Maintenance Manual

TMP4100-Series/400
PINSTAMP ® Marking System

This manual contains maintenance information for the Telesis

TMP4100-Series/400 Marking Systems. These systems use the
TMC400 Controller and the TMP4100 hand-held pneumatic-pin
marker, the TMP4100E hand-held electric-pin marker, or the
TMP4150 fixture-mounted pneumatic-pin marker.

This manual may be supplemented and kept current by Change

Notices and Revisions.

Manual No. 33473 Rev. –

Telesis Technologies, Inc. March 2000

28181 River Drive
P.O. Box 1000
Circleville, Ohio 43113
 TMP4100-Series/400 Maintenance

List of Effective Pages

DATES OF MANUAL AND CHANGED PAGES:
Original Issue....................................March 2000

NOTE
The portion of the text affected by the change is indicated by a vertical line in
the outer margins of the page. Changes to illustrations (other than diagrams
and schematics) are identified with a miniature pointing hand. Shading is used
to highlight the area of diagrams and schematics containing a change.

This publication consists of the following pages:

(0 indicates Original; Integers indicate Change.)

PAGE CHG NO.

Title Page................................................ 0
A through D ............................................ 0
i through iv.............................................. 0
1-1 through 1-2 ....................................... 0
2-1 through 2-8 ....................................... 0
3-1 through 3-6 ....................................... 0
4-1 through 4-12 ..................................... 0
A-1 through A-10.................................... 0

INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES.

Those responsible for maintaining this publication should ensure that all previous changes
have been received and incorporated.

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 TMP4100-Series/400 Maintenance

Foreword
Telesis Technologies, Inc. (hereinafter referred to as Telesis) reserves the right to change the information
and specifications contained in this manual without prior notice. The reader should consult Telesis to
determine whether such changes have been made.

In no event shall Telesis be liable for any incidental, indirect, special, or consequential damages
whatsoever, including but not limited to lost profits, arising out of, or relating to this manual or the
information it contains, even if Telesis has been advised, has knowledge, or should have knowledge of the
possibility of such damages.

Telesis expressly warrants the equipment it manufactures as set forth in the Standard Terms and Conditions
of Sale. Telesis makes no other warranties, expressed or implied, including and without limitation,
warranties as to merchantability or fitness for a particular purpose.

The information contained in this manual is confidential and is proprietary to Telesis or its licensors.
All rights reserved. Printed in the U.S.A.

©2000 Telesis Technologies, Incorporated

Telesis® and Pinstamp® are registered trademarks of Telesis Technologies, Incorporated.

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TMP4100-Series/400 Maintenance

Software/Firmware License Agreement

IMPORTANT: THE SUBJECT PROGRAMS ARE LICENSED BY TELESIS TECHNOLOGIES, INC.
TO END-USERS FOR THEIR USE ONLY ON THE TERMS BELOW . ACCEPTING AND USING
THESE PROGRAMS INDICATES YOUR ACCEPTANCE OF THESE TERMS. THIS IS A LEGAL
AGREEMENT BETWEEN YOU, THE END USER, AND TELESIS TECHNOLOGIES, INC.

1) GRANT OF LICENSE. Telesis Technologies, Inc. (Telesis) agrees to grant to you a non-exclusive license to
use the Telesis software/firmware program (the program) subject to the terms and conditions of this license
agreement.

2) DEFINITION OF TERMS. The term software refers to a computer program stored on a floppy diskette, hard,
drive, magnetic tape, or paper tape that must be loaded into the computer’s memory to be executed. The term
firmware refers to a computer program stored in semiconductor memory (ROM, PROM, EPROM, EEPROM,
NVRAM, etc.) that is an integral part of the computer’s memory. Together, these forms of computer programs
are referred to as the program.

3) COPYRIGHT. The program(s) and documentation is owned by Telesis and is protected by United States
copyright laws and international treaty provisions. The program(s) contain trade secrets and proprietary
property of Telesis. You may make one copy of the program(s) solely for backup or archival purposes
provided that the copy clearly displays the Telesis copyright notice. Additional copies may be made when
authorized to do so in writing by Telesis. In addition to any other right of Telesis, Telesis has the right to
terminate this license if the terms of the license are violated.

4) RESTRICTION ON USE AND TRANSFER. The single-processor version(s) of the program(s) and
documentation are to be used on one computer on embedded system at any one time. The multi-processor
version(s) of the program(s) and documentation may be used over a network provided that the number of
computers accessing the network simultaneously shall not exceed the number authorized by Telesis or for
which you paid the corresponding multi-processor fee. You may not distribute the programs or
documentation to a third party. You may transfer the license and complete package (retaining nothing) if the
transferee agrees to the terms of this License Agreement. Neither the program(s) nor the documentation may
be changed or translated without express written permission of Telesis. You may not reverse engineer,
decompile or disassemble the program(s).

5) WARRANTY for the subject program(s) is covered under the Telesis Standard Terms and Conditions of
Sale.

6) TERM. The license is effective until terminated. It will be terminated if you fail to comply with any term
or condition of this License Agreement. You may terminate this License Agreement at any time. In the
event of termination, you agree to destroy the program(s) and documentation together with all copies and
related material.

7) YOUR USE OF THIS PROGRAM(S) acknowledges that you have read this License Agreement and agree to
its terms. This agreement is complete and supersedes any other agreement that may have related to the
subject matter of this agreement.

D
 TMP4100-Series/400 Maintenance

Table of Contents
PARAGRAPH PAGE

List of Effective Pages .......................................................................................................................... A

Foreword ............................................................................................................................................... C
Software/Firmware License Agreement ............................................................................................... D
List of Illustrations ................................................................................................................................ iii
List of Tables ........................................................................................................................................ iii
Safety Summary .................................................................................................................................... iv

Chapter 1
General Information
1.1 Maintenance Overview ............................................................................................................ 1-1
1.2 Maintenance Precautions ......................................................................................................... 1-2
1.2 Telesis Customer Service......................................................................................................... 1-2
1.3 Additional Publications............................................................................................................ 1-2

Chapter 2
Troubleshooting
2.1 Marking Head .......................................................................................................................... 2-1
2.2 Controller ................................................................................................................................. 2-6

Chapter 3
Test and Verification
3.1 Interface Checks....................................................................................................................... 3-1
3.1.1 Host Interface .................................................................................................................... 3-1
3.1.2 Discrete I/O Interface ........................................................................................................ 3-2
3.1.3 TTL I/O Interface .............................................................................................................. 3-3
3.2 Resistance Checks.................................................................................................................... 3-4
3.2.1 Stepper Motor Resistance.................................................................................................. 3-4
3.2.2 Solenoid Resistance........................................................................................................... 3-4
3.3 Continuity Checks.................................................................................................................... 3-5

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TMP4100-Series/400 Maintenance

Table of Contents
PARAGRAPH PAGE

Chapter 4
Maintenance Procedures
4.1 Overview .................................................................................................................................. 4-1
4.2 Repair Procedures..................................................................................................................... 4-2
4.2.1 Impact Pin Reconditioning................................................................................................. 4-2
4.3 Cleaning Procedures ................................................................................................................. 4-4
4.3.1 Impact Pin / Pin Cartridge.................................................................................................. 4-4
4.3.2 Marking Head Rail............................................................................................................. 4-4
4.4 Replacement Procedures .......................................................................................................... 4-5
4.4.1 Impact Pin / Pin Cartridge.................................................................................................. 4-5
4.4.2 Marker Standoff (TMP4100, TMP4100E) ........................................................................ 4-6
4.4.3 Solenoid Valve (TMP4100)............................................................................................... 4-6
4.4.4 Solenoid Valve (TMP4150)............................................................................................... 4-8
4.4.5 Solenoid Valve (TMP4100E) ............................................................................................ 4-8
4.5 Reference Data ......................................................................................................................... 4-11
4.5.1 Spare Parts ......................................................................................................................... 4-11
4.5.2 Replacement Parts.............................................................................................................. 4-11
4.5.3 Ordering Parts .................................................................................................................... 4-11

Appendix A
Material Safety Data Sheets
Carbide Impact Pins............................................................................................................................... A-3
Steel Impact Pins ................................................................................................................................... A-7

ii
 TMP4100-Series/400 Maintenance

List of Illustrations
FIGURE PAGE

4-1 Pin Cone Angle and Length .......................................................................................................... 4-2

List of Tables
TABLE PAGE

2-1 Troubleshooting the Marking Head .............................................................................................. 2-1

2-2 Troubleshooting the Controller..................................................................................................... 2-6

3-1 Host Connector Pin Assignments.................................................................................................. 3-1

3-2 I/O Connector Input Checks.......................................................................................................... 3-2
3-3 I/O Connector Output Checks ....................................................................................................... 3-2
3-4 TTL I/O Connector Input Checks ................................................................................................ 3-3
3-5 Stepper Motor Resistance Checks................................................................................................. 3-4
3-6 Solenoid Resistance Checks.......................................................................................................... 3-4
3-7 Marking Head Extension Cable Pin Assignments ........................................................................ 3-5

4-1 Impact Pin Lengths........................................................................................................................ 4-2

iii
TMP4100-Series/400 Maintenance

Safety Summary
The TMP4100/400 Marking System uses high voltage power supplies and high pressure pneumatic supplies.
Accordingly, there is some danger when working with, and near, PINSTAMP® marking machines. The
following safety precautions should be observed at all times.

• Eye protection may be required when working in close proximity of an operating marker.

• Ear protection may be required when working with or near an operating marker.

• Keep all body parts, jewelry, and clothing clear of the marker while it is operating.

• TMP4100, TMP4150: Do not disconnect the tubing while air pressure is applied to the lines.

• Do not remove or defeat the Marking System’s safety features or protective guards.

• Never use the marker in any manner or for any purpose other than that for which it was designed.

Warnings, Cautions, and Notes are placed throughout this manual to alert you to important information.
These messages have the following significance.

WARNING

Warnings contain information that is essential to the personal safety of the user.

CAUTION

Cautions contain information that is essential to avoid damage to the equipment.

NOTE
Notes call attention to information of special importance at specific points within the text.

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 TMP4100-Series/400 Maintenance

Chapter 1
General Information

*** NOTICE ***

This manual documents the TMP4100, the TMP4100E, and the TMP4150 marking heads.

The TMP4100 and TMP4150 heads contain a pneumatic pin that uses air pressure to drive the
pin from and return the pin to the pin cartridge. The TMP4100E uses no air pressure. The
TMP4100E (electric) uses an electric solenoid to drive and an internal spring to assist pin return.

Maintenance of the marking heads is very similar. Where variation do exist, they will be
clearly identified within the text to inform you of the differences.

TMP4100, TMP4100E: The TMP4100 and TMP4100E markers are hand-held markers. They
may be used in any orientation except inverted (that is, with the handle pointing upward).

TMP4150: The TMP4150 is a fixture-mounted marker for in-line use. The marking head may
be mounted in any orientation except inverted (that is, with the mounting holes pointing
upward). Typically, it should be mounted on a tooling fixture with the pin pointing
downward. The TMP4150 marking head employs a protective boot to help prevent
contaminants from entering the marking head cavity.

The marking system design and specifications are subject to change without prior notice.

1.1 MAINTENANCE OVERVIEW

This manual provides troubleshooting, testing, verification, repair, and replacement procedures for the
marking system. Material Safety Data Sheets (MSDS) for the carbide and steel impact pins used with the
marking system are included in the Appendix of this manual.

Any additional troubleshooting, fault isolation, servicing, maintenance, or repair of TMP4100-Series /400
Marking Systems that is not explicitly contained in this manual must be performed by distributors or repair
agencies authorized by Telesis Technologies, Inc.

1-1
General Information

1.2 MAINTENANCE PRECAUTIONS

Turn all power OFF when performing maintenance on the marker.

Ensure that all equipment energy sources are turned off or disconnected and that the switches/valves are
either locked or tagged while equipment is cleaned or serviced.

TMP4100, TMP4150: Ensure that appropriate pneumatic lock-out valves are installed.

1.2 TELESIS CUSTOMER SERVICE

Telesis Customer Service offers the following assistance:

Phone Support - Telesis Customer Service offers free phone support to answer questions during normal
business hours (8:00 a.m. to 5:00 p.m. Eastern Time).
An after-hours phone message service is available by calling (800) 867-8670 (U.S. and Canada only).

On-Site Service - Telesis can send Customer Service professionals to your facility to perform equipment
start-up, repair, maintenance, and training.

Service Contracts - As part of your Service Contract, you receive periodic maintenance and quick on-site
customer service if a problem should occur.

Factory Service - Telesis Customer Service can repair defective parts in our factory to save you money.

Bulletin Board Service - A Bulletin Board Service is available by calling (740) 474-5579. This service
allows you to look at product listings and leave messages.

For more information on any of these services, call (800) 867-8670 (U.S. and Canada) or (740) 477-5000 and
ask for Customer Service. Our FAX number is (740) 477-5002.

1.3 ADDITIONAL PUBLICATIONS

Additional information about the TMP4100-Series /400 Marking Systems may be found in the following
publications:

TMP4100-Series/400 Operator’s Manual

TMP4100-Series/400 Installation Manual

Additional servicing, repair, and overhaul information is provided in the TMP4100-Series Service Manual
and the TMC400 Service Manual. These service manuals, however, are only made available to repair
agencies trained and authorized by Telesis Technologies, Inc.

1-2
 TMP4100-Series/400 Maintenance

Chapter 2
Troubleshooting

2.1 MARKING HEAD

This section provides troubleshooting information for the marking head. Refer to Table 2-1 to identify
problems, their probable causes, and corrective action. If a defective component has been identified, refer to
Chapter 4 to repair or replace the component. If these procedures fail to correct the problem, contact Telesis
Customer Service.

Table 2-1. Troubleshooting the Marking Head

PROBLEM
Cartridge base/frame mechanism does not
initialize when placed ONLINE. No
apparent movement.
Neither axis initializes or only one axis
moves.
PROBABLE CAUSE
When the ONLINE function is selected,
the cartridge base/frame will seek home.
This causes the cartridge base/frame to
traverse to the middle left edge of its
travel (as viewed from the back of the
marker). When the cartridge base/frame
is already home, it will make a small
movement away from home in both axes,
then seek home again.
1. Control may be interrupted between
the controller and the marker.
2. Power to the controller or to the drive
motors may be down.
3. Defective cable between the controller
and marking head.
4. X-axis pulley loose, Y-axis cam loose,
or cam flag bound on sensor.
CORRECTIVE ACTION
Refer to the TMP4100-Series/400
Operator’s Manual for data entry and
function selection.
1. Inspect the cable and connectors
between the controller and the
marking head.
Check continuity. Refer to Chapter 3.
2. Check the inlet fuses on the power
entry module. Refer to the TMP4100-
Series/400 Operator’s Manual for
details.
3. Disconnect marker cable from
controller.
Check resistance at marking head
cable connector. Refer to Chapter 3.
If resistance is within tolerance, check
continuity of marker extension cable (if
used). Refer to Chapter 3.
If cable checks good, replace
controller.
4. Check the axis in question. Remove
the four screws on the sides of the
head cover and visually inspect.
Try to move the axis in question and
observe the pulley/cam to see if it
moves independently of the motor.
(This would indicate a loose
pulley/cam.)

(continued on next page)

2-1
Troubleshooting
Table 2-1. Troubleshooting the Marking Head (continued)
PROBLEM
The marker sounds as if the motors are
running, but there is no motion in one or
both axes.
Cartridge base/frame is attempting to
initialize. The motor or motors continue to
sound as if they are running and the
cartridge base/frame appears stalled at or
near the home position. Head doesn’t find
the home location.
2-2
PROBABLE CAUSE
1. X-axis pulley loose or Y-axis cam
loose.
2. The rail/carriage or pulleys may be
bound or defective.
1. There may be an interference
preventing the cartridge base/frame
from reaching home.
2. If both motors are stalled at the home
location, a common factor such as
power or a connector associated with
the Home PCB could be at fault.
3. If only one axis is stalled, the home
position sensor for the stalled axis
may be defective.
4. The home position flag may be out of
position for the stalled axis.
(continued on next page)
CORRECTIVE ACTION
1. Turn off power to the controller.
Disconnect the marking head cable
from the controller.
TMP4100, TMP4150: Shut off air
pressure to the marking head.
Remove the cover from the marker.
Inspect drive system. Replace if
damaged.
Turn the X-axis pulley and check for
slippage on the motor.
If pulley is tight, check the motor
resistance. Refer to Chapter 3.
If motor resistance is out of tolerance,
replace the marking head.
2. Try to physically move the axis that
will not move electrically.
Check for external and internal causes
such as the mounting structure or
parts which may be limiting the full
travel of the cartridge base/frame and
cartridge components.
1. Check for external and internal causes
such as the mounting structure or
parts which may be limiting the full
travel of the cartridge base/frame and
cartridge components.
2. Check continuity of marker extension
cable (if used). Specifically, check the
X HOME, Y HOME, +5VDC, and
+5VDC RETURN signals. Refer to
Chapter 3.
3. Inspect the flag and sensor associated
with the malfunctioning axis. The flags
must pass between the opposed legs
of the sensors
Ensure the sensor is not cracked or
broken.
4. When positioning the flags, ensure
there is safe passage of the flag
between the sensors legs.
If the cartridge/pin does not find home in
the X-axis, try to push the cartridge/pin
to the left to the center of the window
(as viewed from the back). Place the
marker online (press F2). If the
marker now homes properly, the X-
axis opto is out of adjustment. (The
flag is passing the opto causing the
head to run into the hard stop.) Move
the opto closer to the home side. Re-
test by pushing the cartridge/pin to the
right, then placing the marker online.

Table 2-1. Troubleshooting the Marking Head (continued)
PROBLEM
Cartridge base/frame is attempting to
initialize. The motor or motors continue to
sound as if they are running and the
cartridge base/frame appears stalled at or
near the home position. Head doesn’t find
the home location. (continued)
The marking pin does not fire.
The marking is not properly located on the
process material.
The marking is cut off, truncated.
The marked characters are grouped in
intervals. Gaps exist between character
intervals or characters are overlapped.
The indentation depth is insufficient.
TMP4100-Series/400 Maintenance
PROBABLE CAUSE
5. Defective cable between the controller
and marking head.
Marking head cable defective
1. The X and Y coordinates may be
incorrect.
2. The cartridge base/frame mechanism
may not be correctly positioned due to
a slip or stall which may have
occurred previously.
Pin may be hanging up in cartridge or
solenoid may not be operating.
1. The cartridge base/frame mechanism
may be mechanically locked up.
2. The impact pin may be sticking into
the target material.
1. TMP4150: The Pin Stroke distance
may be too large, or
2. The pin may be too short due to
sharpening, and may “bottom out” in
the pin bore before impacting or
expending all the energy in making an
indentation.
TMP4100, TMP4150: On the larger
pins (150S) there is a built in
pneumatic cushion that slows the pin
prior to bottoming out in the cartridge.
3. The impact pin tip might be dull or
broken.
(continued on next page)
CORRECTIVE ACTION
5. Disconnect marker cable from
controller.
Check resistance at marking head
cable connector. Refer to Chapter 3.
If resistance is within tolerance, check
continuity of marker extension cable (if
used). Refer to Chapter 3.
If cable checks good, replace
controller.
Disconnect the marker cable from the
controller and check the solenoid
resistance at the marker cable connector.
Refer to Chapter 3.
1. Refer to the TMP4100-Series/400
Operator’s Manual for proper X,Y
orientation.
2. Excessive shock loading of the
marking head can cause the cartridge
base/frame to slip out of position.
Reset the marker and verify that
placement is correct on subsequent
mark operations.
Clean the pin cartridge as required.
From the Supervisor Mode, pulse the
solenoid. Refer to the TMP4100-
Series/400 Operator’s Manual for details
on pulsing the impact pin.
1. Inspect the rail to determine if they are
free.
Clean rail and apply light oil (3-in-1).
If the rail/carriage is worn and causing
binding, replace the marking head.
2. Verify the right pin type is selected for
your marker.
TMP4100, TMP4150: Drive Air should
be a minimum of 70 psi (4.8 bars).
Reduce the angle of the conical
impact pin tip to prevent sticking and
a faster withdrawal from the target
material.
1. TMP4150: Move the surface to be
marked closer to the pin, or reposition
the marker so that the pin is closer to
the target surface.
2. Replace pin as required. Refer to
Chapter 4.
2. Sharpen pin or replace pin as
required. Refer to Chapter 4.
2-3
Troubleshooting
Table 2-1. Troubleshooting the Marking Head (continued)
PROBLEM
The indentation depth or diameter is too
large for the character size.
The indentation depth is inconsistent.
Indentation depth is inconsistent in a
particular area of the marking window.
2-4
PROBABLE CAUSE
1. TMP4150: The Pin Stroke distance
may be too large.
2. TMP4100, TMP4150: The Drive Air
pressure may be too high.
3. Pin angle too shallow.
1. If contiguously formed indentations
start out large then diminish, the
cartridge base/frame mechanism
traversing speed may exceed the
impact pin optimum rate. This could
be the result of an incorrect setup
selection of pin stroke or pin type
2. TMP4100, TMP4150: The Drive Air
tubing to the marking head may be
undersized causing restricted air flow.
3. TMP4100, TMP4150: The Drive Air
tube may be restricted causing
decreased flow to the valves, or
plugged exhaust port.
4. TMP4100, TMP4150: The Drive Air
pressure regulator may be defective.
5. TMP4100, TMP4150: The valve may
be dirty or defective.
1. TMP4100, TMP4150: The coiled Drive
Air tubing may be kinked or restricted
when traversing
2. TMP4100, TMP4150: Loose or
incorrectly mounted head cartridge.
3. TMP4100, TMP4150: Worn cartridge,
or excessive dirt/oil in the Drive Air
making the pin stick.
(continued on next page)
CORRECTIVE ACTION
1. TMP4150: Reduce the Pin Stroke
distance to reduce the depth and
diameter.
2. TMP4100, TMP4150: Reduce the
Drive Air pressure as required.
3. Use sharper pin.
1. Verify accuracy of setup parameters.
2. TMP4100, TMP4150: The Drive Air
supplying the regulators should be no
less than 1/2" and the tubing
supplying the marker should be 1/4"
minimum and not exceed 50 feet (13
meters).
3. TMP4100, TMP4150: Ensure the filter
is not clogged or dirty. Clean as
necessary. Check the Drive Air tubing
from the regulator to the marking
head, and inside the marker, for
crimped air lines or restrictions.
4. TMP4100, TMP4150: Verify that the
outlet air pressure is regulating
properly. Replace if pressure
variations of more than 5 psi (0.3
bars) are common.
5. TMP4100, TMP4150: Swapping the
valve with a working valve.
1. TMP4100, TMP4150: Inspect the
tubing from the valve to the manifold
for cracks, restrictions or crimps in the
tubing.
2. TMP4100, TMP4150: Check for a
loose cartridge, leaking air, or a
cartridge mounted incorrectly.
3. TMP4100, TMP4150: Inspect the pin
cartridge for excessive "blow by" air.
Remove the cartridge, push the pin
into the cartridge, and release it in a
vertical position (pin down). The pin
should drop freely. If not clean with
isopropyl alcohol and try again.

Table 2-1. Troubleshooting the Marking Head (continued)
PROBLEM
The indentations within the characters are
not placed accurately.
The marked characters are wholly or
partially garbled or skewed.
TMP4100-Series/400 Maintenance
PROBABLE CAUSE
1. In order to optimize the marking times
of the system, it is important to enter
all parameters correctly in order to
synchronize the impact pin impulse
with the end of the cartridge
base/frame move to the current pixel
location. This is accomplished by
accurate entry of Pin Stroke distance
and Pin Type.
TMP4100, TMP4150: Inaccurate entry
of Drive Air pressure.
2. The marker or material to be marked
may be moving relative to each other
during the marking cycle.
1. TMP4100, TMP4150: The incorrect
pin type may be entered, causing a
slip. Sharper pins require slower
marking speeds, and with softer
material, may hang up in the product
being marked.
2. A slip may have occurred while
marking due to an interference.
3. Excessive vibration of the marker in
the plane of the marking surface,
normal to the indentation forces, may
have caused a slip.
4. If the cartridge base/frame
mechanism does not fully travel to the
Home position, it may reach the end
of travel before the marking is
complete.
5. The impact pin may be momentarily
sticking into the target material,
resulting in excessive drag and slip.
(continued on next page)
CORRECTIVE ACTION
1. Verify correct entry of all operating
parameters.
2. In order to assure a high quality mark,
it is important that there is little or no
relative movement between the
marker and material being marked.
1. TMP4100, TMP4150: Verify that the
correct operating parameters have
been entered. On new installations, try
a slower marking speed.
2. The material being marked may have
raised portions which are being struck
by either the impact pin or the
cartridge. A “dry run” with the pin
retracted may verify the possible
interference.
3. Due to the inherent nature of step
motor driven systems, there is the
possibility of exceeding the holding
force of the motors with impulse
forces caused by vibration. Ensure
the mounting of the marker will not
promote vibration in the same plane
as the cartridge base/frame traversing
components.
4. Verify that the full range of travel in
both X and Y directions is achievable
by jogging the unit to its extreme
positions. If full travel is not possible,
check the flag in that direction for
proper location. Check for
interference. Verify there is no
internal binding of parts or tubing.
5. The deeper that the impact pin
penetrates the target material, the
longer it takes to retract from the
material. This is mostly due to the
increased energy transfer into the
target.
2-5
Troubleshooting

Table 2-1. Troubleshooting the Marking Head (continued)

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

The marking time is too long for a given
application.
1. The character density selected may
be too high.
2. The marking mode may be
inappropriate (i.e., Continuous).
1. Reduce the font density or the number
of pixels per inch.
2. TMP4100-Series Marking Systems
are flexible markers. The two marking
modes are Dot Matrix and Continuous.
Each mode has advantages and
disadvantages with respect to speed
and presentation. In the Dot Matrix
mode the pixels are formed while the
head decelerates to the exact location
to place the pixel, then accelerates to
the next location. The Dot Matrix
mode may also have more or less
dots, such as 5x7 compared with
11x16; each font will have increasingly
more dots. The Continuous mode
provides a string of dots tracing the
characters one at a time. The marking
head does not decelerate, then
accelerate after positioning. The
number of pixels per inch determine
the density of the character pixel
formation.

2-6
 TMP4100-Series/400 Maintenance

2.2 CONTROLLER
This section provides troubleshooting information for the controller. Refer to Table 2-2 to identify problems
and their probable cause. If a defective component has been identified, refer to Chapter 4 to repair or replace
the component. If these procedures fail to correct the problem, contact Telesis Customer Service.

Table 2-2. Troubleshooting the Controller

PROBLEM PROBABLE CAUSE

No display on controller keyboard.
Discrete I/O fault.
Serial communication fault.
TTL I/O fault
Loss of system parameters or data after
power is down.
Check power to the controller and the power entry module fuses.
If no problem is found, contact Telesis Customer Service for assistance or contact a
Telesis-authorized maintenance agency for repair.
1. Check the I/O cable.
2. If the problem is an input fault, disconnect the I/O cable and verify the input
voltages. Refer to Chapter 3.
3. If the problem is an output fault, disconnect the I/O cable and verify the output
resistance. Refer to Chapter 3.
1. Check the communication cable.
2. Verify the communication parameters are properly configured for the marking
system. Refer to the TMP4100-Series/400 Operator’s Manual for details.
3. Connect an RS-232 diagnostic light box between the communication cable and the
controller. Verify signals to and from the Host.
1. Check the I/O cable.
2. Disconnect the I/O cable from the TTL I/O connector and verify the resistance at the
connector. Refer to Chapter 3. (Note: Resistance values are based on closed
switches.)
Contact Telesis Customer Service for assistance.

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 TMP4100-Series/400 Maintenance

Chapter 3
Test and Verification

This section provides reference tables to check circuit voltage, resistance, and continuity for TMP4100-
Series/400 Marking Systems.

3.1 INTERFACE CHECKS

The following sections provide pin assignments, signal names, signal descriptions, voltage, and resistance for
the interface connectors on the back panel of the controller.

NOTE
Voltage measurements at the controller connectors are to be take with the power ON.

3.1.1 Host Interface

The following illustration and table show the pin assignments for the controller’s HOST connector.

Table 3-1. HOST Connector Pin Assignments

PIN SIGNAL DESCRIPTION
1 not used
2 TXD RS-232 data from the controller
3 RXD RS-232 data to the controller
4-6 not used
7 GND RS-232 Signal Return (ground)
8-9 not used
10 X– RS-485 bi-directional data – (internally jumpered to pin 12)
11 X+ RS-485 bi-directional data + (internally jumpered to pin 13)
12 X– RS-485 bi-directional data –
13 X+ RS-485 bi-directional data +
14 If using RS-485 in a network, pins 14 and 15 must be jumpered on the last controller in
the network drop for proper network termination.
15 (internally jumpered to pin 10 and to pin 12)
16 - 19 not used
20 +5 VDC Power for optional bar code scanner
21 - 25 not used

3-1
Test and Verification

3.1.2 Discrete I/O Interface

The following illustrations and tables show pin assignments for the controller’s discrete I/O interface. The
input and output checks are to be taken with the I/O interface cable disconnected from the controller. Input
checks are taken at the connector on the controller-end of the interface cable. Output checks are to be take at
the I/O connector on the back of the controller.

NOTE
All discrete I/O signals are to be checked in their ON state.

Table 3-2. I/O Connector Input Checks

PIN-TO-PIN DESCRIPTION VOLTAGE ON STATE
1 to 2 START PRINT 12 to 24 VDC
1 to 3 ABORT 12 to 24 VDC
1 to 4 SEL_0 custom applications only
1 to 5 SEL_1 custom applications only
1 to 6 SEL_2 custom applications only
1 to 7 SEL_3 custom applications only

Note: Pin 1 is Input Common; Pin 8 not used.

Table 3-3. I/O Connector Checks (Outputs)

PIN-TO-PIN DESCRIPTION RESISTANCE ON STATE

9 to 10 DONE 2 ohms (maximum)

9 to 11 READY 2 ohms (maximum)
9 to 12 SPARE OUT custom applications only

Note: Pin 9 is Input Common; Pins 13, 14, 15 not used.

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 TMP4100-Series/400 Maintenance

3.1.3 TTL I/O Interface

The following illustration and table show pin assignments for the controller’s TTL I/O interface. The checks
are to be taken with the TTL I/O interface cable disconnected from the controller. The input checks are
taken at the connector on the controller-end of the interface cable.

NOTE
All discrete I/O signals are to be checked in their ON state.

Table 3-4. TTL I/O Connector Input Checks

PIN-TO-PIN DESCRIPTION RESISTANCE ON STATE
2 to 3 START PRINT 10 ohms (maximum)
2 to 4 ABORT 10 ohms (maximum)

Notes: Pin 1 is reserved for Telesis use only.

Pin 2 is Ground. Pins 5, 6, 7, 8, 9 not used.

3-3
Test and Verification

3.2 RESISTANCE CHECKS

The following information is provided to check the resistance values of the stepper motor circuit and the
solenoid circuit. The checks are to be taken with the marking head cable disconnected from the controller.
The resistance checks are taken at the connector on the end of the marking head cable.

NOTE
Resistance measurements are to be taken with power OFF.

3.2.1 Stepper Motor Resistance

Table 3-5 lists the resistance values for the stepper motor. These checks are made at the connector on the end
of the marking head cable.

Table 3-5. Stepper Motor Resistance Checks

RESISTANCE VALUE

PIN-TO-PIN DESCRIPTION TMP4100 TMP4150 TMP4100E

1 to 2 X-AXIS MOTOR PHASE A 2.0 ohms ±10% 2.0 ohms ±10% 2.0 ohms ±10%
3 to 4 X-AXIS MOTOR PHASE B 2.0 ohms ±10% 2.0 ohms ±10% 2.0 ohms ±10%
5 to 6 Y-AXIS MOTOR PHASE A 2.0 ohms ±10% 2.0 ohms ±10% 2.0 ohms ±10%
7 to 8 Y-AXIS MOTOR PHASE B 2.0 ohms ±10% 2.0 ohms ±10% 2.0 ohms ±10%

3.2.2 Solenoid Resistance

Table 3-6 lists the resistance values for the solenoid. These measurements are taken at the connector on the
end of the marking head cable.

Table 3-6. Solenoid Resistance Checks

RESISTANCE VALUE
PIN-TO-PIN DESCRIPTION TMP4100 TMP4150 TMP4100E
9 to 12 SOLENOID #1 12 ohms ±5% 38 ohms ±5% 8.4 ohms ±5%

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 TMP4100-Series/400 Maintenance

3.3 CONTINUITY CHECKS

The following information is provided to check the continuity of the marking head extension cable (if used).
The checks are to be taken with the marking head extension cable disconnected from the controller and from
the standard marking head cable.

Table 3-7. Marking Head Extension Cable Pin Assignments

FROM TO
J1 J2 FUNCTION
1 1 X MOTOR PHASE 1
2 2 X MOTOR PHASE 2
3 3 X MOTOR PHASE 3
4 4 X MOTOR PHASE 4
5 5 Y MOTOR PHASE 1
6 6 Y MOTOR PHASE 2
7 7 Y MOTOR PHASE 3
8 8 Y MOTOR PHASE 4
9 9 SOLENOID COMMON
10 10 SOLENOID COMMON
12 12 SOLENOID #1 (Impact Pin, TMP4100-Series markers)
13 13 SOLENOID #2 (Impact Pin, TMP4100E only)
14 14 SOLENOID #3 (Impact Pin, TMP4100E only)
15 15 SOLENOID #4 [not used w/ standard TMP4100-Series markers]
16 16 SOLENOID #5 [not used w/ standard TMP4100-Series markers]
17 17 SOLENOID #6 [not used w/ standard TMP4100-Series markers]
20 20 +5 VDC RETURN
21 21 + 5 VDC
22 22 X HOME
25 25 Y HOME
28 28 START PRINT – (+5 VDC RETURN)
29 29 START PRINT +
37 37 CHASSIS GROUND

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 TMP4100-Series/400 Maintenance

Chapter 4
Maintenance Procedures

4.1 OVERVIEW
Maintenance procedures not explicitly contained in this manual must be performed by repair agencies
authorized by Telesis Technologies, Inc.

The following procedures may be performed by the system’s owner/operator.

Refer to the TMP4100-Series/400 Operator’s Manual for details.
• Controller Inlet Fuses Replacement

The following replacement procedures are provided in this chapter.

Refer to the appropriate section in this manual for details.
• Impact Pin / Pin Cartridge Cleaning
• Impact Pin / Pin Cartridge Replacement
• Impact Pin Reconditioning
• Marker Standoff Replacement
• Marking Head (Carriage) Rail Cleaning
• Solenoid Valve Replacement

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Maintenance Procedures

4.2 REPAIR PROCEDURES

Authorized repairs to the TMP4100-Series/400 Marking Systems are listed in the following paragraphs.
Repair procedures not explicitly contained in this manual must be performed by repair agencies authorized by
Telesis Technologies, Inc.

4.2.1 Impact Pin Reconditioning

Periodically, the tips of the impact pins will become dull and require reconditioning. Grind (or replace) the
impact pins on a regular basis to prevent dull pins from producing an unsatisfactory mark.

Pins should be reconditioned at the first sign of mark degradation or when the pin point becomes noticeably
flattened. The length of service between reconditioning will depend on the pin material, the material being
marked and the depth of the mark desired. Table 4-1 lists the lengths for new and reconditioned pins. The
pin cone angle and length are illustrated in Figure 4-1.

Table 4-1. Impact Pin Lengths

PIN TYPE NEW LENGTH MINIMUM LENGTH

25XL (TMP4100, TMP4150) 2.49 in. (63.2 mm) 2.43 in. (61.7 mm)
150S (TMP4100, TMP4150) 2.75 in. (69.9 mm) 2.68 in. (68.1 mm)
25XLE (TMP4100E) 1.77 in. (45.0 mm) 1.70 in. (43.2 mm)

Figure 4-1. Pin Cone Angle and Length

4-2
 TMP4100-Series/400 Maintenance

The recommended grinding wheels for the various pin material are listed below. The minimum pin lengths
allow for only about a 3% reduction in the total length during reconditioning. Therefore, only the smallest
amount of material necessary to obtain a sharp point should be removed. Several small “cuts” should be taken,
instead of larger ones, to avoid removing more material than necessary and to avoid overheating the pin.

PIN MATERIAL GRINDING WHEEL

COMPOSITE METAL ALUMINUM OXIDE (PINK 12A, BEST)

TUNGSTEN CARBIDE SILICONE CARBIDE (GREEN 39C)

WARNING

Read the Material Safety Data Sheets (MSDS) sheets, included in the
Appendix of this manual, prior to reconditioning pins to become familiar
with reconditioning hazards.

Use the appropriate precautions, coolant, and abrasive for the pin material
and the grinding techniques described in the MSDS.

Always wear a respirator, safety glasses, and gloves when grinding metal.

The following will assure properly reconditioned pins:

1. Remove the impact pin / pin cartridge from the marking head. (see procedure)
2. Mount the pin in the fixture, making sure that the pin is supported near its point. This fixture must be
capable of rotating the pin during the grinding operation.

3. Use the proper abrasive wheel for the pin material.

4. Coolant should be used.

5. Keep the abrasive wheel dressed for a straight conical-shaped point on the pin.

6. Set the fixture to obtain the desired pin cone angle.

7. Grind the pin to a sharp point, while continually rotating the pin.

8. Make several light “cuts” to reduce chatter and keep the pin cool. This reduces pin material waste.

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Maintenance Procedures

4.3 CLEANING PROCEDURES

Perform the following procedures to clean the marking head guide rods.

4.3.1 Impact Pin / Pin Cartridge

Perform the following steps to clean the pin cartridge and impact pin.
1. Remove the impact pin / pin cartridge from the marking head. (see procedure)
2. Clean the cartridge using isopropyl alcohol or dish washing detergent and water.
The pins may be cleaned with solvent as long as they are wiped off completely and allowed to dry
before being placed back into the cartridge.
Do not use any petroleum-based solvent, paint thinners, or acetone.
Do not use any oil for lubrication.
3. Install the impact pin / pin cartridge onto the marking head. (see procedure)

4.3.2 Marking Head Rail

Perform the following steps to clean the carriage rail in the marking head.

CAUTION
Ensure the controller power is removed before connecting or disconnecting the marker cable.
The controller may be damaged if the cable is connected or disconnected with power on.

1. TMP4100, TMP4150: Remove all air pressure from the marking system.
2. Remove all electrical power from the marking system.
3. TMP4150: Remove the marking head cover:
a. Lift up on the tabs of the latches located on the sides of the marker.
b. Rotate the tabs counter-clockwise to loosen and disengage the latches.
c. Slide the protective boot over the end of the cartridge.
d. Slide the cover off the marker.
4. TMP4100, TMP4100E: Using a 2.5mm hex key, remove four screws securing right cover to left cover.
5. TMP4100, TMP4100E: Remove the two screws from the end of the standoff (nearest the foot pad).
6. TMP4100, TMP4100E: Separate covers and place right cover aside.
7. Moisten a clean, lint-free, soft cloth with isopropyl alcohol.
8. Carefully wipe any dirt or debris from the rail.
9. Apply a light coat of oil (e.g., 3-IN-1® oil) to the rail.
10. TMP4100, TMP4100E: Align right cover with left cover and secure with four screws.
11. TMP4100, TMP4100E: Install two screws in end of the standoff (nearest the foot pad).
12. TMP4150: Install the marking head cover:
a. Slide the cover over the marker.
b. Engage the latches and rotate the tabs clockwise to tighten.
c. Push down on the tabs (so they lay flat against the sides of the marker.
d. Slide the protective boot up, onto the cartridge.

4-4
 TMP4100-Series/400 Maintenance

4.4 REPLACEMENT PROCEDURES

Authorized replacement of the TMP4100/400 and TMP4100E/400 Marking Systems’ components are listed
in the following paragraphs. Component replacement procedures not explicitly contained in this manual
must be performed by repair agencies authorized by Telesis Technologies, Inc.

4.4.1 Impact Pin / Pin Cartridge

Follow the steps below to remove and replace the impact pin and/or the pin cartridge assembly.

CAUTION
The impact pin and pin cartridge do not require lubrication.
The plastic pin cartridge may become obstructed if lubricated.

Removal
1. TMP4100, TMP4150: Remove all air pressure from the marking system.
2. Remove all electrical power from the marking system.
3. TMP4150: Remove the marking head cover:
a. Lift up on the tabs of the latches located on the sides of the marker.
b. Rotate the tabs counter-clockwise to loosen and disengage the latches.
c. Slide the protective boot over the end of the cartridge.
d. Slide the cover off the marker.
4. Remove two screws that secure the cartridge to the manifold.
5. Gently tip the pin cartridge allowing the impact pin to slide from the open cartridge bore.
6. TMP4100E: Remove the return spring from the pin cartridge.
7. If you are re-using the same cartridge, clean the cartridge bore with isopropyl alcohol. Use care to
prevent contaminants from entering the bore.

Installation
1. TMP4100E: Install the return spring on the small diameter of the impact pin.
2. Insert the impact pin into the cartridge bore.
3. Apply Vibra-Tite to the two screws (removed from the cartridge).
Allow the Vibra-Tite to dry before continuing.
4. TMP4100, TMP4150: Align the exhaust air port (slot/hole) of the pin cartridge with the machined notch
in the manifold.
5. Press the cartridge into place and secure with the two screws. Tighten securely, but do not over tighten.
6. TMP4150: Install the marking head cover:
a. Slide the cover off the marker.
b. Engage the latches and rotate the tabs clockwise to tighten.
c. Push down on the tabs (so they lay flat against the sides of the marker.
d. Slide the protective boot up, onto the cartridge.

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Maintenance Procedures

4.4.2 Marker Standoff (TMP4100, TMP4100E)

Perform the following procedure to replace the standoffs mounted on the front of the TMP4100 or
TMP4100E marking head.

CAUTION
Do not move the pin cartridge by hand. Internal components of the marking
head may be damaged if improperly positioned. Use the system’s Jog
feature or Online command to reposition the pin cartridge.

Removal
1. Place the marker online (or use the Jog feature) to move the pin cartridge to the left side of the marking
window.
2. Using a 2mm hex key, remove the two M3-0.50 x 10 flat head screws from the right side standoff (side
opposite the pin cartridge location) and remove the standoff.

Installation
1. Install the new standoff on the right side of the marker. Secure with two M3-0.50 x 10 flat head screws.
2. Use the Jog feature to move the pin cartridge to the right side of the marking window.
3. Using a 2mm hex key, remove the two M3-0.50 x 10 flat head screws from the left side standoff (side
opposite the pin cartridge location) and remove the standoff.
4. Install the new standoff on the left side of the marker. Secure with two M3-0.50 x 10 flat head screws.

4.4.3 Solenoid Valve (TMP4100)

Perform the following procedure to replace the TMP4100 solenoid valve.
Removal
1. Remove all air pressure from the marking system.
2. Remove all electrical power from the marking system.
3. Remove the standoffs. (see procedure)
4. Using a 2.5mm hex key, remove four M3-0.50 x 25 screws securing right cover to left cover.
Separate covers and place right cover aside.
5. Using a 2mm hex key, loosen set screw in handle holding the push button switch.
6. Remove switch connector J2 from the limit board.
7. Remove the switch assembly from the handle.

4-6
 TMP4100-Series/400 Maintenance

8. Using a 2.5mm hex key, loosen set screw securing the handle to the handle mount. Gently, pry and pull
handle from the mount.
9. Using a 3mm hex key, remove two M4-0.70 x 16 socket head cap screws that secure the handle mount to
the manifold base.
10. Remove the tubing from the bulkhead connector.
11. Remove cable connector J1 from the limit board and disconnect the ground lug.
12. Using a 2.5mm hex key, remove three flat head screws from the bottom of the left cover.
13. Remove the marking unit from the left cover and place left cover aside.
14. Remove the two solenoid wires lugs from J6 and J7 on the limit board
15. Using a 1.5mm hex key, remove two socket head cap screws from the solenoid valve and remove the
solenoid valve from the marking unit.

Installation
1. Install the new solenoid valve assembly. Ensure the gasket is properly positioned.
2. Route the solenoid wires toward the upper, backside of the X-axis motor and push the plugs onto limit
board connectors J6 and J7.
3. Install the marking unit into left cover and secure with three flat head screws.
4. Connect the marking unit cable connector J2 to J1 on the limit board.
5. Attach the ground lug.
6. Connect tubing to bulkhead fitting. Do not kink the tubing.
7. Install the handle mount onto left cover (with radius end of handle toward the back of the marker).
Secure with two M4-0.70 x 16 socket head cap screws.
8. Slide the handle onto the handle mount and tighten the set screw.
9. Install the push button switch assembly (connector end first) through the switch mounting hole.
10. Route the switch wires in and upward through the clearance hole toward the limit board.
11. Connect the switch wires to J2 on the limit board.
12. Secure the switch to the handle with a M3-0.50x3 set screw.
13. Lay the flex snap in the strain relief bushing on the cable assembly in the half-hole in the back of the left
cover with the tab facing down into the half-hole.
14. While holding the bushing in place, lay the right cover on top.
Ensure the push button wires are not pinched between the covers.
15. Secure the right cover with four M3-0.50 x 25 socket head cap screws.
16. Install the standoffs. (see procedure)

4-7
Maintenance Procedures

4.4.4 Solenoid Valve (TMP4150)

Perform the following procedure to replace the TMP4150 solenoid valve.
Removal
1. Remove all air pressure from the marking system.
2. Remove all electrical power from the marking system.
3. Remove the marking head cover:
a. Lift up on the tabs of the latches located on the sides of the marker.
b. Rotate the tabs counter-clockwise to loosen and disengage the latches.
c. Slide the protective boot over the end of the cartridge.
d. Slide the cover off the marker.
4. Remove the two solenoid wires lugs from J6 and J7 on the limit board
5. Using a 1.5mm hex key, remove two socket head cap screws from the solenoid valve and remove the
solenoid valve from the marking unit.

Installation
1. Install the new solenoid valve assembly. Ensure the gasket is properly positioned.
2. Route the solenoid wires toward the upper, backside of the X-axis motor and push the plugs onto limit
board connectors J6 and J7.
3. Install the marking head cover:
a. Slide the cover off the marker.
b. Engage the latches and rotate the tabs clockwise to tighten.
c. Push down on the tabs (so they lay flat against the sides of the marker.
d. Slide the protective boot up, onto the cartridge.

4.4.5 Solenoid Valve (TMP4100E)

Perform the following procedure to replace the TMP4100E solenoid valve.
Removal
1. Remove all electrical power from the marking system.
2. Remove the impact pin / pin cartridge from the marking head. (see procedure)
3. Remove the standoffs. (see procedure)
4. Using a 2.5mm hex key, remove four M3-0.50 x 25 screws securing right cover to left cover.
Separate covers and place right cover aside.
5. Using a 2mm hex key, loosen set screw in handle holding the push button switch.
6. Remove switch connector J2 from the limit board.
7. Remove the switch assembly from the handle.
8. Using a 2.5mm hex key, loosen set screw securing the handle to the handle mount.
Gently, pry and pull handle from the mount.

4-8
 TMP4100-Series/400 Maintenance

9. Using a 3mm hex key, remove two M4-0.70 x 16 socket head cap screws that secure the handle mount to
the manifold base.
10. Remove cable connector J1 from the limit board and disconnect the ground lug.
11. Using a 2.5mm hex key, remove three flat head screws from the bottom of the left cover.
12. Remove the marking unit from the left cover and place left cover aside.
13. Disconnect connectors on J6 and J7.
14. Remove two M3-.05 x 6mm flat head cap screws from the electric pin. Remove the armature and
shim(s).
15. Rotate the solenoid over the end leg.
16. Remove two M3-.05 x 6mm flat head cap screws that secure the solenoid frame to the cartridge base.
17. Remove two nuts securing solenoid to the electric pin base.
18. Note wire routing and location of wire ties. Remove wire ties, as applicable, and remove solenoid.

Installation
1. Mount the solenoid to the electric pin base using the two nuts provided on the solenoid.
2. Thread the wires from the solenoid through the hole in the face of the cartridge base leaving about 1½ to
2 inches protruding from the face.
3. Place the solenoid frame on the face of the cartridge base with wires through the notches and on top.
Align the screw holes and attach with two M3-.05 x 6mm flat head cap screws.
4. Rotate the solenoid over the end of the leg so that wires are on either side of the top leg. Push the
assembly down between the legs, solenoid first.
5. Verify the armature and shim(s) are in place prior to securing the solenoid. Align the holes and attach
with two M3-.05 x 6mm flat head cap screws.

CAUTION
Do not pull the wires through from the backside of the cartridge base. Doing
so might strip insulation from the wires and short the solenoid drivers.

6. Push the wires from the front through the notches while taking up the slack from the back of the
cartridge base until all slack is removed from the wires.
7. Route the wires down the side of the frame, opposite the cam, allowing enough wire with slight slack
when the cartridge is at the cam side of the frame.
8. Place a wire tie around the frame and wires immediately ahead of the boss for the right side pulley (as
viewed from the top). Place a second wire tie around wires and through the frame’s large rear hole.
9. Plug the wires into jacks J6 and J7.
10. Install the marking unit into left cover and secure with three flat head screws.

4-9
Maintenance Procedures

11. Connect the marking unit cable connector J2 to J1 on the limit board.
12. Attach the ground lug.
13. Install the handle mount onto left cover (with radius end of handle toward the back of the marker).
Secure with two M4-0.70 x 16 socket head cap screws.
14. Slide the handle onto the handle mount and tighten the set screw.
15. Install the push button switch assembly (connector end first) through the switch mounting hole.
16. Route the switch wires in and upward through the clearance hole toward the limit board.
17. Connect the switch wires to J2 on the limit board.
18. Secure the switch to the handle with a M3-0.50x3 set screw.
19. Lay the flex snap in the strain relief bushing on the cable assembly in the half-hole in the back of the left
cover with the tab facing down into the half-hole.
20. While holding the bushing in place, lay the right cover on top.
Ensure the push button wires are not pinched between the covers.
21. Secure the right cover with four M3-0.50 x 25 socket head cap screws.
22. Install the impact pin / pin cartridge onto the marking head. (see procedure)
23. Install the standoffs. (see procedure)

4-10
 TMP4100-Series/400 Maintenance

4.5 REFERENCE DATA

The following information will assist you in obtaining components to maintain the marking system.

4.5.1 Spare Parts

Refer to the TMP4100-Series/400 Operator’s Manual for a list of recommended spares. The manual also
lists the available marking pins and pin cartridge assemblies that can be used with the TMP4100-Series
marking heads.

4.5.2 Replacement Parts

Refer to Table 4-2 for a list of replaceable components and their part numbers.

Table 4-2. TMP4100-Series/400 Replacement Parts

PART NO. DESCRIPTION

30953 Marker Standoff, TMP4100

30942 Marker Standoff, TMP4100E
27339 Solenoid Valve, TMP4100E
35014 Solenoid Valve, TMP4100, TMP4150

4.5.3 Ordering Parts

If you need parts for the marking system, be sure to specify the TMP4100-Series model number and serial
number when ordering. Contact the Telesis Sales Department at:

Telesis Technologies, Incorporated

28181 River Drive
Circleville, Ohio 43113
PHONE (800) 654-5696 (U.S. and Canada)
(740) 477-5000
FAX (740) 477-5001

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 TMP4100-Series/400 Maintenance

Appendix A
Material Safety Data Sheets

This Appendix contains Material Safety Data Sheets (MSDS) for carbide and steel impact
pins. The impact pins are used by the TMP4100-Series/400 Marking Systems for imprinting
messages into various materials.

Read the MSDS sheets prior to reconditioning pins to become familiar with potential
reconditioning hazards. Always wear a respirator, safety glasses, and gloves when grinding
metal. Use the appropriate precautions, coolant, abrasive, and grinding techniques for the pin
material as described in the Material Safety Data Sheets.

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Appendix A

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A-2
 TMP4100-Series/400 Maintenance

MATERIAL SAFETY DATA SHEET

CARBIDE PINS

1. PRODUCT DEFINITION
CHEMICAL NAME: TRADE NAME & SYNONYMS:
Cemented carbide product All Carbide Grades

CHEMICAL FAMILY: MOLECULAR WEIGHT:

Refactory Metal Carbide Varies with grade

2. HAZARDOUS INGREDIENTS
MATERIAL CAS # % BY WEIGHT*** OSHA PEL ACGIH TLV

Tungsten Carbide 12070-12-1 0 - 97% 5 mg/m3 5 mg/m3

(limits for water insoluble tungsten compounds) 10 mg/m3 STEL 10 mg/m3 STEL
Cobalt 7440-48-4 0 - 30% 0.05 mg/m3 0.05 mg/m3
Nickel 7440-02-0 0 - 20% 1 mg/m3 1 mg/m3
Tantalum Carbide 12070-06-3 0 - 55% 5 mg/m3 5 mg/m3
(limits for tantalum metal dusts)
Molybdenum 12069-89-5 0 - 15% 10 mg/m3**** 10 mg/m3
(limits for insoluble molybdenum compounds)
Chromium Carbide(Cr3C2) 12012-35-0 0 - 5% 0.5 mg/m3 0.5 mg/m3
(limits for chromium III compounds, as Cr)

This product contains substances which are subject to the reporting requirements of Section 313 of Title III of the
Superfund Amendments and Reauthorization Act of 1986 and 40 CFR Part 372.

During normal usage cemented carbide products do not present inhalation, ingestion or other chemical hazards of any
kind. Wet or dry grinding of these products may release dusts of potentially hazardous ingredients which can be inhaled,
swallowed, or come in contact with skin and eyes. During wet grind, the dust can be suspended or dissolved in the
coolant mist.

3. PHYSICAL DATA
Physical State: Solid pH: N/A
Boiling Point: N/A* Specific Gravity (H2O - 1): 5.0-15.0
Freezing Point: N/A Odor Threshold: N/A
Vapor Pressure: N/A Percent Volatile by Volume: 0
Vapor Density: N/A Evaporation Rate: N/A
Water Solubility: Insoluble Coefficient of Water/Oil Distribution: NE**
Appearance and Odor: Dark Gray Metal/Odorless

A-3
Appendix A

4. FIRE AND EXPLOSION HAZARD DATA

Flash Point: N/A
Test Method Used: ___
Auto-ignition Temperature: N/A
Hard cemented carbide product is not a fire hazard. Dusts generated in grinding operations may ignite if allowed to
accumulate and are subjected to an ignition source.

Flammable Limits: N/A LEL: UEL:

Extinguishing Media: For powder fires, smother with dry sand, dry dolomite, ABC type fire extinguisher or flood with
water.

Special Fire Fighting Procedures: For a powder fire confined to a small area, use a respirator approved for toxic dusts
and fumes. For a large fire, fire fighters should use self-contained breathing apparatus.

Unusual Fire and Explosion Hazards: Dusts may present a fire or explosion hazard when exposed to high temperature
or ignition sources. However, this is not expected to be a problem under normal handling conditions.

Hazardous Combustion Products: May generate toxic fumes when heated.

5. HEALTH HAZARD DATA

Routes of Exposure: X Skin Contact N/A Skin Absorption X Eye Contact
X Acute Inhalation X Chronic Inhalation X Ingestion

Effects of Exposure: X Carcinogenicity X NTP X IARC

N/A Other X Sensitization N/A Teratogenicity
N/A Mutagenicity N/A Reproductive Toxicity
N/A Synergistic Materials

Inhalation - Dusts or mists can cause irritation of the nose and throat. Inhalation can result in an allergic reaction in
individuals previously sensitized, causing difficult breathing. Dusts or mists also have the potential for causing transient
or permanent respiratory disease, including occupational asthma and interstitial fibrosis in a small percentage of exposed
individuals. Symptoms include productive cough, wheezing, shortness of breath, chest tightness and weight loss. Nickel
is suspected of causing nasal and lung cancer. Symptoms include pain, bleeding, nasal obstruction, vision impairment,
weight loss and voice resonance change.

Skin Contact - Can cause irritation or an allergic skin rash due to chromium, cobalt, or nickel sensitization in people
susceptible to allergic reactions.

Eye Contact - Can cause irritation or conjunctivitis.

Ingestion - Ingestion of large amounts of cobalt over a period of time has the potential for causing blood, heart, and other
organ problems. Current scientific information indicates no adverse effects are likely from ingestion of small amounts of
nickel dust generated from these products.

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 TMP4100-Series/400 Maintenance

5. HEALTH HAZARD DATA (continued)

Carcinogenicity - The National Toxicology Program (NTP) found there was sufficient evidence of carcinogenicity of
nickel in experimental animals and limited evidence for the carcinogenicity of nickel in humans. The International
Agency for Research on Cancer (IARC) found there was inadequate evidence that metallic cobalt and metallic nickel are
carcinogenic to humans, but since there was sufficient evidence that they carcinogenic to animals, IARC concluded that
metallic cobalt and metallic nickel are possibly carcinogenic to humans. IARC and NTP found
there was inadequate data for the carcinogen city of chromium and trivalent chromium compounds. Cobalt has not been
classified as a known or suspected carcinogen by NTP or OSHA. Nickel and chromium have not been classified as a
known or suspected carcinogen by OSHA.

Conditions Aggravated by Exposure - Lung and other pulmonary and skin conditions may be aggravated by exposure.

Emergency and First Aid Procedures:

INHALATION - If symptoms of pulmonary involvement develop (coughing, wheezing, shortness of breath, etc.),
remove from exposure and seek medical attention.

SKIN CONTACT - If irritation or rash occurs, thoroughly wash affected area with soap and water and isolate from
exposure. If irritation or rash persists, seek medical attention.

EYE CONTACT - If irritation occurs, flush with large amounts of water. If irritation persists, seek medical attention.

INGESTION - If substantial quantities are swallowed, dilute with a large amount of water, induce vomiting and seek
medical attention.

6. REACTIVITY DATA
Stability: Unstable X Stable

Hazardous Polymerization: May Occur X Will Not Occur

Incompatibility: Contact of dust with strong oxidizers may cause fire or explosions.

Materials to Avoid: Strong acids and oxidizers.

Hazardous Decomposition Products: Thermal decomposition may release tungsten carbide, cobalt, and nickel metallic
oxides.

Conditions to Avoid: N/A

7. SPILL OR LEAK PROCEDURES

Steps To Be Taken In Case Material Is Released Or Spilled: Ventilate area of spill. Clean up using methods which
avoid dust generation such as vacuum (with appropriate filter to prevent airborne dust levels which exceed the PEL or
TLV), wet dust mop or wet clean-up. If airborne dust is generated, use an appropriate NIOSH approved respirator.

Waste Disposal Method: Dispose of in accordance with appropriate government regulations. May be sold as scrap for
reclaim.

A-5
Appendix A

8. SPECIAL PROTECTION INFORMATION

Respiratory Protection: Use an appropriate NIOSH approved respirator if airborne dust concentrations exceed the
appropriate PEL or TLV. All appropriate requirements set forth in 29 CFR 1910.134 should be met.

Ventilation: Use local exhaust ventilation which is adequate to limit personal exposure to airborne dust to levels which
do not exceed the PEL or TLV.

Protective Gloves: Protective gloves or barrier cream are recommended when contact with dust or mist is likely. Prior
to applying the barrier cream or use of protective gloves, wash thoroughly.

Eye Protection: Safety glasses with side shields or goggles are recommended.

Other Protective Equipment: N/A

9. SPECIAL PRECAUTIONS
Precautions to be Taken in Handling and Storage: Maintain good housekeeping procedures to prevent dust
accumulation during grinding. Avoid inhalation and direct skin contact with dust.

Other Precautions: Clean up using methods which avoid dust generation such as vacuum (with appropriate filter to
prevent airborne dust levels which exceed PEL or TLV), wet dust mop or wet clean-up. If airborne dust is generated, use
an appropriate NIOSH approved respirator.

Wash hands thoroughly after handling, before eating or smoking. Wash exposed skin and remove soiled clothing at the
end of work shift. Do not shake clothing, rags or other items to remove dust. Dust should be removed by washing or
vacuuming (with appropriate filters) the clothing, rags, or other items.

Periodic medical examinations are recommended for individuals regularly exposed to dust or mist.

"FOR CHEMICAL EMERGENCY"

Spill, Leak, Fire, Exposure, or Accident
Call CHEMTREC - Day or Night: 1-800-424-9300

10. ADDITIONAL INFORMATION

In case of questions, please call: Issue Date: July, 1992
Telesis Technologies, Inc.
Customer Service Supersedes: September, 1991
(800) 654-5696 (U.S. and Canada) or
(740) 477-5000 (ask for Customer Service)
(740) 477-5001 (FAX)
Although Telesis has attempted to provide accurate information herein, Telesis makes no representation regarding the
accuracy or completeness of the information and assumes no liability for any loss, damage or injury of any kind which
may result from or arise out of the use of or reliance on the information by any person.

LEGEND
* N/A = Not Applicable *** Depends on grade specification
** NE = Not Established **** Total dust

#15-00-605

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 TMP4100-Series/400 Maintenance

MATERIAL SAFETY DATA SHEET

STEEL PINS

1. PRODUCT DEFINITION
STEEL PINS DATE OF PREPARATION:
November 1, 1985

PRODUCT NAME:
A Supplemental Chemistry Sheet will be issued for each grade shipped to each customer. See Section 2.

2. HAZARDOUS INGREDIENTS
MATERIAL CAS NUMBER MATERIAL CAS NUMBER

Aluminum (Al) 7429-90-5 Manganese (Mn) 7439-96-5

Carbon (C) 7440-44-0 Molybdenum (Mo) 7439-98-7
Chromium (Cr) 7440-47-3 Nickel (Ni) 7440-02-0
Cobalt (Co) 7440-48-4 Selenium (Se) 7782-49-2
Columbium (Cb) 7440-03-1 Silicon (Si) 7440-21-3
Niobium (Nb-syn with Cb) Titanium (Ti) 7440-32-6
Copper (Cu) 7440-50-8 Tungsten (W) 7440-33-7
Iron (Fe) 7439-89-6 Vanadium (V) 7440-62-2

No Threshold Limit Values (TLVs) exist for specialty steels. TLV may be applicable to constituent elements.
A Supplemental Chemistry Sheet will be sent covering each grade or type of steel purchased. It will have the maximum
level of each element that is present and required to be reported by OSHA Hazard Communication Standard 29 CFR
1910.1200.
See Appendix A for the Permissible Exposure Limits as determined by OSHA, ACGIH, and/or IDLH for each
component.

3. PHYSICAL DATA
Physical State: Solid pH: N/A
Boiling Point: 686-5660° C Specific Gravity: 1.8-19.3
Freezing Point: N/A Odor Threshold: N/A
Vapor Pressure: N/A Percent Volatile by Volume: N/A
Vapor Density: N/A Evaporation Rate: N/A
Water Solubility: Insoluble (except Manganese) Coefficient of Water/Oil Distribution: N/A
Appearance and Odor: Solid, Odorless Metal Melting Point: 2-17-3410° C

See Appendix A, Chemical and Physical Properties, for additional data (if any) for each element.

A-7
Appendix A

4. FIRE AND EXPLOSION HAZARD DATA

Flash Point: None

Fire Point: None

This product is a noncombustible metal.

See Appendix A for any applicable Fire and Explosion Data for each element.

5. HEALTH HAZARD DATA

A. GENERAL COMMENTS
We do not consider this product in the form it is sold to constitute a physical hazard or a health hazard. Subsequent
operations, such as heating above 1200° F, cutting, and/or grinding, may cause some of the ingredients to change to a
form which could affect exposed workers.

Routes of Exposure: X Skin Contact N/A Skin Absorption X Eye Contact

X Acute Inhalation X Chronic Inhalation X Ingestion

Emergency First Aid:

Inhalation - Remove to fresh air. If condition continues, consult physician.

Eye Contact - Flush well with running water to remove particulate. Seek medical attention.

Skin Contact - Brush off excess dirt. Wash area well with soap and water.

Ingestion - Seek medical attention if large quantities of material have been ingested. (Ingestion of significant
amounts of metal is unlikely.)

B. CONSTITUENT HAZARDS
See Appendix A, Permissible Exposure Limits, for the Threshold Limit Values (TLVs) for each constituent.

Effects of Overexposure:

Acute Exposure - Excessive inhalation of fumes from many metals can produce an acute reaction known as “metal
fume fever”. Though metals such as copper and zinc have been most associated with metal fume fever, it is
suspected by some authorities that other metallic fumes may produce this condition.
Symptoms consist of chills and fever (very similar to, and easily confused with, flu symptoms), which come on a few
hours after exposure. Long term effects of metal fume fever have not been noted.

Chronic Exposure - Excessive and repeated inhalation of chromium fumes or dust may cause severe irritation,
ulceration, or cancer in the respiratory system – nose, throat and lungs. It is generally believed that the hexavalent
forms of chromium (Cr+6) are responsible for these effects. Similarly, excessive inhalation of nickel fumes has been
associated with respiratory cancer. Both chromium and nickel are sensitizers and may cause allergic reactions.
Excessive and prolonged inhalation of manganese (generally over two years of exposure) can cause damage to the
central nervous system – specifically, the pathology resembles Parkinson’s Disease. Molybdenum is not foreseen as
a hazard in the present context. Though molybdenum has caused toxicity (anemia and poor growth) in farm animals,
there is no documented toxicity to humans due to industrial exposures.

A-8
 TMP4100-Series/400 Maintenance

6. REACTIVITY DATA
Stability: Unstable X Stable

Hazardous Polymerization: May Occur X Will Not Occur

Incompatibility: Reacts with strong acids to generate hydrogen gas.

Materials to Avoid: Strong acids and oxidizers.

Hazardous Decomposition Products: Metallic oxides.

Conditions to Avoid: Avoid generation of airborne dust and fumes.

7. SPILL OR LEAK PROCEDURES

Steps To Be Taken In Case of Release or Spill: N/A

Special Precautions: Use good housekeeping practices to prevent accumulations of dust and to keep airborne dust
concentrations at a minimum.

Waste Disposal Method: Dust, etc. — Follow federal, state, and local regulations regarding disposal.

See Appendix A, Handling Procedures, for additional data (if any) for each element.

8. SPECIAL PROTECTION INFORMATION

Ventilation Requirements: Use general or local exhaust ventilation to keep airborne concentrations of dust and fumes
below the TLV. Consult a professional hygienist.

Respiratory Protection: If fumes, misting, or dust conditions occur, consult a professional hygienist. Provide NIOSH
approved respirators.

Gloves: Gloves and barrier creams may be necessary to prevent skin sensitization and dermatitis.

Personal Protective Equipment: Always consult a professional hygienist.

Eye Protection: Safety glasses should always be worn when grinding or cutting. Face shields should be worn when
welding or burning.

Other Clothing or Equipment: As required

A-9
Appendix A

9. EMERGENCY FIRST AID INFORMATION

If acute overexposure to fumes occurs, remove the victim to fresh air, then seek medical assistance. See Section 5,
Health Hazard Data, Part A, General Comments, for details.

10. ADDITIONAL INFORMATION

In case of questions, please call:

Telesis Technologies, Inc.
Customer Service
(800) 654-5696 (U.S. and Canada) or
(740) 477-5000 (ask for Customer Service)
(740) 477-5001 (FAX)
Although Telesis has attempted to provide accurate information herein, Telesis makes no representation regarding the
accuracy or completeness of the information and assumes no liability for any loss, damage or injury of any kind which
may result from or arise out of the use of or reliance on the information by any person.

A-10