Mecmesin Multitest 0.5d Installation and operating manual

Multitest 0.5d, 1d & 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

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 2 of 58
1. Contents
1. Contents............................................................................................ 2
2. Change History ................................................................................. 3
3. Warnings and Cautions..................................................................... 4
4. Latest firmware version: - I : V1.01-03 M : V1.01-02....................... 5
5. Firmware release notes..................................................................... 5
6. Visual Identification of Motor Type .................................................... 6
7. Preparation for working inside the base casting................................ 7
8. Transformer removal and Replacement Parvalux............................. 9
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

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 3 of 58
2. Change History
Iss.
Date
Effective
S.No.
DCR
No.
Author
Document /
clarification Change
Mechanical Change
0A
06/08/08
-
-
BMC
Initial Draft Instruction
01
13/03/09
-
-
TF
Various
02
09/04/10
-
1700
TF
Additions to spare parts list & fault finding, latest
software version & error codes included.
03
15-06-11
-
1855
TF
Error 2 fault - added 110V issue
432-448 & 432-449 added
Error 9 fault - 307-044 x 2
V1.01-01
Added a 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
30/07/15
-
2287
SL
Error 8 additional info. 428-186 added. Firmware
updates dated. Fault 17 added DCR 2287 up rate fuse
07
11/03/16
-
2548
SL
Motor mounting changed
08
02/02/17
-
2724
GG
PED Open Issue 10068 -
Update service manual
change history table to include
Sno. & Mechanical change
columns & DCR 2724

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
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.

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 5 of 58
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.
840-214 "-d" PROGRAMMING 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, instead of braking it by shorting the
motor terminals, to stop back-drive under load
Implemented in version 1.01-01 (DCR1818) March 2011
Temperature flag for H-bridge ICs now ignored.
Implemented in version 1.01-00 (DCR 1574). April 2009
Code updated to allow it to be configured as a Vortex-d

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
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.
Implemented in version 1.01-02 (DCR 1607). March 2010
‘Error code 6 & Error code 10 messages. (Flyspray ID 157).
- Parameter addresses in eeprom moved to new previously 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 Vortex-d (code written for 1.01-00).
Implemented in version 1.01-00. (Prototype release only).
Code updated to allow it to be configured as a Vortex-d
6. Visual Identification of Motor Type
1. The earth stud and position/orientation of the inlet filter can be used to identify
the motor type.
Parvalux Stand
Dunker Stand

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 7 of 58
7. Preparation for working inside the base casting
2. Ensure 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

Multitest 0.5d, 1d & 2.5d
Service and 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

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 9 of 58
8. Transformer removal and Replacement Parvalux
7. Remove the base plate as per 7, Instructions 2 to 5
8. Locate the transformer as
identified in the photograph
9. Remove the
grey/blue/brown/mauve
transformer connections to the
mains inlet filter
10. 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 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 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
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
countersunk screws holding
the mains inlet filter and ease
it out of position.
15. Disconnect 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 for this purpose –make sure it is fitted
Refitting of the Transformer is the reverse of the above procedure

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 11 of 58
10. 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. 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.

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
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,
which is retained 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 Filter
is the reverse of the above procedure

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 13 of 58
11. 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. 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 the reverse of the above procedure

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 14 of 58
12. 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.
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.

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
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. 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 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 16 of 58
13. 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’),
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 cause stand to go in
reverse direction.

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
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. 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

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 18 of 58
14. 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
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 direction.
This is opposite to how the Parvalux
motors connected.

Multitest 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
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.
58. Remove the motor mounting plate from
the motor.
Earlier Test stands
This is fixed to the 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, 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 0.5d, 1d & 2.5d
Service and Repair Manual
Number 022-005
Issue Number: 08
Page 20 of 58
15. 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. Locate the control PCB as
identified in the photograph
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.
Refitting the PCBs is the reverse of the above procedure.
Note the following photographs and instructions