Installation & Operation of Mecmesin Interlocked Machine Guarding

Revision ID

11258
Manual
431-971

1 Installation & Operation of Mecmesin Interlocked Machine Guarding

MLTE Front Cover

 

Mecmesin Logo

431-971

March 2020

2 Introduction

Mecmesin standard interlocked guarding is designed to seamlessly integrate with a Mecmesin OmniTest, MultiTest-dV and MultiTest-i motorised test stand.

This document covers the installation and operation of the following products:

Single Column Test Stands

  • 432-680 - MultiTest 0.5 kN Interlocked Guard
  • 432-681 - MultiTest 1 kN Interlocked Guard
  • 432-682 - MultiTest 2.5 kN Interlocked Guard
  • 432-684 - OmniTest 5 & 7.5 kN Interlocked Guard

Twin Column Test Stands

  • 805-017+G - MultiTest-i 10 kN & Interlocked Guard
  • 805-016+G - MultiTest-i 25 kN & Interlocked Guard
  • 805-023+G - MultiTest-i 50 kN & Interlocked Guard
  • 815-004+G - MultiTest-xt 10 kN & Interlocked Guard
  • 815-005+G - MultiTest-xt 25 kN & Interlocked Guard
  • 815-006+G - MultiTest-xt 50 kN & Interlocked Guard
  • 820-010+G - OmniTest 10 kN & Interlocked Guard
  • 820-025+G - OmniTest 25 kN & Interlocked Guard
  • 820-050+G - OmniTest 50 kN & Interlocked Guard
Safe operation and use must be observed at all times, failure to follow instruction may lead to loss of warranty or injury. This user manual must be read in full before operating your test stand in conjunction with the guarding.
All interlocked guarding provided for torque test systems - (Vortex-i, xt, Helixa-i, xt and Vortex-dV) are supplied as 'PDVs' (Product Design Variants). This means they will be supplied as a additional item upon special request only. Please contact your local Mecmesin sales representative or authorised distributor for more details. This document does not cover those products or operations.

For further guidance relating to software operation refer to the user manual below: 

 VectorPro Logo  

VectorPro™ User Manual - Introduction and Initial Setup (431-955-04)

Covers the initial setup and installation of VectorPro, as well as the basics of the software functionality and user manuals. Further guidance relating to other aspects of VectorPro can be accessed through this user manual.

For more information relating to a test stands operation, please refer to the user manual supplied with the device.

2.1 User Manual Icons

Throughout this manual, the icons shown below are used to identify important health and safety information as well as additional installation/operation guidance. Do not proceed until each individual message is read and thoroughly understood. 

2.1.1 Warning

The warning icon highlights a situation or condition that may lead to possible personal injury or damage to the associated equipment.

2.1.2 Caution

The caution icon indicates a situation or condition that could cause the equipment to malfunction leading to possible damage. 

2.1.3 Information

The information icon indicates additional or supplementary information about the action, activity or application.
Table of Contents

3 Guard Safety Overview

The interlocked guarding helps to provide additional ingress protection to your test system, helping to reduce the risk of an operator or object coming into contact with a moving test stand. The guard is designed to be used in a dry, clean and tidy environment and should be placed on a stable and load appropriate work platform away from potentially hazardous environments or items. Mecmesin motorised test stands are designed to be used while under constant supervision, the addition of an interlocked guard does not alter this requirement, failure to monitor a test stand in operation could lead to damage to the equipment or injury to others.

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 stand and interlock guarding’s functionality. Preventative safety measures prior to operation, in accordance with all relevant operator manuals, should also be considered. Risk assessments of the guarding and associated test stand is recommended and should be carried out where appropriate. Internal company operating procedures should also be generated where necessary.
All standard Mecmesin supplied guards are fitted with clear Polycarbonate sheeting to help maximise viewing of the test area. These sheets are fitted to the front panel of twin column systems and all sides of single column guarding (Front, rear and sides).

4 Operator Safety

After successful completion of installation and training, it is a mandatory requirement that the interlock switch is set to key position ‘1’ (or interlocked guard connected for test stands below 5 kN). The key (or override plug) should then be removed and given to an assigned supervisor or safety officer within the organisation and stored away. The key (or override plug) is still required for calibration and service requirements.

4.1 Training

Before using either the test stand or guarding, it is essential that each person operating the equipment is fully trained in the safe use of motorised testing machines and the guarding’s functionality. Training can be arranged by contacting Mecmesin Ltd or an authorised distributor.

Mecmesin test stands have the ability to generate forces large enough to cause permanent injury to human limbs when placed between the crosshead and the base. Fingers, hands and other parts of the body should be kept away from the moving crosshead and shroud opening.
Interlocked machine guards should be considered in all test methods as they provide additional ingress protection to the end-user. This helps to reduce the risk of injuries occurring due to contact between the test stand and the operator.

4.2 Eye Protection and Protective Clothing

Although a standard Mecmesin interlocked guard will provide some protection against projectiles that may be ejected when a brittle sample fails, the device has primarily been designed to provide ingress protection to prevent the operator and other items from coming into contact with the moving test stand. 

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.

Eye protection should always be used. Ensure an approved pair of safety spectacles are worn at all times.
Additional personal protection may be necessary if destructive testing or volatile failure of a test piece is likely. Consideration needs to be given to the likely behaviour of the samples being tested and the use of any appropriate personal protective equipment that may be needed.

A risk assessment should be carried out prior to using the test stand to ensure that all necessary safety measures have been considered and carried out. It is important to review the risk assessment if new tests or new samples are introduced.

Recommended Operating Position

Mecmesin recommends that the test stand and guard assembly are placed so that the front panel is clearly visible and can be reached. For single column test stands, this will typically require the base of the machine to be approximately at waist height.

An example of the recommended operation position is shown in the image above. Here the operator has easy access to the front panel as well as a clear view over the entire test stand.

Please Note: The illustration shown above is not to scale. 
Improper mounting of the test stand can lead to injury or damage to the machine. This may occur instantly, or over time, test stands that are placed too high or low can lead to repetitive strain injuries.
For twin column and taller single column models, the level at which the test stand can be placed may be restricted by the height of the ceiling.

6 System Diagrams

Below are system diagrams for the four main guarding variants. Click on an individual system diagram to view a larger version of the image.

6.1 MultiTest - 0.5 kN, 1 kN & 2.5 kN

Below is a list of Mecmesin Interlocked Guards compatible with single column MultiTest systems (please note that only 432-682 is shown in the system diagrams):

  • 432-680 - MultiTest 0.5 kN Interlocked Guard
  • 432-681 - MultiTest 1 kN Interlocked Guard
  • 432-682 - MultiTest 2.5 kN Interlocked Guard

MultiTest-dV Diagrams

1 Door Handle
2 Clear Polycarbonate Sheet
3 Control Panel Access
4 Interlock Mechanism
5 Rear Panel Access

6.2 OmniTest - 5 kN & 7.5 kN

Below is a list of Mecmesin Interlocked Guards compatible with single column OmniTest systems:

  • 432-684 - OmniTest 5 kN & 7.5 kN Interlocked Guard

OmniTest 5.0 & 7.5 Diagram

1 Door Handle
2 Clear Polycarbonate Sheet
3 Control Panel Access
4 Interlock Mechanism
5 Rear Panel Access

6.3 Twin Column Test Stands – 10 kN & 25 kN

Below is a list of all available 10 kN and 25 kN Mecmesin twin column test systems fitted with interlocked guards (please note that 820-010+G/820-025+G is shown in the system diagrams):

  • 805-017+G - MultiTest-i 10 kN & Interlocked Guard
  • 805-016+G - MultiTest-i 25 kN & Interlocked Guard
  • 815-004+G - MultiTest-xt 10 kN & Interlocked Guard
  • 815-005+G - MultiTest-xt 25 kN & Interlocked Guard
  • 820-010+G - OmniTest 10 kN & Interlocked Guard
  • 820-025+G - OmniTest 25 kN & Interlocked Guard

OmniTest 10 & 25 Diagram

 

1 Door Handle
2 Clear Polycarbonate Sheet
3 Control Panel Access
4 Side Connectors Panel
5 Force/Transducer Socket

6.4 Twin Column Test Systems – 50 kN

Below is a list of all available 50 kN Mecmesin twin column test systems fitted with interlocked guards (please note that only 820-050+G is shown in the system diagrams):

  • 805-023+G - MultiTest-i 50 kN & Interlocked Guard
  • 815-006+G - MultiTest-xt 50 kN & Interlocked Guard
  • 820-050+G - OmniTest 50 kN & Interlocked Guard

OmniTest 50 Diagram

1 Door Handle
2 Clear Polycarbonate Sheet
3 Control Panel Access
4 Connectors Panel
5 Force/Transducer Socket

7 Unpacking and Parts Supplied

7.1 Single Column Test Stands - Inspection and Unpacking

Information relating such the exact weight and dimensions of each interlocked guard model is located in the 'Specification' section of this manual.

Before installing or operating your Mecmesin guarding please ensure that no visible damage has occurred during the shipping of the guarding.

Important! If any damage is discovered, do not proceed with the installation.

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. 

Use safe handling procedures to remove heavy items from the packaging, if you are unsure how to safely move the guarding consult your organisation’s health and safety representative or contact your local Mecmesin agent for assistance.
Once the guarding is safely removed from the packaging, place it onto a stable and level surface. Ensure this surface can safely carry the weight of the guarding and is suitable to secure the system to.

7.2 Twin Column Test Stands – Inspection and Unpacking

Mecmesin twin column test stands ordered with interlocked guarding come pre-assembled as one unit. For weight and dimensions of twin column test systems with an additional interlocked guard, please see the 'Specification' section of this manual. 

For safe handling and placement of the test stand, please refer to your systems user manual for more information.

7.3 Packaging

We strongly recommend that you retain the packaging for the machine guard as this can be re-used if the device needs to be returned to your authorised Mecmesin distributor for periodic servicing or modification. 

7.4 Safe Handling of Single Column Interlock Guards

To install the test stand’s guarding it is required to lift and move the interlocked guard, improper lifting technique or handling of the guard could lead to injury or damage to the equipment.

Before moving the guard, an assessment should be carried out by a qualified individual to determine how to move the guarding safely. 

Due to the weight and size of the guarding, it is recommended that at least two people are needed to lift a single column guard during the installation phase. Refer to the 'Specification' section for the precise weight of the guard.

7.5 Additional Items Supplied with Your Guard

The items supplied with your guard varies depending on the model. The next section contains a list of the parts supplied with the interlocked guard. Please note some items are only supplied for xt systems.

For single column test stands, a set of metric hex keys are required to remove and refit screws supplied in the guard assembly.

7.5.1 432-680, 432-681, 432-682 - MultiTest 0.5 kN, 1 kN, 2.5 kN 

Part No. Description Qty
409-080 Guard Foot Spacer Block 4
420-638 M6 x 35 Skt Cap 4
- Guard Door Key 2
408-843 10mm Tee Slot Nut (only required for xt-console mounting) 1
408-921 Console Arm Mounting Bracket (only required for xt-console mounting) 1
420-076 M5x5 Grub Screw (only required for xt-console mounting) 2
420-536 M8x12 Skt Cap (only required for xt-console mounting) 2

7.5.2 432-684 - OmniTest 5 kN & 7.5 kN Only 

Part No. Description Qty
- Guard Door Key 2

7.5.3 10 kN, 25 kN and 50 kN Twin Column Guarded Systems

Part No. Description Qty
- Guard Door Key 2
408-921 Console Arm Mounting Bracket (Only required for xt-console mounting) 4
420-536 M8 x 12 mm Socket Cap (Only required for xt-console mounting) 2

8 Single Column Guard Installation

Before installing a single column guard, it is important to read the next section in full, failure to do so could lead to injury or damage to the test equipment.

8.1 Prerequisites

Before installing your single column guarding, ensure you are working in a suitable area.

It is important that there is a clear, stable work surface to place both the guard and the associated test stand that is suitable to secure the system to, and that all potential risks have been assessed before starting the installation phase.

Installation of interlocked machine guarding should only be carried out by qualified,  authorised personnel. 

Failure to follow the installation instructions within this manual could result in serious injury to the user or those around the machinery. It could also cause damage to the equipment or surrounding environment.

Due to the weight and size of the guarding, it is recommended that at least two people are needed to lift single column guarding during the installation phase. Refer to the  'Specification' section for the precise weight of the guard.
Mecmesin recommends that a full risk assessment is carried out covering the placement and operation of the interlocked guard in conjunction with your test stand fixtures. This should be carried out by the end-user.
When fitted, the guard is designed to enclose the test stand and its working area. The machine itself is placed within the enclosed assembly.  Although the guard will be supplied assembled, there is a requirement for some dismantling in order to complete the installation process.

8.2 MultiTest Single Column - Installation Guide

Unpack the guard assembly and safely lift it on to a stable work surface that is suitable to secure the system to. Ensuring that the lower plate can be easily accessed. Unlock the guard door using the key supplies.
Check that all connections, including the mains power lead, are disconnected from the MultiTest’s rear panel.

Annotated Guard Base

Locate the four right-angled brackets that connect the guard to the lower base plate. These are circled in the image above. 

Removing the Guard Base

Using a suitable metric hex key remove the existing fixings from the lower section of the right-angled bracket as shown in the image above. This will release the lower base plate from the guard.

Guard Base Removed

Carefully lift the upper guard away from the base plate and place it to one side on a suitable work surface.

Ensure safe handling procedures are followed when lifting the guarding assembly. 

Removing the Feet

Remove the four rubber feet from their threaded holes located on the bottom of the MultiTest system using a suitable flat head screwdriver. This is shown in the image above.

These holes will be used to mount the guard’s baseplate to the bottom of the test stand.

Fitting the Spacers

Secure the guard’s baseplate to the test stand using the four supplied M6 x 35 mm countersunk screws (420-638).

Each screw should pass through the guard’s baseplate, then through one of the supplied spacers (409-080), before locating in the threaded holes on the bottom of the test stand. This is shown in the image below.

Close up of the Spacers

These spacers must be fitted between the guard’s baseplate and the test stand to ensure the stand is sufficiently cooled during operation. 

MultiTest Base Mount

For taller test stands (0.5 kN and 1 kN), it may be necessary to lay the stand on its back to fit the cover. Ensure that the stand is supported when placed in this position.

Lower the main guard body over the test stand and secure it to the base plate using the four supplied screws that had been previously removed. This is shown in the image above. An example of the complete assembly is displayed below.

MultiTest with Guard

Ensure safe handling procedures are followed when lifting the guard assembly onto the base plate. 

Base Hole Pattern

To prevent the test stand from toppling it is strongly advised that the test stand and guard assemblies are secured to a level workbench. The holes circled in the image above should be used to secure the assembly. Dimensions are available in the 'Specification' section.

MultiTest Bench Mount

Using suitable fixings secure the test stand and guard assembly to the workbench using the countersunk mounting holes circled in the image above. It is recommended that through bolts are used with retaining nuts on the underside of the work surface; washers should be used between the work surface and the retaining nuts. 

MultiTest-dV Rear Panel             

MultiTest-i Single Column Rear Panel

                                                                 

Locate the external interlock guard loom and feed it around to the MultiTest rear connectors panel. Ensuring that the cable is not trapped or close to any moving parts. 

Remove the plastic covering from the end of the cable and connect it to the appropriate MultiTest’s rear panel 6-way socket marked 'INTERLOCK', as shown in the images above.

8.3 OmniTest Single Column – Installation Guide

Unpack the guard assembly and safely lift it on to a stable work surface that is suitable to fix the system to. While ensuring that the lower plate can be easily accessed. Unlock the guard door using the key supplied.
Check that all connections, including the mains power lead, are disconnected from the OmniTest’s rear panel. 

The guard can be fitted by either lowering it over the test stand or sliding it in from the rear (used if ceiling height prevents the first method). 

If the guard is to be lowered on to the test stand continue to Step 3. If the guard is to be slid in from the rear of the test stand proceed to sub-section 'Rear Slide Assemble'.
 

Annotated Guard Base

Locate the four right-angled brackets that connect the guard to the lower base plate, these are circled in the image above. 

Removing the Guard Base

Using a suitable metric hex key remove the fixings screws from the lower section of the right-angled bracket, as shown in the image above. This will release the lower base plate from the guard.

Guard Base Removed

Carefully lift the upper guard away from the base plate and place it to one side on a suitable work surface.

Ensure safe handling procedures are followed when lifting the guarding assembly.

 

OmniTest Feet Stops

First, the front foot stops will need to be removed before locating the OmniTest single column stand to the base plate. 

Next, carefully slide the OmniTest on to the plate locating the test stand’s rear feet between the two rear foot stops. The rear foot stops are shown in the image above.  

OmniTest Feet Location

Once the OmniTest is located in the rear two stops, fit and secure the front foot stops using the supplied cap head screws. The secured assembly is shown in the image above.

Ensure safe handling procedures are followed when lifting the Omnitest system onto the base plate. 

OmniTest Securing the Guard

It may be necessary to lay the stand on its back to fit the cover. Ensuring that the stand is supported when placed in this position. 

Lower the main guard body over the test stand and secure it the base plate using the four screws that had been previously removed. This is shown in the image above. An example of the complete assembly is displayed below.
OmniTest with Guard

Ensure safe handling procedures are followed when lifting the guard assembly onto the base plate.

Base Plate Hole Pattern OmniTest

To prevent the test stand from toppling it is advised that the test stand and guard assemblies are secured to a level workbench. The holes circled in the image above should be used to secure the assembly. The holes are 6mm in diameter and are countersunk. Dimensions for the holes can be found in the 'Specification' section.

It is recommended that through bolts are used with retaining nuts on the underside of the work surface; washers should be used between the work surface and the retaining nuts. 

Interlock OmniTest Rear Connector

Locate the external interlock guard loom and carefully fit it to the OmniTest’s rear connectors panel. Ensuring that the cable is not trapped or close to any moving parts. 

Remove the plastic covering from the end of the cable and connect it to the OmniTest’s rear panel 6-way socket marked 'INTERLOCK', as shown in the image to the right.

8.3.1 Rear Slide Assembly Method

The following steps cover how to fit the guarding from the rear of the test stand. 

To slide the guard in from the rear of the test stand, as opposed to lowering it from the top of the test stand, the front extrusion will need to be removed.

Guarding Top Cap Removal

Remove the top caps from both each side of the lower front extrusion, as shown in the images above. The cap should be moved upward to release it from the extrusion, this is displayed in the image below. 

Remove Lower Top Cap

Removing Front Extrusion Cross Member

Use an Allen key to loosen the two retaining screws in the front extrusion as shown in the image above. 

The image shown includes the test stand. However, in reality, the test stand would not be in the picture at this stage of installation.

Slacken the Extrusion

Once both screws have been loosened, carefully lift the extrusion section upwards to remove.

OmniTest Feet Stops

First, the front foot stops will need to be removed before locating the OmniTest single column stand to the base plate. 

Next, carefully slide the OmniTest on to the plate locating the test stand’s rear feet between the two rear foot stops. The rear foot stops are shown in the image above.  

OmniTest Feet Location

Once the OmniTest is located in the rear two stops, fit and secure the front foot stops using the supplied cap head screws. The secured assembly is shown in the image above.

Ensure safe handling procedures are followed when lifting the OmniTest system onto the base plate. 

Pictured above is the guard, with the front frame section and door removed, ready to be fitted to the test stand.  

The guard can now be slid into place from the rear of the test stand, taking care not to cause damage during this process. 

Ensure safe handling procedures are followed when lifting the guard assembly onto the base plate.

The next step is to re-attach the front extrusion. First, position the extrusion as shown in the image above

Then tighten the fixings as shown

Once the extrusion is secured, re-fit the top caps to each section.

Base Plate Hole Pattern OmniTest

To prevent the test stand from toppling it is advised that the test stand and guard assemblies are secured to a level workbench. The holes circled in the image above should be used to secure the assembly. The holes are 6mm in diameter and are countersunk. Dimensions for the holes can be found in the 'Specification' section.

 

It is recommended that through bolts are used with retaining nuts on the underside of the work surface; washers should be used between the work surface and the retaining nuts. 

Interlock OmniTest Rear Connector

Locate the external interlock guard loom and carefully fit to the OmniTest’s rear connectors panel. Ensuring that the cable is not trapped or close to any moving parts. 

Remove the plastic covering from the end of the cable and connect it to the OmniTest’s rear panel 6-way socket marked 'INTERLOCK', as shown in the image to the right.

8.4 xt Console Installation

For xt systems, the console needs to be fitted to the guarding, instead of the test stand. This can be completed by following the steps below. Please note Steps 1 and 2 only apply to single column test stands; twin column test stands come with the Tee-slot nut fitted.

For single column guards, ensure that the guarding assembly has been mechanically secured to a stable work surface, before fitting the xt console. This is to prevent the risk ot toppling or tilting with the extra weight and work needed to fit the console assembly. 

Remove the Top Cap

To prevent the console from being obscured by the guarding’s door, it is recommended that the xt console is fitted to the right-front extrusion, (this is highlighted in the image above). Remove the top cap from the right-hand extrusion, as shown in the image below. 

Remove Top Cap Close

Tee Slot Nut

Slide the supplied 10mm Tee-slot nut (part number 408-843) into the extrusion. Ensure that the Tee-slot nut is oriented, so the two M8 holes are at the top.

Position the Nut

Position the nut as per the image above; this should be just above the door latch. Lock the Tee-slot nut it in place using the two supplied grub screws provided into the holes highlighted above.

Align the Holes

With the Tee-slot nut in position, align the holes in the console arm mounting bracket with the M8 holes in the Tee-slot nut.

Fixing the Mounting Bracket

The image above shows the mounting bracket secured to the guarding’s extrusion. When fitting, ensure the bracket is correctly aligned to the frame before securing it in place with the two supplied cap screws.

Fitting the Console Arm

Fit the console arm to the rear of the mounting bracket using the two supplied countersunk Torx-head screws.

Console Fitted

The image above shows the console arm and xt console correctly fitted to the guarding.

It is recommended that two people are used to fit the console; one to hold the console arm and one to secure the fixing screws. Improper handling could lead to damage to the equipment or injury.

Adjust the Height

If the height of the console arm needs adjusting, unscrew both supplied socket cap screws and remove the mounting bracket with the console.

Re-position the Nut

Slacken off the M5 grub screws using an Allen key and slide the bracket to the desired height. Tighten the grub screws and then refit the mounting bracket and console.

It is recommended that two people are used to fit the console; one to hold the console arm and one to secure the fixing screws. Improper handling could lead to damage to the equipment or injury.
 

8.4.1 Single Column Override Plug

Override Plug

Single column test stands below 5 kN use an override plug, instead of a key switch, to override the interlock circuit. The override plug is shown in the image above.

To override the guard and allow the use of the test stand without the guard’s interlock function active, fit the override plug to the interlock socket located on the test stand’s rear connectors panel, as highlighted in the image above.

To activate the interlock guard, remove the override plug, ensuring it is stored in a safe location, and connect the guard’s loom to the interlock socket located on test stand’s rear connectors panel.

8.5 Twin Column Guard Bung

To allow addition cables to pass through the guarding there is an additional hole located next to ELS socket, as shown in the image below:

Twin Column Bung

You can remove the twin column guard bung by pushing it out from inside of the guard.

Removed Bung

Remove any load from the test stand and ensure the power supply is switch off before removing the guard bung. Failure to do so could lead to damage to the equipment or injury.
Mecmesin strongly advises that the guard bung is left fitted to the side panel at all times during normal test use, especially when the machine is running.

8.6 Checking the Interlock Function and Operation

Once the installation is complete, the next step is to test the interlock circuit. First, ensure that all required cables have been connected to the machine and the device is switched on and ready to use. The interlock’s functionality is described below.

A set of interlock keys are provided, these are used to enable and disable the interlock circuit. 

For single column test stands below 5 kN, an interlock override plug is provided with the test stand. This is fitted to the stands rear panel connector to disable the test stand’s interlock circuit instead of using a key switch.

8.6.1 Interlock Key Switch Set to ‘0’ (Override Plug Connected)

Interlock Disabled

With the key switch set to the ‘0’ position (key horizontal), the interlock circuit is disabled and the guard door can be opened without error. 
The test stand can be moved up or down freely and cannot be interrupted by the interlocked guard.

For single column test stands below 5 kN, the interlock override plug should be fitted in place of the guard’s connector. This will allow the system to be moved freely without interruption from the interlock circuit.

8.6.2 Interlock Key Switch Set to ‘1’ (Interlocked Guard Connected)

Interlock Enabled

With the interlock cable fitted and the key switch set to the ‘1’ position (key vertical), the interlock circuit function is enabled. 

For single column test stands below 5 kN, simply fit the interlocked guard’s connector in place of the override plug.

Opening the door will inhibit the motor drive of the test stand, and a warning will be displayed on the front panel (OmniTest and dV test stands only) and software (if connected). The user can not move the machine. If a test is in operation as the door is opened, the test will be immediately stopped.

8.7 MultiTest-dV and OmniTest Interlock Function Test

The following section only applies to MultiTest-dV and OmniTest systems.

Work through the table below row-by-row setting the interlock key switch as per the first column and the guard door position as per the second column.

For MultiTest-dV test stands, fit the interlock override plug when the first column states a switch position of ‘0’ and the interlocked guard’s connector at switch position of ‘1’.

Next, invoke the test stand operation stated in the third column. This will involve either manually jogging the test stand or attempting to run a test. Check the error message and front panel status of the test stand against the ‘Error Message’ and ‘Front Panel’ columns: 

Switch Position Guard Door Status Stand Operation Error Message Front Panel VectorPro Message
0 Door Closed Jog UP or DOWN None Front Panel Ready None
0 Open Guard Door     Jog UP or DOWN None Front Panel Ready None
0 Open Guard Door RUN Test None Front Panel Ready None
1 Door Closed Jog UP or DOWN None Front Panel Error None
1 Open Guard Door Jog UP or DOWN INTERLOCK ACTIVE Front Panel Error Warning Message Displayed
1 Open Guard Door RUN Test INTERLOCK ACTIVE Front Panel Error Warning Message Displayed

Please refer to the section 'VectorPro - Warning Message' for more information relating to VectorPro warning messages.

Should any of the above checks fail to indicate the correct test stand state or operation, then consult your test stand's relevant user manuals. Seek assistance from a local agent or Mecmesin Technical Support if the fault cannot be rectified.
Failure to adhere to these checks could cause damage to both the end-user and test equipment. It may also affect the warranty terms.

8.8 MultiTest-i Interlock Function Test

The following section only applies to MultiTest-i test stands.

Work through the table below row-by-row setting the interlock key switch as per the first column and the guard door position as per the second column. 

Next, invoke the stand operation stated in the third column, this will involve either jogging the test stand in Emperor or attempting to run a test. Check any error message in Emperor against the ‘Error Message’ column in the table:

Switch Position Guard Door Status Stand Operation Software Error Message
0 Door Closed Jog UP or DOWN None
0 Open Guard Door     Jog UP or DOWN None
0 Open Guard Door RUN Test None
1 Door Closed Jog UP or DOWN None
1 Open Guard Door Jog UP or DOWN INTERLOCK OPENED
1 Open Guard Door RUN Test INTERLOCK OPENED

Please refer to the section 'Emperor - Warning Message' for more information relating to Emperor warning messages.

Should any of the above checks fail to indicate the correct test stand state or operation, then consult your test stand’s relevant user manuals. Seek assistance from a local agent or Mecmesin Technical Support if the fault cannot be rectified.
Failure to adhere to these checks could cause damage to both the end-user and test equipment. It may also affect the warranty terms.

9 Operation

9.1 Scope of Use

Mecmesin interlocked guarding helps to provide additional ingress protection against foreign objects while also reducing the risk of an operator coming into contact with a moving test stand.

The guard is designed to be used in a dry, clean and tidy environment and should be placed on a stable and load appropriate work platform away from potentially hazardous environments or items.

Mecmesin motorised test stands are designed to be used while under constant supervision, the addition of an interlocked guard does not alter this requirement, failure to monitor a test stand in operation could lead to damage to the equipment or injury to others.

The interlocked machine guard has the following primary functions:

  • Provide ingress protection to operators when using the machine. To prevent hand trap conditions or deliberate interaction with the test area during the test sequence.
  • The ability to end a test sequence or ensure that the machine motor drive is inhibited if the interlock circuit is broken (door opened).
  • Permanently enable/disable interlock function with a removable key or override plug.
Although the guarding’s design will stop ejection of some materials, it is not designed to act as a shield against projectiles created during a test. The primary function of the guarding is to provide ingress protection.
Should there be a need to calibrate the machine, or perform maintenance or service tasks to be completed, the interlock can be disabled with appropriate authorisation.

9.2 MultiTest-dV and OmniTest Interlocked Guard Examples

9.2.1 Example 1

Switch Position Guard Door Status Stand Operation Error Message Front Panel VectorPro Message
0 Door Closed Jog UP or DOWN None Front Panel Ready None

In this example, the authorised user requires the door to be open while jogging the test stand. A scenario where jogging the machine with the door open may be beneficial is when first fitting a set of grips to the test stand.

As the interlock key switch is set to ‘0’ (override plug connected for MultiTest-dV test stands), the guarding does not restrict the test stand’s movement and the system can be jogged with the door open.

If the interlock key switch is set back to ‘1’ (interlock guard connected for MultiTest-dV test stands) the operator will be unable to jog the machine with the door open.

9.2.2 Example 2

Switch Position Guard Door Status Stand Operation Error Message Front Panel VectorPro Message
1 Open Guard Door Jog UP or DOWN INTERLOCK ACTIVE Front Panel Error Warning Message Displayed

In this example, the operator is attempting to jog the test stand with the door open, but the stand will not move. 

As the interlock system is active, the test stand is displaying the error message ‘INTERLOCK ACTIVE’. The test stand’s motor will remain restricted until the door is closed. Once the door is closed the error condition will disappear, allowing the test stand to be moved.

9.2.3 Example 3

Switch Position Guard Door Status Stand Operation Error Message Front Panel VectorPro Message
1 Operator Opens Guard Door Test Running INTERLOCK ACTIVE Front Panel Error Warning Message Displayed

In this example, the operator has opened the guard door while the test was running. As the interlock system is active, the test will immediately stop, and the test stand will display the following message ‘INTERLOCK ACTIVE’.

If the test stand is being used injunction with VectorPro, the data capture for the sample will be aborted and a warning message will be displayed. The motor drive will remain inhibited until the door is closed.

9.2.4 VectorPro™ - Warning Message

If the interlocked guard door is opened during a test (and the interlock system is active) the warning message shown below will be displayed:

VectorPro Warning Message

At this point, the test will be aborted, and the machine drive will be inhibited. Closing the guard door will remove the machine display panel error, but the test sample being recorded in VectorPro cannot be continued. The test is automatically aborted.

9.2.5 VectorPro™ - Pause Operation

When using VectorPro in conjunction with an interlocked machine guard, certain operations allow for the guard warnings to be overwritten. These timeline operations are in the ‘Pause’ section of VectorPro and they allow the door to be opened without aborting a test.

When a ‘Pause’ operation in the test timeline is reached, the test stand will stop and the window shown below is displayed onscreen. This indicates which button to press on the front panel to continue the test.

Front Panel Pause Button

While the test is paused, the guard door may be opened and closed. Once ‘Play’ is pressed, the test will continue. If the door is left open when pressing ‘Play’, the test will immediately abort.

Opening the guard door without a software ‘Pause’ active will also operate the interlock circuit in the usual manner. 

Interlock Active Message

During a ‘Pause’ operation, the following message will be displayed on the test stand’s front panel when opening the guard; ‘Interlock Active !’. This is shown in the image above.

For more information relating to ‘Pause’ operations, please read on from the section 'Pause Operations' of the 'VectorPro™ User Manual - Designing a Test MT Version'.

9.2.6 VectorPro™ - Pause Operation Safety

When using a ‘Pause’ function in conjunction with a Mecmesin interlocked guard, the following information should be observed:

During a test, if the door is opened the test stand’s motor drive will be halted. Potential high forces could still be applied in the specimen under test and risk of damage or injury could be present to the operator.
Should these warnings be active when the interlocking door is closed and the interlock is enabled, then seek assistance and do not proceed with any operations. Seek qualified help and arrange for service of the machine.
With the interlock enabled, should any part of the interlock circuit connectivity become faulty, then the interlock will fail in a safe manner and activate the standard warnings.

9.3 MultiTest-i and xt Interlocked Guard Examples

9.3.1 Example 1

Switch Position Guard Door Status Stand Operation Software Error Message
0 Door Closed Jog UP or DOWN None

In this example, the authorised user requires the door to be open will jogging the test stand. A scenario where jogging the machine with the door open may be beneficial is when first fitting a set of grips to the test stand.

As the interlock key switch is set to ‘0’ (override plug fitted for single column systems) the guarding does not restrict the test stand’s movement. The system can be jogged with the door open.  

If the interlock key switch is set back to ‘1’ (override plug removed for single column test stand and the guard loom connected) the operator will be unable to jog the machine with the door open.

9.3.2 Example 2

Switch Position Guard Door Status Stand Operation Software Error Message
1 Open Guard Door Jog UP or DOWN INTERLOCK OPENED

In this example, the operator is attempting to jog the test stand with the door open, but the stand will not move as the interlock system is active. 

Emperor will display a pop-up window with the following message ‘Emergency stop button pressed or interlock opened…’. 

The test stand’s motor will remain restricted until the error condition is removed. To re-enable the test stand’s motor drive, close the door and press ‘OK’ on the pop-up window displayed in Emperor. See the section 'Emperor - Warning Message' for more information.

9.3.3 Example 3

Switch Position Guard Door Status Stand Operation Software Error Message
1 Operator Opens Guard Door Test Running INTERLOCK OPENED

In this example, the operator has opened the guard door while the test was running. As the interlock system is active, the test will immediately stop, and the Emperor will display a pop-up window with the following message ‘Emergency stop button pressed or interlock opened…’. 

The test stand’s motor will remain restricted until the error condition is removed. 

To re-enable the test stand’s motor drive, close the door and press ‘OK’ on the pop-up window displayed in Emperor. See the section 'Emperor - Warning Message' for more information.

9.3.4 Emperor - Warning Message

If the interlocked guard door is opened (and the interlock system is active) the warning message shown below will be displayed:

Emperor Warning Message
At this point, the test stand’s motor drive will be inhibited. If a test is in operation, it will be aborted. To re-enable the test stand’s motor drive, close the door and press ‘OK’ on the pop-up window displayed in Emperor.

Pressing ‘Abort’ will disconnect the test stand and the message shown below will be displayed:

Emperor Error Message

9.4 Responsible Use of Interlock Override

Overriding the guard interlock enables the door to be opened without interrupting the test stand’s ability to move. Although the interlock should, typically, always be functioning (not overridden) there are some scenarios where the interlock may need to be disabled, examples include:

  • Test Setup – When first setting up the test stand with grips and sample, it is often necessary to make several manual adjustments to the fixtures. In this scenario overriding the interlock enables better access and visibility of the fixtures, thus helping to reduce setup time when compared to the same procedure with the guard’s interlock active. The interlock should be reactivated upon completing the setup.
  • Test Stand Servicing – Certain service procedures will require the interlock to be overridden. Servicing is only to be undertaken by Mecmesin or an approved distributor. 
    A full risk assessment should be carried out for the process of operating the test stand with the interlocked guard overridden. Clear procedures should be defined to determine when it is safe to operate under these conditions.

10 Servicing, Maintenance and Repair

Once the guard is installed, it should provide a trusted long-term resource for safe and reliable testing.

10.1 Servicing

Mecmesin guards contain no user-serviceable parts and are designed to be service free.

Periodic inspection and maintenance such as cleaning and lubrication of hinges with a machine grade oil are recommended. 

10.2 Maintenance & Cleaning

It is advised that periodic inspection of the outside of your guard is performed and your guard is cleaned to enable clear viewing of the test stand and to prevent the build-up of debris or dust. 

To clean the guard first remove any loose debris with a soft brush, then wipe down the surfaces of the guarding using a damp cloth. A dry cloth may be used to dry surfaces and remove any watermarks.

Ensure that the mains power supply is disconnected from the test stand before cleaning any part of the guarding.
When cleaning, care must be taken to avoid corrosive liquids and abrasive tools. The polycarbonate glass sheets can scratch or discolour with certain cleaning products. Avoid the use of organic solvents or any other cleaning fluid.

10.3 Repair

If the guard fails or appears to behave unusually, contact your local supplier for support. Do not continue to use the test stand until the guarding has been inspected and, if necessary, repaired by Mecmesin or a Mecmesin authorised distributor. 

Do not attempt any repairs without consulting Mecmesin or an authorised distributor, doing so may lead to injury, damage of equipment and loss of warranty.

11 Specifications

11.1 Single Column Test Systems

Machine Guarding 0.5 1 2.5 5
Guard Part Number 432-680 432-681 432-682 432-684
Compatible Mecmesin Test Systems MultiTest-0.5 kN MultiTest-i 1 kN MultiTest-2.5 kN OmniTest 5 kN
MultiTest-xt 0.5 kN MultiTest-xt 1 kN MultiTest-xt 2.5 kN OmniTest 7.5 kN
MultiTest-dV 0.5 kN MultiTest-dV 1 kN MultiTest-dV 2.5 kN  
Dimensions
Height+ 1713 mm 1502 mm 993 mm 1163 mm
Width 470 mm 470 mm 470 mm 500 mm
Depth (door closed) 480 mm 480 mm 480 mm 652 mm
Max Depth (door open) 803 mm 803 mm 803 mm 1015 mm
Weight (guard only) 42 kg 39 kg 30 kg 40 kg
Sample/Accessory Space
Max Width 386 mm 386 mm 387 mm 420mm
Max Diameter++ 131 mm 131 mm 131 mm 180 mm (OmniTest 5.0 kN)
134 mm (OmniTest 7.5 kN)
Interlocking Device
Class Tongue-actuated position switch                
Installation of Guarding
Approved Operator(s) End-user or Mecmesin representative
Environment Specification
Operating temperature 10 C to 40
Operating relative humidity 30 % - 80 % (non-condensing)

+ Excluding guard feet
++ Measured from the centre of the load cell

11.2 Twin Column Test Systems

Machine Guarding 10 25 50
Compatible Mecmesin Test Systems - guards supplied fitted to test stand. Part number of complete test system shown in brackets 805-017+G MultiTest-i 10kN + Guard 805-016+G MultiTest-i 25 kN+ Guard 805-023+G MultiTest-i 50 kN+ Guard
815-004+G MultiTest-xt 10 kN + Guard 815-005+G MultiTest-xt 25 kN Guard 815-006+G MultiTest-xt 50 kN + Guard
820-010+G OmniTest 10 kN + Guard 820-025+G OmniTest 25 kN + Guard 820-059+G OmniTest 50 kN + Guard
Dimensions
Height+ 1500 mm 1500 mm 1931 mm
Width (excl key) 826 mm 826 mm 864 mm
Depth (door closed) 556 mm 556 mm 613 mm
Max Depth (door open) 1150 mm 1150 mm 1215 mm
Weight (system)* 192 kg 192 kg 354 kg
Sample/Accessory Space
Max Width 366 mm 366 mm 420 mm
Max Diameter++ 330 mm 330 mm 322 mm
Interlocking Device
Class Tongue-actuated position switch
Environment Specification
Operating temperature 10 C to 40
Operating relative humidity 30 % - 80 % (non-condensing)

* Excluding accessories such as attached consoles
++ Measured from the centre of the load cell

12 Dimensions

12.1 MultiTest Single Column

MultiTest Single Column Dimensions

MultiTest Single Column Dimensions

12.2 OmniTest Single Column

OmniTest Single Column Dimensions

OmniTest 7.5 Single Column Dimensions

OmniTest Single Column Dimensions

12.3 Twin Column Test Systems

Twin Column 10-25 Dimensions

Twin Column 50 Dimensions

13 Certification

To view the 'Declaration of Conformity' for the relevant product type or variant, click on the document number in the table below:

  Product or Variant   Document Number
  MultiTest-i, xt and FPT (all single column variants)    431-DoC22
  MultiTest-i, xt (all twin column variants)   431-DoC23
  MultiTest-dV (including dV(u), OT-0.5 and OT-1)   431-DoC24
  OmniTest-5, 7.5 (single column)   431-DoC27
  OmniTest-10, 25, 50 (twin column)   431-DoC28
  MultiTest Single Column (interlocked guard only)   431-DoC32
  OmniTest Single Column (interlocked guard only)   431-DoC33

  

Original instructions published in English language.
Mecmesin Ltd © 2019.

Patrick Collins
Technical Director, Mecmesin