Maintenance Manual - A&A Machinery Moving · 2017. 1. 15. · Manual No. 33473 Rev. – Telesis Technologies, Inc. March 2000 28181 River Drive P.O. Box 1000 Circleville, Ohio 43113

Manual No. 33473 Rev. –

Telesis Technologies, Inc. March 200028181 River DriveP.O. Box 1000Circleville, Ohio 43113

Maintenance ManualTMP4100-Series/400

PINSTAMP ® Marking System

This manual contains maintenance information for the TelesisTMP4100-Series/400 Marking Systems. These systems use theTMC400 Controller and the TMP4100 hand-held pneumatic-pinmarker, the TMP4100E hand-held electric-pin marker, or theTMP4150 fixture-mounted pneumatic-pin marker.

This manual may be supplemented and kept current by ChangeNotices and Revisions.

TMP4100-Series/400 Maintenance

A

List of Effective Pages

DATES OF MANUAL AND CHANGED PAGES:

Original Issue....................................March 2000

N O T E

The portion of the text affected by the change is indicated by a vertical line inthe outer margins of the page. Changes to illustrations (other than diagramsand schematics) are identified with a miniature pointing hand. Shading is usedto 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................................................ 0A through D ............................................ 0i through iv.............................................. 01-1 through 1-2 ....................................... 02-1 through 2-8 ....................................... 03-1 through 3-6 ....................................... 04-1 through 4-12 ..................................... 0A-1 through A-10.................................... 0

INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES.

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


B

This page intentionally left blank.


C

Foreword

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

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

Telesis expressly warrants the equipment it manufactures as set forth in the Standard Terms and Conditionsof 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.


D

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 USINGTHESE PROGRAMS INDICATES YOUR ACCEPTANCE OF THESE TERMS. THIS IS A LEGALAGREEMENT 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 touse the Telesis software/firmware program (the program) subject to the terms and conditions of this licenseagreement.

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 termfirmware 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 programsare referred to as the program.

3) COPYRIGHT. The program(s) and documentation is owned by Telesis and is protected by United Statescopyright laws and international treaty provisions. The program(s) contain trade secrets and proprietaryproperty of Telesis. You may make one copy of the program(s) solely for backup or archival purposesprovided that the copy clearly displays the Telesis copyright notice. Additional copies may be made whenauthorized to do so in writing by Telesis. In addition to any other right of Telesis, Telesis has the right toterminate 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) anddocumentation are to be used on one computer on embedded system at any one time. The multi-processorversion(s) of the program(s) and documentation may be used over a network provided that the number ofcomputers accessing the network simultaneously shall not exceed the number authorized by Telesis or forwhich you paid the corresponding multi-processor fee. You may not distribute the programs ordocumentation to a third party. You may transfer the license and complete package (retaining nothing) if thetransferee agrees to the terms of this License Agreement. Neither the program(s) nor the documentation maybe 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 ofSale.

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

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


i

Table of ContentsPARAGRAPH PAGE

List of Effective Pages .......................................................................................................................... AForeword ............................................................................................................................................... CSoftware/Firmware License Agreement ............................................................................................... DList of Illustrations................................................................................................................................ iiiList of Tables ........................................................................................................................................ iiiSafety Summary .................................................................................................................................... iv

Chapter 1General Information

1.1 Maintenance Overview ............................................................................................................ 1-11.2 Maintenance Precautions ......................................................................................................... 1-21.2 Telesis Customer Service......................................................................................................... 1-21.3 Additional Publications............................................................................................................ 1-2

Chapter 2Troubleshooting

2.1 Marking Head .......................................................................................................................... 2-12.2 Controller ................................................................................................................................. 2-6

Chapter 3Test and Verification

3.1 Interface Checks....................................................................................................................... 3-13.1.1 Host Interface .................................................................................................................... 3-13.1.2 Discrete I/O Interface ........................................................................................................ 3-23.1.3 TTL I/O Interface .............................................................................................................. 3-33.2 Resistance Checks.................................................................................................................... 3-43.2.1 Stepper Motor Resistance.................................................................................................. 3-43.2.2 Solenoid Resistance........................................................................................................... 3-43.3 Continuity Checks.................................................................................................................... 3-5


ii

Table of ContentsPARAGRAPH PAGE

Chapter 4Maintenance Procedures

4.1 Overview .................................................................................................................................. 4-14.2 Repair Procedures..................................................................................................................... 4-24.2.1 Impact Pin Reconditioning................................................................................................. 4-24.3 Cleaning Procedures ................................................................................................................. 4-44.3.1 Impact Pin / Pin Cartridge.................................................................................................. 4-44.3.2 Marking Head Rail............................................................................................................. 4-44.4 Replacement Procedures .......................................................................................................... 4-54.4.1 Impact Pin / Pin Cartridge.................................................................................................. 4-54.4.2 Marker Standoff (TMP4100, TMP4100E) ........................................................................ 4-64.4.3 Solenoid Valve (TMP4100)............................................................................................... 4-64.4.4 Solenoid Valve (TMP4150)............................................................................................... 4-84.4.5 Solenoid Valve (TMP4100E) ............................................................................................ 4-84.5 Reference Data ......................................................................................................................... 4-114.5.1 Spare Parts ......................................................................................................................... 4-114.5.2 Replacement Parts.............................................................................................................. 4-114.5.3 Ordering Parts .................................................................................................................... 4-11

Appendix AMaterial Safety Data Sheets

Carbide Impact Pins............................................................................................................................... A-3Steel Impact Pins ................................................................................................................................... A-7


iii

List of IllustrationsFIGURE PAGE

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

List of TablesTABLE PAGE

2-1 Troubleshooting the Marking Head .............................................................................................. 2-12-2 Troubleshooting the Controller..................................................................................................... 2-6

3-1 Host Connector Pin Assignments.................................................................................................. 3-13-2 I/O Connector Input Checks.......................................................................................................... 3-23-3 I/O Connector Output Checks....................................................................................................... 3-23-4 TTL I/O Connector Input Checks ................................................................................................ 3-33-5 Stepper Motor Resistance Checks................................................................................................. 3-43-6 Solenoid Resistance Checks.......................................................................................................... 3-43-7 Marking Head Extension Cable Pin Assignments ........................................................................ 3-5

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


iv

Safety SummaryThe 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. Thefollowing 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.

W A R N I N G

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

C A U T I O N

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

N O T E

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


1-1

Chapter 1General Information

* * * N O T I C E * * *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 thepin from and return the pin to the pin cartridge. The TMP4100E uses no air pressure. TheTMP4100E (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 beclearly identified within the text to inform you of the differences.

TMP4100, TMP4100E: The TMP4100 and TMP4100E markers are hand-held markers. Theymay 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 maybe mounted in any orientation except inverted (that is, with the mounting holes pointingupward). Typically, it should be mounted on a tooling fixture with the pin pointingdownward. The TMP4150 marking head employs a protective boot to help preventcontaminants from entering the marking head cavity.

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

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

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

General Information

1-2

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 areeither locked or tagged while equipment is cleaned or serviced.

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

1.2 TELESIS CUSTOMER SERVICETelesis Customer Service offers the following assistance:

Phone Support - Telesis Customer Service offers free phone support to answer questions during normalbusiness 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 equipmentstart-up, repair, maintenance, and training.

Service Contracts - As part of your Service Contract, you receive periodic maintenance and quick on-sitecustomer 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 serviceallows 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 andask for Customer Service. Our FAX number is (740) 477-5002.

1.3 ADDITIONAL PUBLICATIONSAdditional information about the TMP4100-Series /400 Marking Systems may be found in the followingpublications:

TMP4100-Series/400 Operator’s Manual

TMP4100-Series/400 Installation Manual

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


2-1

Chapter 2Troubleshooting

2.1 MARKING HEADThis section provides troubleshooting information for the marking head. Refer to Table 2-1 to identifyproblems, their probable causes, and corrective action. If a defective component has been identified, refer toChapter 4 to repair or replace the component. If these procedures fail to correct the problem, contact TelesisCustomer Service.

Table 2-1. Troubleshooting the Marking Head

PROBLEM PROBABLE CAUSE CORRECTIVE ACTION

Cartridge base/frame mechanism does notinitialize when placed ONLINE. Noapparent movement.

When the ONLINE function is selected,the cartridge base/frame will seek home.This causes the cartridge base/frame totraverse to the middle left edge of itstravel (as viewed from the back of themarker). When the cartridge base/frameis already home, it will make a smallmovement away from home in both axes,then seek home again.

Refer to the TMP4100-Series/400Operator’s Manual for data entry andfunction selection.

Neither axis initializes or only one axismoves.

1. Control may be interrupted betweenthe controller and the marker.

1. Inspect the cable and connectorsbetween the controller and themarking head.

Check continuity. Refer to Chapter 3.

2. Power to the controller or to the drivemotors may be down.

2. Check the inlet fuses on the powerentry module. Refer to the TMP4100-Series/400 Operator’s Manual fordetails.

3. Defective cable between the controllerand marking head.

3. Disconnect marker cable fromcontroller.

Check resistance at marking headcable connector. Refer to Chapter 3.

If resistance is within tolerance, checkcontinuity of marker extension cable (ifused). Refer to Chapter 3.

If cable checks good, replacecontroller.

4. X-axis pulley loose, Y-axis cam loose,or cam flag bound on sensor.

4. Check the axis in question. Removethe four screws on the sides of thehead cover and visually inspect.

Try to move the axis in question andobserve the pulley/cam to see if itmoves independently of the motor.(This would indicate a loosepulley/cam.)

(continued on next page)

Troubleshooting

2-2

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


The marker sounds as if the motors arerunning, but there is no motion in one orboth axes.

1. X-axis pulley loose or Y-axis camloose.

1. Turn off power to the controller.Disconnect the marking head cablefrom the controller.

TMP4100, TMP4150: Shut off airpressure to the marking head.

Remove the cover from the marker.Inspect drive system. Replace ifdamaged.

Turn the X-axis pulley and check forslippage on the motor.

If pulley is tight, check the motorresistance. Refer to Chapter 3.

If motor resistance is out of tolerance,replace the marking head.

2. The rail/carriage or pulleys may bebound or defective.

2. Try to physically move the axis thatwill not move electrically.

Check for external and internal causessuch as the mounting structure orparts which may be limiting the fulltravel of the cartridge base/frame andcartridge components.

Cartridge base/frame is attempting toinitialize. The motor or motors continue tosound as if they are running and thecartridge base/frame appears stalled at ornear the home position. Head doesn’t findthe home location.

1. There may be an interferencepreventing the cartridge base/framefrom reaching home.

1. Check for external and internal causessuch as the mounting structure orparts which may be limiting the fulltravel of the cartridge base/frame andcartridge components.

2. If both motors are stalled at the homelocation, a common factor such aspower or a connector associated withthe Home PCB could be at fault.

2. Check continuity of marker extensioncable (if used). Specifically, check theX HOME, Y HOME, +5VDC, and+5VDC RETURN signals. Refer toChapter 3.

3. If only one axis is stalled, the homeposition sensor for the stalled axismay be defective.

3. Inspect the flag and sensor associatedwith the malfunctioning axis. The flagsmust pass between the opposed legsof the sensors

Ensure the sensor is not cracked orbroken.

4. The home position flag may be out ofposition for the stalled axis.

4. When positioning the flags, ensurethere is safe passage of the flagbetween the sensors legs.

If the cartridge/pin does not find home inthe X-axis, try to push the cartridge/pinto the left to the center of the window(as viewed from the back). Place themarker online (press F2). If themarker now homes properly, the X-axis opto is out of adjustment. (Theflag is passing the opto causing thehead to run into the hard stop.) Movethe opto closer to the home side. Re-test by pushing the cartridge/pin to theright, then placing the marker online.



2-3



Cartridge base/frame is attempting toinitialize. The motor or motors continue tosound as if they are running and thecartridge base/frame appears stalled at ornear the home position. Head doesn’t findthe home location. (continued)

5. Defective cable between the controllerand marking head.

5. Disconnect marker cable fromcontroller.

Check resistance at marking headcable connector. Refer to Chapter 3.

If resistance is within tolerance, checkcontinuity of marker extension cable (ifused). Refer to Chapter 3.

If cable checks good, replacecontroller.

The marking pin does not fire. Marking head cable defective Disconnect the marker cable from thecontroller and check the solenoidresistance at the marker cable connector.Refer to Chapter 3.

The marking is not properly located on theprocess material.

1. The X and Y coordinates may beincorrect.

1. Refer to the TMP4100-Series/400Operator’s Manual for proper X,Yorientation.

2. The cartridge base/frame mechanismmay not be correctly positioned due toa slip or stall which may haveoccurred previously.

2. Excessive shock loading of themarking head can cause the cartridgebase/frame to slip out of position.Reset the marker and verify thatplacement is correct on subsequentmark operations.

The marking is cut off, truncated. Pin may be hanging up in cartridge orsolenoid may not be operating.

Clean the pin cartridge as required.

From the Supervisor Mode, pulse thesolenoid. Refer to the TMP4100-Series/400 Operator’s Manual for detailson pulsing the impact pin.

The marked characters are grouped inintervals. Gaps exist between characterintervals or characters are overlapped.

1. The cartridge base/frame mechanismmay be mechanically locked up.

1. Inspect the rail to determine if they arefree.

Clean rail and apply light oil (3-in-1).

If the rail/carriage is worn and causingbinding, replace the marking head.

2. The impact pin may be sticking intothe target material.

2. Verify the right pin type is selected foryour marker.

TMP4100, TMP4150: Drive Air shouldbe a minimum of 70 psi (4.8 bars).

Reduce the angle of the conicalimpact pin tip to prevent sticking anda faster withdrawal from the targetmaterial.

The indentation depth is insufficient. 1. TMP4150: The Pin Stroke distancemay be too large, or

1. TMP4150: Move the surface to bemarked closer to the pin, or repositionthe marker so that the pin is closer tothe target surface.

2. The pin may be too short due tosharpening, and may “bottom out” inthe pin bore before impacting orexpending all the energy in making anindentation.

TMP4100, TMP4150: On the largerpins (150S) there is a built inpneumatic cushion that slows the pinprior to bottoming out in the cartridge.

2. Replace pin as required. Refer toChapter 4.

3. The impact pin tip might be dull orbroken.

2. Sharpen pin or replace pin asrequired. Refer to Chapter 4.


Troubleshooting

2-4



The indentation depth or diameter is toolarge for the character size.

1. TMP4150: The Pin Stroke distancemay be too large.

1. TMP4150: Reduce the Pin Strokedistance to reduce the depth anddiameter.

2. TMP4100, TMP4150: The Drive Airpressure may be too high.

2. TMP4100, TMP4150: Reduce theDrive Air pressure as required.

3. Pin angle too shallow. 3. Use sharper pin.

The indentation depth is inconsistent. 1. If contiguously formed indentationsstart out large then diminish, thecartridge base/frame mechanismtraversing speed may exceed theimpact pin optimum rate. This couldbe the result of an incorrect setupselection of pin stroke or pin type

1. Verify accuracy of setup parameters.

2. TMP4100, TMP4150: The Drive Airtubing to the marking head may beundersized causing restricted air flow.

2. TMP4100, TMP4150: The Drive Airsupplying the regulators should be noless than 1/2" and the tubingsupplying the marker should be 1/4"minimum and not exceed 50 feet (13meters).

3. TMP4100, TMP4150: The Drive Airtube may be restricted causingdecreased flow to the valves, orplugged exhaust port.

3. TMP4100, TMP4150: Ensure the filteris not clogged or dirty. Clean asnecessary. Check the Drive Air tubingfrom the regulator to the markinghead, and inside the marker, forcrimped air lines or restrictions.

4. TMP4100, TMP4150: The Drive Airpressure regulator may be defective.

4. TMP4100, TMP4150: Verify that theoutlet air pressure is regulatingproperly. Replace if pressurevariations of more than 5 psi (0.3bars) are common.

5. TMP4100, TMP4150: The valve maybe dirty or defective.

5. TMP4100, TMP4150: Swapping thevalve with a working valve.

Indentation depth is inconsistent in aparticular area of the marking window.

1. TMP4100, TMP4150: The coiled DriveAir tubing may be kinked or restrictedwhen traversing

1. TMP4100, TMP4150: Inspect thetubing from the valve to the manifoldfor cracks, restrictions or crimps in thetubing.

2. TMP4100, TMP4150: Loose orincorrectly mounted head cartridge.

2. TMP4100, TMP4150: Check for aloose cartridge, leaking air, or acartridge mounted incorrectly.

3. TMP4100, TMP4150: Worn cartridge,or excessive dirt/oil in the Drive Airmaking the pin stick.

3. TMP4100, TMP4150: Inspect the pincartridge for excessive "blow by" air.

Remove the cartridge, push the pininto the cartridge, and release it in avertical position (pin down). The pinshould drop freely. If not clean withisopropyl alcohol and try again.



2-5



The indentations within the characters arenot placed accurately.

1. In order to optimize the marking timesof the system, it is important to enterall parameters correctly in order tosynchronize the impact pin impulsewith the end of the cartridgebase/frame move to the current pixellocation. This is accomplished byaccurate entry of Pin Stroke distanceand Pin Type.

1. Verify correct entry of all operatingparameters.

TMP4100, TMP4150: Inaccurate entryof Drive Air pressure.

2. The marker or material to be markedmay be moving relative to each otherduring the marking cycle.

2. In order to assure a high quality mark,it is important that there is little or norelative movement between themarker and material being marked.

The marked characters are wholly orpartially garbled or skewed.

1. TMP4100, TMP4150: The incorrectpin type may be entered, causing aslip. Sharper pins require slowermarking speeds, and with softermaterial, may hang up in the productbeing marked.

1. TMP4100, TMP4150: Verify that thecorrect operating parameters havebeen entered. On new installations, trya slower marking speed.

2. A slip may have occurred whilemarking due to an interference.

2. The material being marked may haveraised portions which are being struckby either the impact pin or thecartridge. A “dry run” with the pinretracted may verify the possibleinterference.

3. Excessive vibration of the marker inthe plane of the marking surface,normal to the indentation forces, mayhave caused a slip.

3. Due to the inherent nature of stepmotor driven systems, there is thepossibility of exceeding the holdingforce of the motors with impulseforces caused by vibration. Ensurethe mounting of the marker will notpromote vibration in the same planeas the cartridge base/frame traversingcomponents.

4. If the cartridge base/framemechanism does not fully travel to theHome position, it may reach the endof travel before the marking iscomplete.

4. Verify that the full range of travel inboth X and Y directions is achievableby jogging the unit to its extremepositions. If full travel is not possible,check the flag in that direction forproper location. Check forinterference. Verify there is nointernal binding of parts or tubing.

5. The impact pin may be momentarilysticking into the target material,resulting in excessive drag and slip.

5. The deeper that the impact pinpenetrates the target material, thelonger it takes to retract from thematerial. This is mostly due to theincreased energy transfer into thetarget.


Troubleshooting

2-6



The marking time is too long for a givenapplication.

1. The character density selected maybe too high.

1. Reduce the font density or the numberof pixels per inch.

2. The marking mode may beinappropriate (i.e., Continuous).

2. TMP4100-Series Marking Systemsare flexible markers. The two markingmodes are Dot Matrix and Continuous.Each mode has advantages anddisadvantages with respect to speedand presentation. In the Dot Matrixmode the pixels are formed while thehead decelerates to the exact locationto place the pixel, then accelerates tothe next location. The Dot Matrixmode may also have more or lessdots, such as 5x7 compared with11x16; each font will have increasinglymore dots. The Continuous modeprovides a string of dots tracing thecharacters one at a time. The markinghead does not decelerate, thenaccelerate after positioning. Thenumber of pixels per inch determinethe density of the character pixelformation.


2-7

2.2 CONTROLLERThis section provides troubleshooting information for the controller. Refer to Table 2-2 to identify problemsand their probable cause. If a defective component has been identified, refer to Chapter 4 to repair or replacethe 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.

Check power to the controller and the power entry module fuses.

If no problem is found, contact Telesis Customer Service for assistance or contact aTelesis-authorized maintenance agency for repair.

Discrete I/O fault. 1. Check the I/O cable.

2. If the problem is an input fault, disconnect the I/O cable and verify the inputvoltages. Refer to Chapter 3.

3. If the problem is an output fault, disconnect the I/O cable and verify the outputresistance. Refer to Chapter 3.

Serial communication fault. 1. Check the communication cable.

2. Verify the communication parameters are properly configured for the markingsystem. Refer to the TMP4100-Series/400 Operator’s Manual for details.

3. Connect an RS-232 diagnostic light box between the communication cable and thecontroller. Verify signals to and from the Host.

TTL I/O fault 1. Check the I/O cable.

2. Disconnect the I/O cable from the TTL I/O connector and verify the resistance at theconnector. Refer to Chapter 3. (Note: Resistance values are based on closedswitches.)

Loss of system parameters or data afterpower is down.

Contact Telesis Customer Service for assistance.

Troubleshooting

2-8



3-1

Chapter 3Test and Verification

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

3.1 INTERFACE CHECKSThe following sections provide pin assignments, signal names, signal descriptions, voltage, and resistance forthe interface connectors on the back panel of the controller.

N O T E

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

3.1.1 Host InterfaceThe 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 inthe 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

Test and Verification

3-2

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

N O T E

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




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.


3-3

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

N O T E

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.


3-4

3.2 RESISTANCE CHECKSThe following information is provided to check the resistance values of the stepper motor circuit and thesolenoid 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.

NOTEResistance measurements are to be taken with power OFF.

3.2.1 Stepper Motor ResistanceTable 3-5 lists the resistance values for the stepper motor. These checks are made at the connector on the endof 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 ResistanceTable 3-6 lists the resistance values for the solenoid. These measurements are taken at the connector on theend 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%


3-5

3.3 CONTINUITY CHECKSThe 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 fromthe standard marking head cable.

Table 3-7. Marking Head Extension Cable Pin Assignments

FROMJ1

TOJ2 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]



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


3-6



4-1

Chapter 4Maintenance Procedures

4.1 OVERVIEWMaintenance procedures not explicitly contained in this manual must be performed by repair agenciesauthorized 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

Maintenance Procedures

4-2

4.2 REPAIR PROCEDURESAuthorized 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 byTelesis Technologies, Inc.

4.2.1 Impact Pin ReconditioningPeriodically, the tips of the impact pins will become dull and require reconditioning. Grind (or replace) theimpact 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 noticeablyflattened. The length of service between reconditioning will depend on the pin material, the material beingmarked and the depth of the mark desired. Table 4-1 lists the lengths for new and reconditioned pins. Thepin 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


4-3

The recommended grinding wheels for the various pin material are listed below. The minimum pin lengthsallow for only about a 3% reduction in the total length during reconditioning. Therefore, only the smallestamount 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)

W A R N I N G

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

Use the appropriate precautions, coolant, and abrasive for the pin materialand 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 becapable 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.


4-4

4.3 CLEANING PROCEDURESPerform the following procedures to clean the marking head guide rods.

4.3.1 Impact Pin / Pin CartridgePerform the following steps to clean the pin cartridge and impact pin.


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 drybefore 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 RailPerform the following steps to clean the carriage rail in the marking head.

C A U T I O N

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.


4-5

4.4 REPLACEMENT PROCEDURESAuthorized replacement of the TMP4100/400 and TMP4100E/400 Marking Systems’ components are listedin the following paragraphs. Component replacement procedures not explicitly contained in this manualmust be performed by repair agencies authorized by Telesis Technologies, Inc.

4.4.1 Impact Pin / Pin CartridgeFollow the steps below to remove and replace the impact pin and/or the pin cartridge assembly.

C A U T I O N

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.


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 toprevent 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 notchin 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.


4-6

4.4.2 Marker Standoff (TMP4100, TMP4100E)Perform the following procedure to replace the standoffs mounted on the front of the TMP4100 orTMP4100E marking head.

C A U T I O N

Do not move the pin cartridge by hand. Internal components of the markinghead may be damaged if improperly positioned. Use the system’s Jogfeature 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 markingwindow.

2. Using a 2mm hex key, remove the two M3-0.50 x 10 flat head screws from the right side standoff (sideopposite 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 (sideopposite 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.


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.


4-7

8. Using a 2.5mm hex key, loosen set screw securing the handle to the handle mount. Gently, pry and pullhandle 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 tothe 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 thesolenoid 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 limitboard 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 leftcover 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)


4-8

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.


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 thesolenoid 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 limitboard 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



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.


4-9

9. Using a 3mm hex key, remove two M4-0.70 x 16 socket head cap screws that secure the handle mount tothe 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 andshim(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 to2 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 theassembly 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 attachwith two M3-.05 x 6mm flat head cap screws.

C A U T I O N

Do not pull the wires through from the backside of the cartridge base. Doingso 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 thecartridge 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 slackwhen 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 (asviewed 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.


4-10

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 leftcover 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)


4-11

4.5 REFERENCE DATAThe following information will assist you in obtaining components to maintain the marking system.

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

4.5.2 Replacement PartsRefer 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 PartsIf you need parts for the marking system, be sure to specify the TMP4100-Series model number and serialnumber when ordering. Contact the Telesis Sales Department at:

Telesis Technologies, Incorporated28181 River DriveCircleville, Ohio 43113PHONE (800) 654-5696 (U.S. and Canada)

(740) 477-5000FAX (740) 477-5001


4-12



A-1

Appendix AMaterial Safety Data Sheets

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

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

Appendix A

A-2



A-3

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(limits for tantalum metal dusts)

12070-06-3 0 - 55% 5 mg/m3 5 mg/m3

Molybdenum(limits for insoluble molybdenum compounds)

12069-89-5 0 - 15% 10 mg/m3**** 10 mg/m3

Chromium Carbide(Cr3C2)(limits for chromium III compounds, as Cr)

12012-35-0 0 - 5% 0.5 mg/m3 0.5 mg/m3

This product contains substances which are subject to the reporting requirements of Section 313 of Title III of theSuperfund 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 anykind. 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 thecoolant mist.

3. PHYSICAL DATA

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

Appendix A

A-4

4. FIRE AND EXPLOSION HAZARD DATA

Flash Point: N/ATest 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 toaccumulate 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 withwater.

Special Fire Fighting Procedures: For a powder fire confined to a small area, use a respirator approved for toxic dustsand 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 temperatureor 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 ContactX Acute Inhalation X Chronic Inhalation X Ingestion

Effects of Exposure: X Carcinogenicity X NTP X IARCN/A Other X Sensitization N/A TeratogenicityN/A Mutagenicity N/A Reproductive ToxicityN/A Synergistic Materials

Inhalation - Dusts or mists can cause irritation of the nose and throat. Inhalation can result in an allergic reaction inindividuals previously sensitized, causing difficult breathing. Dusts or mists also have the potential for causing transientor permanent respiratory disease, including occupational asthma and interstitial fibrosis in a small percentage of exposedindividuals. Symptoms include productive cough, wheezing, shortness of breath, chest tightness and weight loss. Nickelis 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 peoplesusceptible 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 otherorgan problems. Current scientific information indicates no adverse effects are likely from ingestion of small amounts ofnickel dust generated from these products.


A-5

5. HEALTH HAZARD DATA (continued)

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

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 whichavoid dust generation such as vacuum (with appropriate filter to prevent airborne dust levels which exceed the PEL orTLV), 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 forreclaim.

Appendix A

A-6

8. SPECIAL PROTECTION INFORMATION

Respiratory Protection: Use an appropriate NIOSH approved respirator if airborne dust concentrations exceed theappropriate 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 whichdo not exceed the PEL or TLV.

Protective Gloves: Protective gloves or barrier cream are recommended when contact with dust or mist is likely. Priorto 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 dustaccumulation 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 toprevent airborne dust levels which exceed PEL or TLV), wet dust mop or wet clean-up. If airborne dust is generated, usean appropriate NIOSH approved respirator.

Wash hands thoroughly after handling, before eating or smoking. Wash exposed skin and remove soiled clothing at theend of work shift. Do not shake clothing, rags or other items to remove dust. Dust should be removed by washing orvacuuming (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, 1992Telesis 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 theaccuracy or completeness of the information and assumes no liability for any loss, damage or injury of any kind whichmay 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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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 maximumlevel of each element that is present and required to be reported by OSHA Hazard Communication Standard 29 CFR1910.1200.

See Appendix A for the Permissible Exposure Limits as determined by OSHA, ACGIH, and/or IDLH for eachcomponent.

3. PHYSICAL DATA

Physical State: Solid pH: N/ABoiling Point: 686-5660° C Specific Gravity: 1.8-19.3Freezing Point: N/A Odor Threshold: N/AVapor Pressure: N/A Percent Volatile by Volume: N/AVapor Density: N/A Evaporation Rate: N/AWater Solubility: Insoluble (except Manganese) Coefficient of Water/Oil Distribution: N/AAppearance 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.

Appendix A

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

Routes of Exposure: X Skin Contact N/A Skin Absorption X Eye ContactX 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 significantamounts of metal is unlikely.)

B. CONSTITUENT HAZARDSSee 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 “metalfume fever”. Though metals such as copper and zinc have been most associated with metal fume fever, it issuspected 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 fewhours 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 hexavalentforms of chromium (Cr+6) are responsible for these effects. Similarly, excessive inhalation of nickel fumes has beenassociated 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 thecentral nervous system – specifically, the pathology resembles Parkinson’s Disease. Molybdenum is not foreseen asa 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.


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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 dustconcentrations 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 fumesbelow the TLV. Consult a professional hygienist.

Respiratory Protection: If fumes, misting, or dust conditions occur, consult a professional hygienist. Provide NIOSHapproved 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 whenwelding or burning.

Other Clothing or Equipment: As required

Appendix A

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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 theaccuracy or completeness of the information and assumes no liability for any loss, damage or injury of any kind whichmay result from or arise out of the use of or reliance on the information by any person.

Documents

Maintenance Manual - A&A Machinery Moving · 2017. 1. 15. · Manual No. 33473 Rev. – Telesis Technologies, Inc. March 2000 28181 River Drive P.O. Box 1000 Circleville, Ohio 43113