remove the M3x10 countersunk screws holding the mains inlet filter and ease it out of position 28 Note Record the connections between the transformer and mains inlet filter Disconnect grey blue brown mauve connectors from transformer to mains inlet filter and the earth connection to the inlet filter 29 The mains inlet filter can now be completely removed Refitting of the Mains Filter is ...

Страница 14: ...e plate as per 7 Instructions 2 to 6 31 Locate the rear panel as identified in the photograph 32 Remove the inlet filter as per Section 11 33 Using a 2 5mm allen key remove the 3 off screws retaining the Rear Panel to the base casing Highlighted in red 34 Remove the rear panel earth connection 35 Cut the cable ties retaining the connector looms ...

Страница 15: ...3 from J19 on the control board 37 Disconnect the communications loom 352 190 rear panel I O from J6 on the control board 38 The complete rear panel can now be lifted out for replacement as an assembly or the replacement of the panel itself or any of the connectors looms Refitting of the Rear Panel is the reverse of the above procedure ...

Страница 16: ...ncoder also known as the tachometer is attached to the base casing via a mounting plate retained with 3 off M6 x 12 cap head screws 41 Locate the motor as identified in the photograph 42 Remove the Transformer as per 8 Instructions 7 to 12 43 Remove the motor red black connections to the PCB Red from J10 Black from J11 44 Record the connections before removing refitting the wrong way round will ca...

Страница 17: ...ed encoder tachometer 46 Remove the 3 off M6x12 socket cap head motor retaining screws 47 Lift the motor out of the base casing 48 Remove the drive coupling from the motor drive shaft and fit to the new motor ensuring that the long dog point grub screw locates on the machined flat Use Loctite 243 to retain both grub screws Refitting of the Motor is the reverse of the above procedure ...

Страница 18: ...the tachometer is attached to the base casing via a mounting plate retained with 3 off M6 x 12 cap head screws 51 Locate the motor as identified in the photograph 52 Remove the Transformer as per Section 9 53 Remove the motor red black connections to the PCB Red from J11 Black from J10 54 Record the connections before removing refitting the wrong way round will cause stand to go in reverse directi...

Страница 19: ...he motor using 4 off M4 x 12 screw skt cap and 4 off 35mm hexagon spacers From Serial Number This is fixed with 4 off M4 x 45 skt cap screws through 4 off 35mm long stainless steel spacers Remove the drive coupling from the motor drive shaft and fit to the new motor note that in the picture the motor mounting plate and pillars have been removed for clarity using 2 off M4 x 5 dog point grub screws ...

Страница 20: ...raph 61 Parvalux Remove the transformer as per 8 62 Dunker Remove the transformer as per Section 9 63 Parvalux Remove the motor as per Section 13 64 Dunker Remove the motor as per Section 14 65 Remove all loom connections to the PCB 66 NOTE record the connections before removing 67 Remove the 4 off M3x6 pan head pozi drive screws retaining the control PCB on to the hex pillars and lift out the PCB...

Страница 21: ...se plate as per 7 Instructions 2 to 6 NOTE General anti static precautions should be observed 69 Record the wiring loom connections to all front panel components and disconnect 70 Remove earth loom from front panel by unscrewing Nyloc nut 71 Remove the 6 off Nyloc retaining nuts 72 The front panel may now be removed from the base casing ...

Страница 22: ...ts as described in the following instructions 74 Re assemble with replacement parts as necessary Refitting of the Front Panel is the reverse of the above procedure Note When refitting the front panel ensure that the self adhesive EMC gasket material is not disturbed Replace damaged sections or the entire gasket if necessary ...

Страница 23: ... connection take care excessive force can break the lug 76 Pull off loom connection 77 Note the orientation of the switch and maintain this orientation on re assembly 78 Using a suitable tool unscrew the collar retaining the Emergency Stop button and remove completely enabling the Emergency Stop to be withdrawn through the front of the front panel 79 Fit replacement Emergency Stop Refitting the Em...

Страница 24: ...ecautions should be observed To ensure the correct readability a 300 164 V01 MT d FRONT PANEL PCB ASSY and 301 032 V01 MT d LCD MODULE ASSY are replaced 80 Remove the 4 off M3 Nyloc 81 Lift off the front panel pcb assembly 82 Remove the 4 off 9mm spacers and lift off the LCD module Refitting the front panel interface PCB is the reverse of the above procedure ...

Страница 25: ...laced by removing the base the front panel assembly can be left in situ 83 Remove the front panel PCB as per Section 18 84 Loosen the speed control knob securing screw and remove knob 85 Remove the encoder retaining nut The encoder can now be removed 86 Replace the encoder ensuring that the locating nipple seats correctly see photos below The spindle is shortened to 7mm ...

Страница 26: ... 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 88 Replace the 4 off M3 Nyloc nuts Replacement of speed pot encoder complete ...

Страница 27: ... 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 91 Remove all the shroud retaining screws as shown in the photograph NOTE The screw identified by the black arrow in the photograph is shorter than the other seven 92 Unscrew and remove the 2 off knoblets from the limit switch collets ...

Страница 28: ...0 5d 1d 2 5d Service and Repair Manual Number 022 005 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 ...

Страница 29: ...ling Replacement 94 Remove the shroud as per Section 20 95 Remove M8 x 20 socket cap head screws retaining top crosshead to columns 96 Lift top crosshead clear of columns BEWARE the moving crosshead will come up against the limit switch fixed top collet if lifted too high Lower the moving crosshead if necessary ...

Страница 30: ...n it 98 Lower top crosshead back into position taking care to locate on both columns and limit switch rod 99 Ensure that the top half of the coupling locates correctly into the bottom half of the coupling NOTE For Multitest 1 d the ball screw must pass through the bottom bearing plate before the 12mm drive coupling with M4 x 10 skt grub screw can be fitted In this case loosen the coupling grub scr...

Страница 31: ...Number 08 Page 31 of 58 100 Retighten both M8 x 20 socket cap head screws using Loctite 243 101 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 Use Loctite 243 on the grubscrews ...

Страница 32: ...Slacken fixed top collet on Microswitch rod note the relative positions of the fixed collet 104 Remove the top crosshead as per Section 21 105 Lift top crosshead moving 5crosshead ballscrew as a complete assembly off the columns taking care not to lose the limit switch collets that will come off as the crosshead is removed Refitting of the Ballscrew assembly is the reverse of the above procedure ...

Страница 33: ...ns should be observed 106 Remove the base plate as per 7 Instructions 2 to 6 107 Locate the limit switch as identified in the photograph 108 Partially remove the rear panel as per Section 10 for Parvalux or Section 12 for Dunker and lay clear of the limit switch 109 Remove knoblets from the two adjustable limit switch collets 110 Remove the shroud as per Section 20 ...

Страница 34: ...ber 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 Remove the 2 off M4 x 12 taptite pan head pozi drive screws retaining the limit switch to the base casting ...

Страница 35: ...e Limit Switch is the reverse of the above procedure 115 Adjust top and bottom short locking collars to Factory set limits as listed in the table below Tighten in position using Loctite 243 on the screwthreads Mk 1 Stands 0 5 kN Stands 1 kN Stands 2 5 kN Stands Top Collar 65mm 65mm Bottom Collar 60mm 50mm Mk 2 Stands Top Collar 50mm 50mm 50mm Bottom Collar 60mm 60mm 60mm ...

Страница 36: ...mber 022 005 Issue Number 08 Page 36 of 58 24 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 chassis ...

Страница 37: ...ce that the purple coating has been abraded due to contact with the base casting and with the aluminium mounting plate slot Exposing the conductors which then short to chassis 0 V will cause LEDs to flicker or simulate the action of pressing the jog buttons The remedy is to protect the purple coating from abrasion by the rough metal edges by the application of a suitable insulating tape Internal c...

Страница 38: ...12 Stand fails speed test 13 Speed reading is erratic jumpy or speed is all over the place when I turn speed dial 14 Error 09 is displayed on screen 15 Stand resets itself Switches on and off 16 Stand times out Cross head only travels a short distance 17 1 Stand won t turn on 116 Check fuses in mains inlet filter and ensure it is a 2A time lag T Check that all the looms are connected and in the ri...

Страница 39: ...s using a D V M v Check MCB between TP 4 and TP 1 for a voltage of 5V DC if present move to vii If it is not present disconnect all looms except the transformer then re measure between TP 4 and TP 1 If the 5V DC is still not present replace MCB vi Replace looms one at a time each time checking for 5V DC vii Reprogram front panel PCB vii If none of the above works replace the LCD and front panel PC...

Страница 40: ... to 120VA 22V 352 198 Feb 2010 MCB heat sensing circuitry Error 02 can be displayed if the motor control board heat sensing circuitry has been triggered The trigger was enabled if the ambient temperature in the vicinity of J5 reached 113 o C This was changed by firmware upgrade M V1 01 01 Multitest 2 5d running full load and speed Error 02 can also be displayed with the later Multitest 2 5d Mk2 bl...

Страница 41: ...rod moves freely up and down do you hear a click in both directions of the micro switches 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 iii Check that the limit switch is connected to the motor control PCB iv Check that the limit switch IDC cable do...

Страница 42: ...y connected to the back of the stand ii Check that the communication loom has been correctly connected to the motor control PCB iii Using a D V M check the continuity of the communication loom iv Check that the com s loom is wired correctly v If all of the above are ok then replace the motor control PCB NOTE The above checks are assuming that the gauge and connector loom being used are in working ...

Страница 43: ...ck that the stand has been correctly set up i e as a 1 or 2 5 D ii Check that the tachometer is correctly positioned on top of the ballscrew iii Using a D V M check that the motor is being supplied voltage iv Check that the motor tachometer loom has been correctly fitted to the motor and the motor control PCB v If all of the above are ok then replace the motor 14 Speed reading is erratic jumpy or ...

Страница 44: ...ER SPEED POT 15 Error 09 is displayed on screen i The limit switches are set too close together i e both trigger Move limit switch actuators further apart ensuring that the moving crosshead will not damage the test piece ii Check the limit switch assy is securely connected to the PCB iii Continuity test limit switch assy IDC cable iv The fault maybe caused by a faulty 307 044 OPTO SWITCH OPB625 on...

Страница 45: ...oom which connects the front panel PCB and motor control PCB vi Check continuity of looms using a D V M vii Check the connection between the front panel PCB and the LCD viii If all of the above are ok then replace the LCD or Motor Control PCB 17 Stand times out Cross head only travels a short distance If the Motor Control PCB does not receive feedback or if the feedback is incorrect the crosshead ...

Страница 46: ... cables and transformer loom Mains voltage power supply is at the bottom end of the tolerance allowed for our systems 230V 10 about 207Vac The Error 02 message is also displayed if the PCB heat sensing circuitry has been activated Error 02 can also be displayed with the later Multitest 2 5d blue base version if run at full speed and load The sales brochure and operating manual recommend that this ...

Страница 47: ...e the Stand Reverse occurs to avoid the error message Error 09 Limit optical switch conflict Possible opto fault Replace 2 x 307 044 OPTO SWITCH OPB625 on 300 148 V01 LIMIT SWITCH ASSY or the limit switches are set too close i e both trigger Error 10 Front Panel PCB memory write error U1 on LCD PCB Error 11 Front Panel PCB memory read error U1 on LCD PCB Over travelled Emergency stop Faulty Emerge...

Страница 48: ... the RS232 looms On the right a photo of the SPI loom 352 189 from the build instructions The photos below were taken on our test jig to simplify the photos The SPI loom is the 5 way cable connecting the Front Panel PCB to the Motor PCB between J16 on Motor PCB and J7 on LCD PCB SPI connection on the Motor Control PCB ...

Страница 49: ... 005 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 This is not to be confused with RS232 Rear 352 193 is the loom with the PC connection to the back panel ...

Страница 50: ...testing communications the methods in this guide can used as a method of obtaining data from the device Important notes about the communications setting Before carrying out testing using HyperTerminal all programs should be closed If this is not possible ensure all programs that use COM ports are closed Failure to do this will result in communications not working or corrupted data If you need to c...

Страница 51: ...ill return its settings Return this information to the Mecmesin Support Team to decipher 29 Note regarding HyperTerminal FUNterm When the system is correctly setup a from HyperTerminal gives a response of load displacement e g 0 000 3 8632 If the gauge is not connected to the MultiTest d or the gauge is not powered up and you send a you will receive 1 as the response ...

Страница 52: ...ts being sent to Emperor Lite when used with a gauge You can upgrade the stand with the latest firmware 4 using our d stand programmer this is windows based and can be downloaded from a Distributor Zone link It requires a USB to serial lead to update the MT d front panel The MT d motor control PCB firmware does not cause the spike issue but can also be upgraded using the programmer This PCB firmwa...

Страница 53: ...0 5d 1d 2 5d Service and Repair Manual Number 022 005 Issue Number 08 Page 53 of 58 31 Dimensions Mk2 Stand Mk2 test stands have a blue base casting 32 Dimensions Mk1 Stand Mk1 test stands had a grey base casting ...

Страница 54: ...Multitest 0 5d 1d 2 5d Service and Repair Manual Number 022 005 Issue Number 08 Page 54 of 58 33 Dimensions Anvil plate 408 477 F ANVIL PLATE Further information ...

Страница 55: ... for the 25 way I O connector on the back of the MultiTest d is 1 Ground 2 Rx for Communication with Gauge 3 Tx for Communication with Gauge 16 External 5v 21 Stand Reverse UP 22 Stand Reverse DOWN The pin out for the 9 way RS232 connector on the back of the MultiTest d is 2 Stand TXD 3 Stand RXD 5 Ground Parvalux Stand Dunker Stand ...

Страница 56: ...448 1 LIMITSWITCH COMPLETE ASSEMBLY Mk1 MT 1 d Mk2 MT 2 5 d 432 449 1 LIMITSWITCH COMPLETE ASSEMBLY Mk1 MT 2 5 d Mk2 MT 1 d 406 422 1 MULTITEST Mk1 MT 1 d Mk2 MT 2 5 d LIMIT SWITCH ROD 406 403 1 MULTITEST Mk1 MT 2 5 d LIMIT SWITCH ROD 406 569 1 MULTITEST Mk2 MT 1 d LIMIT SWITCH ROD 406 570 1 MULTITEST Mk2 MT 0 5 d LIMIT SWITCH ROD 300 148 V01 1 LIMIT SWITCH PCB ONLY 307 044 2 OPTO SWITCH OPB625 Co...

Страница 57: ...ACER 406 593 1 END CAP 408 028 F99 1 MULTITEST MOVING X HEAD 408 310 1 MULTITEST TOP X HEAD 411 002 2 DU BUSH 1212 411 003 3 DU BUSH 2030 411 118 5 THRUST WASHER KOYO AS1226 411 119 2 THRUST BEARING KOYO AXK1226 A 413 037 1 ADJUSTABLE HANDLE LEVER M8 415 022 2 DISC SPRING 180002 420 039 2 WASHER M3 0 5 ZINC 420 053 1 SCREW GRUB SKT M4x10 420 063 2 SKT GRUB SCREW M4x4MM 420 236 1 M12x1 NUT LOCKING ...

Страница 58: ...r 08 Page 58 of 58 420 039 2 WASHER M3 0 5 ZINC 420 053 1 SCREW GRUB SKT M4x10 420 063 2 SKT GRUB SCREW M4x4MM 420 236 1 M12x1 NUT LOCKING PITCH 420 246 1 WASHER FLAT M12 1 5mm THK 420 297 1 M4x24 DOWEL PIN 424 010 2 M6 LKG COLLAR 890214 424 107 1 COUPLER SET SCREW STYLE 12mm ...

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