Mecmesin MultiTest 0.5-dV Installation and operating manual

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 1 of 32
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Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 2 of 32
1. Contents
1. Contents............................................................................................ 2
2. Change History ................................................................................. 3
3. Warnings and Cautions..................................................................... 4
4. Preparation for working inside the base casting................................ 5
5. Transformer removal and Replacement............................................ 6
6. Mains Filter Replacement.................................................................. 7
7. Rear Panel Replacement.................................................................. 8
8. Motor Replacement......................................................................... 10
9. VIC PCB Replacement.................................................................... 12
10. Front Panel Replacement................................................................ 13
11. Emergency Stop Replacement........................................................ 14
12. Shroud Removal and Replacement................................................. 15
13. Ballscrew Coupling Replacement.................................................... 17
14. Ballscrew, Top and Moving Crosshead Assembly Replacement .... 19
15. Limit Switch Assembly Replacement............................................... 20
16. Fault finding and cure...................................................................... 23
17. Fault messages............................................................................... 26
18. Dimensions - Anvil plate.................................................................. 28
19. Rear connector pin-outs.................................................................. 29
20. Spare Parts List............................................................................... 30
20. Dial LED Status Summary............................................................... 32

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 3 of 32
2. Change History
Iss.
Date
Effective
S.No.
DCR
No.
Author
Document /
clarification Change
Mechanical Change
0A
11/01/16
-
-
SL
-
Initial Draft Instruction
0B
11/03/16
-
2548
SL
-
Motor mounting changed
01
10/11/16
-
-
GG
4 x unknown serial No.
markers replaced with date
indicators. New front panel
part No. corrected. Spare
Parts aligned with Spare
Parts Price List.
-
02
02/02/17
-
2724
GG
PED Open Issue 10068 -
Update service manual
change history table to
include Sno. & Mechanical
change columns, 910-427
added to SPPL & DCR 2724

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 4 of 32
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.

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 5 of 32
4. Preparation for working inside the base casting
1. Ensure that the test stand is switched-off
and disconnected from the mains supply
2. Support the test stand safely in an inverted
position
3. Remove 4-off rubber feet 22mm
dia x 10mm retained by
countersunk screws.
4. 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
5. 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

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 6 of 32
5. Transformer removal and Replacement
6. Remove the base plate as per 4, Instructions 1 to 4
7. Locate the transformer as
identified in the photograph
8. Remove the grey/blue/brown/mauve
transformer connections to the mains
inlet filter. Removing the two screws
securing the mains inlet filter will aid
removal.
9. Remove the yellow/orange
transformer connections to the PCB
NOTE - record the connections before
removing
10. Remove the 4-off M4x10 csk socket cap screws retaining the transformer
mounting plate to the motor assembly
11. 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 for this purpose –make sure it is fitted
Refitting of the Transformer is the reverse of the above procedure

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 7 of 32
6. Mains Filter Replacement
12. Remove the base plate as per 4, Instructions 1 to 5
13. Locate the rear panel as
identified in the photograph
14. Remove the M3x10 countersunk screws holding the mains inlet filter and
ease it out of position
15. 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.
16. The mains inlet filter can now be completely removed
Refitting of the Mains Filter
is the reverse of the above procedure

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 8 of 32
7. Rear Panel Replacement
17. Remove the base plate as per 4, Instructions 1 to 5
18. Locate the rear panel as identified in the
photograph.
19. Remove the inlet filter as per. Section 6
20. Using a 2.5mm allen key remove the 3-off
screws retaining the Rear Panel to the base
casing. Highlighted in red.
21. Remove the rear panel earth connection
22. Cut the cable ties retaining the
connector looms.

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 9 of 32
23. Disconnect from the VIC board the
rear panel USB 4 way loom (x10)
and the RJ11 6 way loom (X3)
24. Disconnect the digital I/O loom (352-248) rear panel (I/O) from PL1
(EXPANSION I/O) on the VIC board
25. 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

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 10 of 32
8. Motor Replacement
26. Remove the base plate as per 4, Instructions 1 to 5
27. The motor/gearbox unit, complete with an
encapsulated encoder (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.
28. Locate the motor as identified in the
photograph
29. Remove the Transformer as per
Section 5.
30. Remove the motor red/black connections to
the VIC PCB:
Red from J11, Black from J10.
31. Record the connections before removing -
refitting the wrong way round will cause
stand to go in reverse direction.

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 11 of 32
32. Disconnect motor encoder loom (352-
191-V01) from J2.
33. Remove the 3-off M6x12 socket cap head
motor retaining screws
34. Lift the motor out of the base casing.
35. Remove the motor mounting plate from
the motor.
Test Stands –(Prior to 31/05/16)
This is fixed to the motor using 4 off
M4 x 12 screw skt cap and 4 off 35mm
hexagon spacers.
Test Stands –(From 31/05/16)
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 old motor
drive shaft and fit to the new motor using (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, securing them
with loctite 243. The motor shaft and adaptor
are keyed for alignment.
Refitting of the Motor
is the reverse of the above procedure

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 12 of 32
9. VIC PCB Replacement
Warning:
General anti-static precautions should be observed whilst handling the PCB
36. Remove the base plate as per 4, Instructions 1 to 5
37. Locate the Vic PCB as identified in the
photograph
38. Remove the transformer as per 5.
39. Remove the motor as per Section 9.
40. Remove all loom connections to the
PCB
41. NOTE - record the connections before
removing
42. Remove the 4-off M3x6 pan head pozi drive
screws retaining the control PCB on to the
hex pillars and lift out the PCB.
Refitting the PCBs is the reverse of the above procedure.
Note the following photographs and instructions

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 13 of 32
10.Front Panel Replacement
43. Remove the base plate as per 4, Instructions 1 to 5
NOTE: General anti-static precautions
should be observed.
44. Cut any cable ties securing the
looms together.
45. Disconnect the Emergency Stop
loom (352-188) from the
Emergency Stop button on the front
panel to E-STOP (x8) on the VIC
board
46. Disconnect the DV 20 way front
panel loom from the front panel.
47. Remove the 6-off M3 x 16 pan head
screws (420-478).
48. The front panel may now be
removed from the base casing.
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.
43
44
45

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 14 of 32
11.Emergency Stop Replacement
NOTE: General anti-static precautions should be observed.
49. Depress the release lug on rear of
Emergency Stop button to release
loom connection - take care -
excessive force can break the lug.
50. Pull off loom connection.
51. Note the orientation of the switch,
and maintain this orientation on re-
assembly.
52. 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.
53. Fit replacement Emergency Stop.
Refitting the Emergency Stop button
is the reverse of the above procedure

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 15 of 32
12.Shroud Removal and Replacement
54. Remove the base plate as per 4, Instructions 1 to 5
55. Remove the 3-off plastic snap action rivets retaining the top cap to the shroud
and lift off the cap.
56. Remove all the shroud retaining
screws, as shown in the
photograph.
.
57. Unscrew and remove the 2-off knoblets from the limit switch collets
FIXINGS TO TOP
CROSSHEAD
FIXINGS TO
BASE

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 16 of 32
58. Lift the shroud until it comes clear of the columns/crossheads
Refitting of the Shroud
is the reverse of the above procedure

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 17 of 32
13.Ballscrew Coupling Replacement
59. Remove the shroud as per Section 12.
60. Remove M8 x 20 socket cap head screws
retaining top crosshead to columns
61. Undo the 2 grub screws holding the
drive coupling to the bottom of the
ballscrew.
62. Pull the top crosshead upwards and this
should help remove the drive coupling as it
is forced against the bottom brace.
Remove the drive coupling.

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 18 of 32
63. Lower top crosshead back into
position taking care to locate on
both columns and limit switch rod.
64. Ensure that the top half of the
coupling locates correctly into the
bottom half of the coupling
65. 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.
NOTE: 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
screws first, then lift the ballscrew upwards and
out of the coupling.
66. Retighten both M8 x 20 socket cap
head screws using Loctite 243
20mm

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 19 of 32
14.Ballscrew, Top and Moving Crosshead Assembly Replacement
67. Remove the shroud as per Section 12.
68. Slacken fixed top collet on
Microswitch rod (note the relative
positions of the fixed collet)
69. Remove the top crosshead as per Section 13.
70. 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

Multitest 0.5dV, 1dV & 2.5dV
Service and Repair Manual
Number 022-780
Issue Number: 02
Page 20 of 32
15.Limit Switch Assembly Replacement
NOTE: General anti-static precautions should be observed.
71. Remove the base plate as per 4, Instructions 1 to 5
72. Locate the limit switch as identified in the
photograph
73. Partially remove the rear panel as per Section 7 and lay clear of the limit switch
74. Remove knoblets from the two
adjustable limit switch collets
75. Remove the shroud as per Section 12.
76. Slacken grub screws retaining top and bottom fixed collets (note the relative positions of all
four collets)