Mecmesin OmniTest-5.0 User manual

Scope of this document
This document covers all Mecmesin Force and Torque test systems that are mains
powered.
MECMESIN TEST FRAMES HAVE BEEN DESIGNED AND
MANUFACTURED IN A CONTROLLED SYSTEM TO ENSURE
COMPLIANCE WITH ALL RELEVANT EUROPEAN COMMUNITY
DIRECTIVES.
DECLARATION OF CONFORMITY: A copy of the relevant Declaration of Conformity can
be found in the rear of this manual (see section 7.0). Alternatively, electronic copies are
available at the help section of the Mecmesin website: help.mecmesin.com
2019 © Mecmesin Ltd, supplied with Mecmesin test systems and not for redistribution
Part no. 431-398-05

A Guide to Safe Use of Mains Powered Test Systems Mecmesin 1
Contents
1. Icons Used In Manual 3
2. Installing Your Test System 4
2.1 Receiving and Unpacking 4
2.2 Placing and securing the machine 4
2.3 Emergency stop button (E-stop) 4
2.4 Ventilation 5
2.5 Electrical Supply and Earthing 5
3. Using Your Test System 6
3.1 Interlocked Enabled Test Systems 6
3.2 Switching on 7
3.3 Computer-controlled test frames 7
3.4 In the event of a mains power failure 8
3.5 Finishing a test 8
3.6 Using computer-controlled or console-controlled systems with other
equipment 8
4. Removing or Relocating Your Test System 14
4.1 Lifting the test system 14
4.2 Disabling and scrapping 14
5. Servicing, Calibration, Maintenance and Repair 15
5.1 Replacing fuses 15
5.2 Servicing and calibration 15
5.3 Cleaning 16
5.4 Repair 16
6. Operator Safety 17
6.1 Training 17
6.2 Avoid prolonged use of the console or keyboard and mouse 17
6.3 Eye protection and protective clothing 17
7. EC Declaration of Conformity 19
7.1 Document Listing 19

2 Mecmesin A Guide to Safe Use of Mains Powered Test Systems

A Guide to Safe Use of Mains Powered Test Systems Mecmesin 3
CAUTION
The exclamation point icon indicates a situation or condition that could
cause equipment malfunction or damage. Do not proceed until the
caution message is read and thoroughly understood.
Caution messages will be displayed bold type.
INFORMATION
This icon indicates additional or supplementary information about the
action, activity or application.
Information messages will be displayed in bold type.
WARNING
The raised hand icon highlights a situation or condition that may lead to
injury or worse. Do not proceed until the warning is read and thoroughly
understood.
Warning messages will be displayed in bold type.
1. Icons Used In Manual

4 Mecmesin A Guide to Safe Use of Mains Powered Test Systems
2. Installing Your Test System
2.1 Receiving and Unpacking
Before installing or operating your Mecmesin test system please ensure that no visible
damaged has occurred during the shipping process.
If any damage is present, contact your local supplier immediately who will decide the
most appropriate action and rectify the situation as quickly as possible.
Important! If any damage is discovered do not proceed with the
installation and do not connect to the mains supply under any
circumstances
Use safe handling procedures to remove heavy items from the packaging, if
you are unsure how to safely move the test system, consult your
organisation’s health and safety representative or contact your local
Mecmesin agent for assistance.
Once the test system is safely removed from the packaging, place it onto a
stable and level surface. Ensure this surface can safely carry the weight of the
test system.
We strongly recommend that you retain the packaging for the test system as this can be
re-used when the frame needs to be returned to your authorised Mecmesin distributor for
servicing and calibration. Instructions for re-packing the test system are given in your
relevant Assembly and Installation manual.
2.2 Placing and securing the machine
See your test system Installation or Operational manual for details of assembly and fixing. This
may require the mounting of anchor brackets, rubber feet, or bolting down using suitable
fixings. Note that for test frames with a height greater than 1 metre, customers in Europe are
required to ensure that for a force of 20 per cent of machine weight, or 250 Newtons
(whichever is less) applied to the top of the test system shall not be capable of toppling it, or
the test system and bench together. Suitable work surfaces to support weight of test systems
should also be ensured.
2.3 Emergency stop button (E-stop)
Ensure that access to the Emergency Stop button is never obstructed. The E-stop button
will stop all movement of the crosshead or rotating platen. Pushing the E-stop button will
override all other controls. When pressed, the E-stop button will stay latched down,

A Guide to Safe Use of Mains Powered Test Systems Mecmesin 5
preventing any movement of the crosshead or rotating platen. To re-set the E-stop button,
rotate it about 30 degrees clockwise.
2.4 Ventilation
To prevent overheating, ensure that all the air ventilation vents on the test system are not
obstructed. Where a console is fitted and if it is cooled by an internal fan, ensure the
console air vents are not obstructed.
Mecmesin test systems should only ever be installed in suitable
environmental conditions. The operating temperature and humidity should
be within the range given in the specification.
2.5 Electrical Supply and Earthing
Connecting a mains powered test frame to the wrong voltage supply will almost certainly
cause extensive damage to the equipment. Mecmesin test systems must only ever be
connected to a mains power installation that has a fully installed earthing system.
Connection of a mains powered test system to an electrical power outlet
without an earth connection is extremely dangerous and could lead to a risk
of electrocution. Consult your organisation’s qualified electrician if unsure.
The combined mains input socket and voltage selector can be found on the rear panel of
the test system (or on the right-hand side of twin-column force systems). Check that the
voltage selector is set correctly for your supply. The voltage that is selected is the one where
the arrows meet (the power inlet is inverted for some test systems):
▲Selector set to 220-240 V
The voltage selection can be changed by switching off the power and removing the power
lead. The fuse cartridge can now be withdrawn. Rotate the fuse carrier and re-fit it so the
desired voltage marking is the correct way up.
See section 5.1 ‘Replacing fuses’ for how to remove the fuse carrier and replace a fuse.

6 Mecmesin A Guide to Safe Use of Mains Powered Test Systems
3. Using Your Test System
3.1 Interlocked Enabled Test Systems
All MultiTest-i and –xt single column systems supplied from June 2019
onward will be interlock enabled from the factory as standard. All single
column systems will eventually be interlock enabled from factory. An
interlock override plug (351-102) will be supplied in the accessories
packaging of these test systems.
MultiTest single column systems being used without an interlock guard
fitted, must have the interlock override plug (351-102) fitted to the rear
interlock connection in order to operate the test system.
▲Interlock Override Plug (351-102) ▲Single Column Interlock Connection
If the MultiTest system is being used with an interlock enabled guard, then the interlock
override plug is not required to be fitted, as the interlock guard wiring should be
connected instead. Refer to Installation and Operation of Mecmesin Interlocked Guarding
manual (part number 431-971)
▲Interlock Guard Cable Connected on MultiTest Single Column

A Guide to Safe Use of Mains Powered Test Systems Mecmesin 7
3.2 Switching on
After all the above points have been checked and confirmed to be correct, you may connect
the machine to the mains outlet only with the supplied mains leads.
When the power is applied with the ON/OFF switch in the ON position, the front panel
will illuminate with led lighting and information messages (on some models), to indicate
the test system is ready for use.
3.3 Computer-controlled test frames
If the test frame is controlled by an external computer running a Microsoft®Windows
operating system, then we strongly recommend that no other programs are used while
Mecmesin Software is running. Commands and inputs to other software programs could
cause problems with Mecmesin software and result in unpredictable behaviour. Extra
consideration should be given to systems that are connected to networks and the
possibility of unexpected actions as a result of external commands.
Care should be taken with computer-controlled devices such as the mouse and keyboard,
such that they are not inadvertently activated, possibly causing the machine or grips to
move unexpectedly.
3.3.1 Remote control software and applications
We specifically advise against the use of remote control software including tablet ‘apps’
that can be used to operate the system remotely from a separate device. With this type of
software it is possible to reproduce the function of the controlling computer or -xt system
touch screen from another device. This could lead to an unsafe situation where the
movement of the stand is controlled remotely—possibly with the operator in another
location and not able to see the stand or any potential hazard.
3.3.2 Program ‘Hold’ or ‘Pause’
‘Hold’ and ‘Pause’ functions are available in some programs. While a ‘Hold’ or ‘Pause’ is in
progress, the system may appear to be inactive, but then may start moving again without
warning. Do not attempt to adjust the grips or remove the sample until a test is
completed.
An operating test system should never be left unattended. Always disconnect
the machine from the mains power supply when not in use to avoid
inadvertent actuation of the machine by untrained personnel.
3.3.3 Console or computer failure and operation of the front panel jog
buttons
If the console or controlling computer fails or becomes inactive, it is still possible to
control the movement of the crosshead (MultiTest or OmniTest) or rotary platen (Vortex)
by using the jog buttons or wheel, on the front panel of the test system. Operate the jog
buttons to recover a trapped sample. Once the sample has been removed, switch off the

8 Mecmesin A Guide to Safe Use of Mains Powered Test Systems
test system and contact your local Mecmesin distributor for advice before using the test
system again.
3.4 In the event of a mains power failure
If the mains power should fail, the test system will stop moving, and the external -xt
console or touch screen controller may shut down with the loss of unsaved sample test
data.
It is possible that when the power fails, the sample could be under
compression or tension in a force testing system, or under torsion in the
case of torque systems. Care should be exercised when attempting to
release a trapped sample from the grips. It is preferable to wait until the
power is restored and then relieve the strain using the jog buttons before
removing the sample.
3.5 Finishing a test
At the end of testing it is good practice to remove the last sample from the grips. Do not
leave a sample under tension or compression in a force testing system, or under torsion in
a torque testing system, when the power is turned off. This could present a hazard should
an attempt be made to recover the sample either before or after power is re-applied to the
test system.
3.6 Using computer-controlled or console-controlled systems with
other equipment
3.6.1 Digital inputs and outputs
MultiTest-i, FPT-H1i, Vortex-i, Helixa-i and their –xt variants test systems are provided
with digital input and output connections that can be used with other devices, e.g.
Programmable Logic Controllers (PLC). If the system has been connected to such an
external device, it is possible for the PLC to have control over the system. Particular
attention should be paid when configuring the ‘START” and ‘HOME’ commands, as these
can cause the crosshead or rotary platen to move without warning and without any input
to the computer, console or front panel jog buttons.
3.6.2 Assemblies of machines and machinery directive
Where a Mecmesin test frame is used in conjunction with other machinery, it is the
responsibility of the designer to ensure that all relevant directives and standards are
complied with. A Mecmesin designed system will always conform to all relevant
standards and Directives. For more info on Mecmesin system operation, please refer to
the relevant installation or operational manual.

A Guide to Safe Use of Mains Powered Test Systems Mecmesin 9
3.6.3 Interlocking guards general information
A standard Mecmesin guard is designed to prevent object ingress and
operator access to moving parts, and load bearing surfaces, while the
machine is in use.
For materials or test methods where there is a potential for high energy
impacts with the guarding, Mecmesin recommend consultation with their
design team, (directly or through a local agent) to correctly specify
application and safety requirements.
Before use, it is recommended that all operators of the machinery are given
comprehensive training covering both the test system and interlock
guarding’s functionality. Preventative safety measures prior to operation, in
accordance with all relevant operator manuals, should also be considered.
Risk assessment of the guarding and associated test system is recommended
and should be carried out where appropriate. Internal company operating
procedures should also be generated where necessary.
Mecmesin supplied interlocked guarding systems should only be serviced
by a trained Mecmesin employee or approved agent. Any attempt by non-
approved personnel may invalidate any warranty claim and could lead to
damage of equipment or injury. Always ensure correct PPE procedures are
in-place and followed where stated.
IMPORTANT: Where a guard with interlock is fitted, it is the equipment
owner’s responsibility to ensure that the keys for the interlock facility are
controlled in such a way that unauthorised de-activation of the safety guard
interlock is prevented.

10 Mecmesin A Guide to Safe Use of Mains Powered Test Systems
3.6.4 Interlocking guards (OmniTest-5 and Twin Column Force Systems)
All OmniTest-5 and OmniTest Twin Column systems are interlock enabled from factory.
This means that although a guard may or may not be fitted and used, the capability and
function is present.
A retro-fit for these systems is available on request, but it can only be installed by
Mecmesin personnel, or an authorised distributor.
The OmniTest systems use a key-switch to enable and disable (override) the interlock
function. This allows for maintenance, calibration or authorised setting of internal test
area. In some cases it also allows interaction with a sample under test in a controlled
manner.
Interlock
Socket
Interlock
Key Switch
▲ OmniTest-5 Interlock “inactive” ▲ OmniTest-5 Interlock
“active”
The OmniTest-5 system has a socket for connecting the interlock guard cable connection.
Below this is the key-switch, with removable key. This has two positions marked ‘0’ and
‘1’. Position ‘1’ (interlock enabled) is shown circled in red, in the above right-hand image.
Interlock Position
Interlocked Guard Fitted
No Interlocked Guard Fitted
‘0’ (inactive)
interlock bypassed
normal system operation
‘1’ (active)
interlock system operational
system locked - cannot drive
▲ OmniTest-5 Interlock Operation
The OmniTest Twin Column test system (not shown), has the same interlock connector
and the same key switch and removable key.
Access to these are on the rear right-hand side of the twin column system on the top
facing surface.

A Guide to Safe Use of Mains Powered Test Systems Mecmesin 11
For full functional description and operational use guidance, please refer to
the Installation and Operation of Mecmesin Interlocked Guarding manual
(part number 431-971)
3.6.5 Interlocking guards (MultiTest Twin-column Force Systems)
All MultiTest Twin-column systems released since May 2015 have, as standard, a facility
for an interlocked guard. Guards for twin column systems will be supplied pre-fitted
from factory. Where a safety guard is not fitted, there is no interlock guard switch to close
the circuit. Instead there is a key switch on the control panel the key switch in ‘active’
position will effectively lock the system.
Interlock
Socket
Interlock
Key Switch
▲Twin-column Interlock “inactive”▲Twin-column Interlock “active”
Interlock Position
Interlocked Guard Fitted
No Interlocked Guard Fitted
<blank> (inactive)
interlock bypassed
normal system operation
INT (active)
interlock system operational
system locked - cannot drive
▲MultiTest Twin-column Interlock Operation
See also instruction sheet Twin-column MultiTest-i / -xt guard interlock connections, (part no.
431-463).
For full functional description and operational use guidance, please refer to
the Installation and Operation of Mecmesin Interlocked Guarding manual
(part number 431-971)

12 Mecmesin A Guide to Safe Use of Mains Powered Test Systems

A Guide to Safe Use of Mains Powered Test Systems Mecmesin 13
3.6.6 Interlocking guards (MultiTest Single column Force Systems)
All MultiTest-i single column systems supplied from June 2019 onward
will be interlock enabled from the factory as standard. All single column
systems will eventually be supplied interlock enabled from factory. An
interlock override plug (351-102) will be supplied in the accessories
packaging of these test systems. Please keep in a safe location during
installation.
MultiTest single column systems being used without an interlock guard
fitted, must have the interlock override plug (351-102) fitted to the rear
interlock connection in order to operate the test system.
▲Interlock Override Plug (351-102) ▲Rear Panel Interlock Connection
Interlock Override
Plug
Interlocked Guard Fitted
No Interlocked Guard Fitted
Not Fitted
interlock system operational
system locked - cannot drive
Fitted
interlock bypassed
normal system operation
▲MultiTest Single column Interlock Operation
For full functional description and operational use guidance, please refer to
the Installation and Operation of Mecmesin Interlocked Guarding manual
(part number 431-971)

14 Mecmesin A Guide to Safe Use of Mains Powered Test Systems
4. Removing or Relocating Your Test System
The test system must be powered down before attaching or removing cables. When the
connectors are not in use, please ensure that they are covered with the connector covers
all the time. No cable should exceed 3 metres in length.
Note: in the case of -xt systems, or if using a touch screen controller, it is advisable to
remove the touch screen console from the test system before moving the machine.
4.1 Lifting the test system
Use safe handling procedures to remove heavy items from the packaging, if
you are unsure how to safely move the test system, consult your
organisation’s health and safety representative or contact your local
Mecmesin agent for assistance.
The specification in your relevant operation manual gives the weight of the
test system. Use suitable lifting equipment if required. The preferred
method of lifting all twin-column systems is by use of the supplied lifting
eye-bolts fitted to the top of both columns. If in doubt, consult your local
supplier to ensure continued safe use.
4.2 Disabling and scrapping
When the test system has reached the end of its useful life, it should be decommissioned.
Remove the electricity supply cable to the test frame and, if appropriate, the console
power adaptor.
Dispose of the test system in accordance with all local and national safety
and environmental requirements.

A Guide to Safe Use of Mains Powered Test Systems Mecmesin 15
5. Servicing, Calibration, Maintenance and Repair
Once the test system is installed it should provide a reliable long-term resource for
specified testing.
Mecmesin test systems contain no user-serviceable parts other than fuses within the
mains inlet socket.
5.1 Replacing fuses
To replace a fuse, first switch off the mains power at the back of the test system and
disconnect the power lead.
Insert the tip of a screwdriver into the fuse carrier slot as shown below, and gently lever
the carrier out:
Removing the fuse carrier Carrier removed to replace fuse Selector set to 220-240 V
The carrier contains two fuses. These should both be replaced with fuses of the same
rating and size as those removed. Refit the fuse carrier with the selector matched to the
mains voltage being used, as shown above.
Reconnect the mains power lead and switch on.
5.2 Servicing and calibration
To ensure optimal safe performance, your test system must be regularly serviced and the
Force or Torque transducers calibrated by Mecmesin Ltd or an authorised distributor.
If the system is damaged in use, advise your local supplier and have the
machine repaired to a safe working condition. Do not use the machine until
it has been repaired.

16 Mecmesin A Guide to Safe Use of Mains Powered Test Systems
5.3 Cleaning
You may need to clean the outside of your test system from time to time. This can be
done by disconnecting the mains electricity supply, removing loose debris with a soft
brush, then wiping with a damp cloth.
Note: when cleaning the membrane keypad, care must be taken to avoid liquids,
especially alcohols, seeping around the edge of the membrane. Therefore, we recommend
the use of a lightly dampened cloth to avoid liquid spillage onto the membrane. Under no
circumstances should organic solvents or any other cleaning fluid be used.
5.4 Repair
If the test system fails, or incorrect operation is suspected, contact your local supplier for
support.
Do not continue use of the test system until it has been fully checked by a
Mecmesin authorised party. This may if necessary, include return and
repair to a Mecmesin approved facility. It will then be returned to you in
safe working condition. Do not attempt to open any system or attempt
repair without consulting Mecmesin or your local supplier.
Unauthorised servicing or repair may invalidate any resulting warranty
claim.