Installation & Maintenance

TMP7000
PINSTAMP Marker

This document contains installation and maintenance

information for the Telesis TMP7000 marking head.

Document No. 29297Telesis Technologies, Inc.

28181 River Drive
P.O. Box 1000
Circleville, Ohio 43113

TMP7000 Installation & Maintenance

Foreword
Telesis Technologies, Inc. (hereinafter referred to as Telesis) reserves the right to change the information and
specifications contained in this document 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 document 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 document is confidential and is proprietary to Telesis or its licensors.

Trademarks
Telesis is a registered trademark of Telesis Technologies, Inc. in the United States and/or other countries.
LOCTITE is a registered trademark of Henkel Corporation.
Poly-Flo is a registered trademark of Asahi/America, Inc. in the United States and other countries.
Teflon is a registered trademark of DuPont (E. I. du Pont de Nemours and Company) or its affiliates.
Vibra-Tite is a registered trademarks of ND Industries, Inc.

2011 Telesis Technologies, Incorporated All Rights Reserved

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Safety Summary
The TMP7000 marking head uses high pressure pneumatic supplies. Accordingly, there is some danger when working with,
and near, marking machines. The following safety precautions should be observed at all times.








Never use the marker in any manner or for any purpose other than that for which it was designed.
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.
Do not remove or defeat the markers safety features or protective guards.
Do not disconnect the tubing while air pressure is applied to the lines.

Warnings, Cautions, and Notes may be placed throughout this document to alert you to important information. These
messages have the following significance.
Warnings contain information that is essential to the personal safety of the user.
Cautions contain information that is essential to avoid damage to the equipment.
Notes call attention to information of special importance at specific points within the text.

ii

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The following Warnings and Cautions are contained in this document.

WARNING
Prior to reconditioning the impact pins, you should read the appropriate Material Safety
Data Sheets (MSDS) to become familiar with handling and/or reconditioning hazards.
Always wear a respirator, safety glasses, and gloves when grinding metal. Use the
appropriate precautions, coolant, and abrasive for the pin material and the grinding
techniques described in the MSDS.

CAUTION
If your equipment arrives during cold weather, allow the components to warm up for
several hours before opening the containers. Exposing the equipment to room
temperatures may cause condensation in the units.
The impact pin and pin cartridge do not require lubrication. The plastic pin cartridge may
become obstructed if lubricated.
Do not connect or disconnect the marker cable while the controller power is ON. Turn
power off before connecting/disconnecting the cable.
Never exceed a drive air pressure of 100 psi (6.9 bar).

NOTICE
Sound pressure-level tests were conducted on the TMP7000 Marking System using a
Larson-Davis Model 710 sound pressure meter while dry firing the marker at a 50%
duty cycle. The maximum sound pressure level during the test cycle was measured at
94.4 dB. The time-weighted average (LEQ) using the 3 db rule without threshold was
83.2 dB. Typical applications average a 20% to 30% duty cycle where the timeweighted average would not exceed 78.8 dB(A).
The sound pressure-level tests were carried out under controlled conditions, imitating as
closely as possible, predicted normal operation. However, noise level is heavily
dependent on the part being impacted. Conditions such as the material being marked,
the rigidity of the work piece, machine settings, ambient noise, etc., may all vary when
in operational use. Such variables will alter the actual noise level.
Despite detailed guidance provided with each machine, variable operating conditions are
beyond the control of Telesis. The responsibility of establishing safe working levels of
use remains with the end user. Accordingly, you should conduct your own sound
pressure-level tests for your application while marking actual work pieces.

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Table of Contents
SUBJECT

PAGE

Foreword.....................................................................................................................................................

Trademarks .................................................................................................................................................

Safety Summary ..........................................................................................................................................

ii

SECTION 1
INSTALLATION
1.1

Overview.......................................................................................................................................

1-1

1.2

Specifications................................................................................................................................

1-1

1.2.1

TMP7000 Marking Head ........................................................................................................

1-1

1.2.2

Filter/Regulator Unit ............................................................................................................

1-2

1.2.3

Storage and Handling Requirements ......................................................................................

1-2

Unpacking the Equipment .............................................................................................................

1-3

1.3.1

Accounting For Equipment ....................................................................................................

1-3

1.3.2

Inspecting for Damage .........................................................................................................

1-3

Installation Requirements ............................................................................................................

1-4

1.3

1.4

1.5

iv

1.4.1

General ..............................................................................................................................

1-4

1.4.2

Environmental Considerations ...............................................................................................

1-4

1.4.3

Marking Head......................................................................................................................

1-4

1.4.4

Filter/Regulator Unit ............................................................................................................

1-5

1.4.5

Facility (Supply) Air .............................................................................................................

1-6

Installation Procedures.................................................................................................................

1-7

1.5.1

Marking Head Installation .....................................................................................................

1-8

1.5.1

Marking Head Installation .....................................................................................................

1-8

1.5.2

Filter/Regulator Unit Installation............................................................................................

1-10

1.5.3

Controller Installation ..........................................................................................................

1-10

1.5.4

Installation Adjustments.......................................................................................................

1-10

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Table of Contents
SUBJECT

PAGE

SECTION 2
MAINTENANCE
2.1

Overview ......................................................................................................................................

2-1

2.2

Maintenance Precautions..............................................................................................................

2-1

2.3

Adjustment Procedures ................................................................................................................

2-1

2.4

Cleaning Procedures .....................................................................................................................

2-1

2.4.1

Marking Pin / Pin Cartridge ...................................................................................................

2-1

2.4.2

Filter/Regulator Unit ............................................................................................................

2-2

2.5

Troubleshooting............................................................................................................................

2-3

2.6

Testing Procedures .......................................................................................................................

2-8

2.6.1

Stepper Motor Resistance.....................................................................................................

2-8

2.6.2

Solenoid Resistance.............................................................................................................

2-8

2.6.3

Marker Extension Cable Continuity ........................................................................................

2-9

Repair Procedures ........................................................................................................................

2-10

2.7.1

Impact Pin Reconditioning ....................................................................................................

2-10

Replacement Procedures ..............................................................................................................

2-12

2.8.1

Marking Pin / Pin Cartridge ...................................................................................................

2-12

2.8.2

Marking Head Enclosure .......................................................................................................

2-13

2.8.3

Drive Belt...........................................................................................................................

2-14

2.8.4

Motor Pulley .......................................................................................................................

2-15

2.8.5

Drive Motor ........................................................................................................................

2-16

2.8.6

Internal Air Tubing (4mm OD) ..............................................................................................

2-17

2.8.7

Opto Assembly, X-Axis.........................................................................................................

2-18

2.8.8

Opto, Assembly, Y-Axis ........................................................................................................

2-19

2.8.9

Solenoid Valve ....................................................................................................................

2-20

Reference Data .............................................................................................................................

2-21

2.9.1

Replacement Parts ..............................................................................................................

2-21

2.9.2

Ordering Parts ....................................................................................................................

2-21

2.9.3

Telesis Customer Support.....................................................................................................

2-22

2.7

2.8

2.9

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List of Illustrations
FIGURE

PAGE

1-1

General Arrangement TMP7000 Installation........................................................................................

1-7

1-2

TMP7000 Marking Head Dimensions and Mounting Details ......................................................................

1-9

2-1

Cleaning the Filter/Regulator Unit ........................................................................................................

2-2

2-2

Pin Cone Angle and Length .................................................................................................................

2-10

List of Tables
TABLE
2-1

PAGE
Troubleshooting the Marking Head.......................................................................................................

2-3

2-2

Stepper Motor Resistance Values .........................................................................................................

2-8

2-3

Solenoid Resistance Checks ................................................................................................................

2-8

2-4

Marker Cable Pin Assignments.............................................................................................................

2-9

2-5

Impact Pin Length (New and Reconditioned) .........................................................................................

2-10

2-6

TMP7000 Replacement Parts ...............................................................................................................

2-21

2-7

TMP7000 Pin Cartridge and Impact Pins ...............................................................................................

2-21

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Section 1
Installation
1.1 OVERVIEW
This section documents the installation of the TMP7000 marking head. The TMP7000 marking head contains a pneumatic pin
that is accelerated to indent a message onto the material being marked. Drive air extends the pin from the cartridge; return
air retracts the pin.
Telesis recommends the marking head be mounted with the pin pointed downward to help prevent debris from falling into
the marking head cavity. Other configurations or usage must first be evaluated before approval can be obtained. Please
consult Telesis Customer Service for more information

1.2 SPECIFICATIONS
The marking equipment design and specifications are subject to change without prior notice.

1.2.1 TMP7000 Marking Head

Dimensions (W x D x H) ........................ 12.00 x 8.75 x 5.75 in.
12.00 x 8.75 x 12.21 in.
12.00 x 8.75 x 12.96 in.

(305 x 222 x 146 mm) without cartridge

(305 x 222 x 310 mm) with pin retracted
(305 x 222 x 329 mm) with pin fully extended

Weight................................................. 22 lb. (10 Kg)

Noise................................................... 94.4 dB (max); 83.2 dB (LEQ)
Refer to the Safety Summary for details.
X-axis Travel ........................................ 6.0 in (150 mm) maximum
Y-axis Travel ........................................ 4.0 in. (100 mm) maximum
Number of Impact Pins .......................... 1
Pin Type .............................................. 150-series
Pin Material .......................................... Powdered Metal or Tool Steel with Carbide Tip
Pin Stroke ............................................ 0.75 in. (19mm) (maximum)
Air Consumption (max).......................... 0.04 SCFM (at idle)
0.60 SCFM (while marking)
Operating Temperature.......................... 32 to 122F (0 to 50C)
Humidity.............................................. 0% to 80%

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1.2.2 Filter/Regulator Unit
The filter/regulator unit includes two regulators with pressure gauges to control the drive air and return air. The first
regulator contains a filter to help remove contaminants from the supply air. The drive air fires the pin from the cartridge.
The return air pushes the pin back into the cartridge.
Operating Temperature.......................... 32 to 122F (0 to 50C)
Operating Pressure................................ 120 psi (8.3 bar) maximum

1.2.3 Storage and Handling Requirements

Do not drop the containers.
Shock .................................................. 75G/11ms half sine-wave
Vibration .............................................. 1.04G (2-200 Hz) random RMS
Store all containers in a dry, heated, non-condensing environment.
Temperature......................................... -4 to 113F (-20 to 45C)
Humidity .............................................. 5% to 95%
Store all containers away from splashing or sprayed moisture.

1-2

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1.3 UNPACKING THE EQUIPMENT
This section provides guidelines for receiving and unpacking the TMP7000 marking equipment.

CAUTION
If your equipment arrives during cold weather, allow the components to warm
up for several hours before opening the containers. Exposing the equipment to
room temperatures may cause condensation in the units.
When your marking equipment arrives, check the shipping cartons for damaged corners, holes through the cardboard, or
any other signs of damage. Ask the delivery service to note any damage to the containers on the delivery receipt. Save all
packing materials in case you need to return any components.

1.3.1 Accounting For Equipment

Check the materials against the packing list. Note any discrepancies to your delivery service and request that they note the
discrepancies on the delivery receipt. The marking equipment consists of:

Marking Head
Marker Cable
Filter/Regulator Unit
Air Lines

Additional components may be included with the marking equipment. Specific information for optional equipment may be
provided in a separate installation manual. Specific information for custom equipment may be provided in a custom
addendum.

1.3.2 Inspecting for Damage

Place the components on a table and inspect each one for damage. Report any damage to your delivery service
immediately.
1.

Inspect the marking head.




2.

Ensure the marking pin is not bent or broken.

Ensure the pin cartridge is not cracked or broken.
Ensure the pin cartridge is not loose. If loose, tighten the mounting hardware securely.

Ensure the connectors are securely attached.

Ensure the connectors are not damaged and the connector pins are not bent or broken.
Ensure the electrical cables are not cut, frayed, or damaged.

Inspect the filter/regulator unit.




5.

Ensure the air line connectors are not damaged

Inspect the cable assemblies.




4.

Ensure the marker cable connector is not damaged and the connector pins are not bent or broken

Inspect the marking pin and pin cartridge.




3.

Gently shake the marking head; ensure there are no loose components

Ensure the fitting threads are not damaged.

Ensure the pressure gauges are not cracked.
Ensure the bowls are not cracked.

Inspect the air lines.

Ensure the air lines are not kinked, cracked, or damaged.

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1.4 INSTALLATION REQUIREMENTS
This marking head is to be mounted on a tooling fixture. If the marker is to be incorporated into a machine or mounted on a
tool stand, safeguards must be designed and implemented at the time of the installation with the other machinery.
If the marker includes custom equipment, refer to the custom Addendum for specific information.
The following items are required for proper installation of the marking head. It is the responsibility of the installing agency
to ensure these requirements are implemented.

1.4.1 General

A safety guard may be required to keep operators away from the moving marking head and marking pin.

A part-present switch may be installed to allow a START PRINT only when a part is in marking position.

Operators may need eye protection while operating the marker.

1.4.2 Environmental Considerations

The marker should not be exposed to sprays, solvents, chemicals, or other contaminants.

Do not operate the marker in an area where flammable mists or fumes are present.

1.4.3 Marking Head

The marking head should be visible from the controller. The standard marker cable is 13 ft. (4m) long.

Provisions should be made to allow vertical adjustments to the marking head, allowing the marker to be positioned
closer to and further away from the part being marked.

Provisions should be made to allow horizontal and lateral adjustments to the marking head, allowing the marker to be
positioned along both the X-axis and the Y-axis.

The part to be marked must be solidly fixed into position.

The marker must be solidly secured and must not move in relation to the part while marking.

1-4

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1.4.4 Filter/Regulator Unit
The filter/regulator unit inlet receives air pressure from the plant air source. The drive air outlet supplies air pressure to the
marker to drive the marking pin out of the pin cartridge for marking. Return air pressure retracts, and holds, the pin in the
cartridge. The drive and return air pressures are controlled by separate regulators on the filter/regulator unit.

The filter unit should be installed within 13 ft. (4 m) of the marking head; 50 ft. (15 m) maximum.

A pneumatic lockout valve (supplied by the customer) should be installed upstream of the filter unit.

A pressure relief valve (supplied by the customer) should be installed upstream of the filter unit.

The pressure relief valve must be set to a maximum pressure of 120 psi (8.3 bar).

Do not connect the filter unit to air systems where compressors are lubricated with fire resistant fluids such as
phosphate ester and di-ester types.

If the supply air is extremely dirty, additional customer-supplied filters may be needed upstream of the filter unit.

The filter unit must be located to allow servicing and draining without damaging other equipment.

Do not install the filter unit in an area subject to direct sunlight, impact blows, or extreme temperatures.

Do not install the filter unit where it will be exposed to aldehydes, keytones, alcohol, or hot water.

Install the regulator so the air flows in the direction of the arrow on the body of the filter unit.

The filter unit bowls must be mounted vertically with the bowl drains at the bottom to permit draining.

Each port of the filter unit must be plumbed (e.g., pressure gauge, line fitting, socket pipe plug).

The customer-furnished supply line to the filter unit should be 13 mm (1/2-in.) inside diameter.

The filter unit requires a 6 mm (1/4-in.) NPT supply air inlet fitting (supplied by customer).

Apply a minimal amount of pipe joint compound to the male threads (only) to seal the pipe joints.

Do not use Teflon tape to seal the pipe joints. Do not apply pipe joint compound to female threads.

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TMP7000 Installation & Maintenance

1.4.5 Facility (Supply) Air
The marking head requires a clean, dry air supply to drive the marking pin. In most cases, plant air is acceptable. The following
guidelines should help you decide if your air supply is suitable for use with the marker.
Condensation. The process of compressing air creates heat. The compressed air cools as it travels through the lines away
from the compressor. The cooling process causes any moisture in the air to condense. Condensation is common in hot
climates or when air lines are routed outside during cold weather. Condensation creates problems in the air valves and
small openings within the marking head. Because you can never remove all the contaminates from an air line, a filtering
system should be installed as close to the marker as possible. This reduces the opportunity for moisture in the supply air to
condense.
Filtering. The least expensive way to filter the air is to use a coalescing filter. This type of filter causes a cyclone effect.
Swirling air and the resulting centrifugal force throws the oil and moisture particles to the outside. There it condenses on a
wall and runs down to the bottom of the bowl in the less turbulent, quiet area. The coalescing filter removes solid particles
(down to 0.3 microns). If the collection of contaminants becomes too great, particles can be picked up and placed in
suspension in the air. Therefore, Telesis recommends an automatic drain on the coalescing filter. In addition to aerosol
particles, the air may contain dust, dirt, and metal shavings. If the air is very dirty, a pre-filter can be used to remove the
larger (5 micron) particulate matter.
Air Flow. The cyclone effect (see above) cannot occur if there is little or no flow of air. Telesis markers use much less air at
idle than when marking. So its during the idle time that the aerosol particles have a chance to cool and condense on the
walls of the cartridge and pin. Most filter manufactures recommend a minimum air flow of 20% of the maximum rated flow
for their equipment to be effective. This is not a problem during marking because the rate of air consumption is relatively
high. A controlled orifice opening (open to the air) can be constructed to keep the flow during idle at or above 20% of the
flow rate. The controlled orifice should be located as close as possible to the marking head.
Plumbing Factors. Another practice for obtaining clean,
dry air is to ensure the equipment is not at the end of the
air line. Plumb the air supply to go up (vertically) off the
main air supply line, then down to the top of a tee. The
stem of the tee should be horizontal and go to the marker.
The bottom of the tee should be a short stub with a drain
valve or drip leg.

Parameters. The following parameters are easily achievable with a pre-filter and most coalescing filters.

Humidity non-condensing
99.97% of the sub-micron particles removed
0.75 micron largest aerosol particle
0.30 micron largest solid particle
40 to 120F (4.4 to 48.9C)
5 micron pre-filter with an auto drain.

Practices. Follow these practices when installing and operating the marker to improve the quality of the air and increase
the reliability of your marking equipment.

Install the filter as close as possible to the marking head, never more than 50 ft. (15 m)

Blow down the air system after installation and before use (at least two minutes at full flow).

1-6

Use Poly-Flo tubing downstream of filter with brass or plated fittings

Use copper, brass or stainless tubing upstream of the filter
Do not use iron pipe or iron fittings.
Do not use Teflon tape
Liquid Teflon is permissible except:
on poly-carbonate plastic threaded holes
on the first thread of male fittings
Use a top tap off the main line with a drip leg. See Plumbing Factors, above.
Do not use poly-carbonate bowls (they will crack when used with synthetic oils).
Always use the largest available feed line and the shortest available run.

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TMP7000 Installation & Maintenance

1.5 INSTALLATION PROCEDURES
Perform the following procedures (in the order listed) to install the marking equipment.
Refer to Figure 1-1 for general arrangement.

NOTICE
It is the responsibility of the installing agency to ensure the installation
requirements are correctly implemented.

Figure 1-1. General Arrangement TMP7000 Installation

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TMP7000 Installation & Maintenance

1.5.1 Marking Head Installation
The marking head is supplied with a sheet metal cover for use in fixture-mounted applications. Mount the marking head to a
suitable, rigid structure as follows. Refer to Figure 1-2 for marking head dimensions and installation details
1.

To allow the marker cable to reach the controller, ensure the marking head location is within 13 ft. (4 m) of the
proposed controller location.

2.

Locate the markers mounting holes on the top of the marking head.

CAUTION
Mounting screws must not extend into the marking head more than 3/8 in. (10 mm).

3.

Use four (minimum) to eight M8 x 1.25 socket head cap screws of sufficient length to attach the marking head to the
mounting surface. Ensure the screws do not bottom out. Tighten screws securely.

4.

Connect the marker cable to the connector on the marking head.

Do not connect the opposite end of the cable at this time.

5.

Connect the drive air (black) tubing to the drive air fitting on the marking head (marked D).

6.

Connect the return air (natural) tubing to the return air fitting on the marking head (marked R).

7.

Proceed to Filter/Regulator Unit Installation.

1-8

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TMP7000 Installation & Maintenance

1.5.2 Filter/Regulator Unit Installation
1.

To allow the air lines to reach the marking head, ensure the filter/regulator mounting location is within 13 ft. (4 m) of
the marker location.

2.

Refer to the Original Equipment Manufacturer (OEM) drawing for filter/regulator unit mounting details.

3.

Rotate the drive air pressure adjustment knob fully counter-clockwise.

4.

Rotate the return air pressure adjustment knob fully counter-clockwise.

5.

Mount the filter/regulator unit vertically to a solid, stable surface.

6.

Secure the filter/regulator unit using four M4 (#8) fasteners.

7.

Connect the drive air (black) from the marking head to the filter/ regulator unit.
Note: The Drive Air fitting on the filter/regulator unit is the tee fitting between the two regulators.

8.

Connect the return air (natural) tubing from the marking head to the filter/ regulator unit.
Note: The Return Air fitting on the filter/regulator unit is the elbow fitting at the right side of the unit..

9.

Install a supply inlet fitting in the left-side of the filter/regulator unit.

10. Ensure the supply air is shut off upstream of the filter/regulator unit.
11. Connect the supply air line to the filter/regulator unit inlet fitting.
DO NOT apply inlet (supply) air pressure to the filter/regulator unit at this time.
12. Proceed to Controller Installation.

1.5.3 Controller Installation

Refer to the Controller Installation/Maintenance Manual that was supplied with your marking system for the following
procedures.
1.

Install the marking system controller.

2.

Perform the electrical and data connections.

3.

Perform the controller checkout.

4.

Proceed with Installation Adjustments.

1.5.4 Installation Adjustments

After all marking equipment is installed, you will need to adjust the system to prepare it for use.
1.

Turn the controller ON.

2.

Start the marking system software.

Refer to the marking system Operation Manual (supplied with your system) for details.

3.

Adjust the following as required.

Refer to the TMP7000 Operation Supplement for details.






1-10

Adjust the drive air pressure

Adjust the return air pressure
Adjust the pin stroke
Adjust the marking depth

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Section 2
Maintenance

2.1 OVERVIEW
This section provides troubleshooting, testing, repair, and replacement procedures for the marking head. Any additional
troubleshooting, fault isolation, servicing, maintenance, or repair of TMP7000 marking head that is not explicitly contained
in this document must be performed by repair agencies authorized by Telesis Technologies, Inc.

2.2 MAINTENANCE PRECAUTIONS

1.

Turn all power OFF when performing maintenance on the marker.

2.

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.

3.

Ensure that appropriate pneumatic lock-out valves are installed.

2.3 ADJUSTMENT PROCEDURES

Periodically, you may need to make certain adjustments to keep your system operating at peak performance.
For procedures to adjust the system air pressure, the pin stroke, and the marking depth of the pin, refer to the
TMP7000 Operation Supplement .

2.4 CLEANING PROCEDURES

The following information is provided to clean the various marking head components.

2.4.1 Marking Pin / Pin Cartridge

Perform the following steps to clean the pin cartridge and marking pin.
1.

Remove the marking pin / pin cartridge from the marking head. See Replacement Procedures.

2.

Clean the pin and cartridge using isopropyl alcohol or dish washing detergent and water.
You may clean them with petroleum solvent, thinner, isopropyl alcohol, or dish washing detergent and water. Ensure
adequate ventilation. Ensure the components are wiped off completely and allowed to dry before being reassembled.

3.

Do not use any petroleum-based solvent, paint thinners, or acetone.

Do not use any oil for lubrication.

Install the marking pin / pin cartridge onto the marking head. See Replacement Procedures.

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TMP7000 Installation & Maintenance

2.4.2 Filter/Regulator Unit
Perform the following procedure when cleaning becomes necessary.
1.

Record the drive air and return air pressures as indicates on the filter/regulator gauges.

2.

Turn off the facility supply (input) air to the filter/regulator unit.

3.

Relieve the drive air pressure. Rotate the drive air pressure control knob fully counterclockwise.

4.

Relieve the return air pressure. Rotate the return air pressure control knob fully counterclockwise.

5.

Unscrew the bowl from body of the unit. See Figure 2-1.

Figure 2-1. Cleaning the Filter/Regulator Unit

6.

Remove the diaphragm/needle assembly from the inside (bottom) of the bowl. Be very careful not to damage the
fine tip on the needle valve.

7.

Clean the bowl with mild soap and water only. Carefully clean the diaphragm/needle assembly.

8.

Dry the cleaned bowl thoroughly.

9.

Place the diaphragm/needle assembly into the bowl.

a.

Center the needle in the small opening at the bottom of the bowl. The diaphragm/needle assembly should sit
squarely in the base of the bowl.

b.

Ensure the diaphragm is seated in the bowl. Be very careful not to damage the fine tip on the needle valve.

10. Screw the bowl onto the body of the unit. Tighten the bowl securely (by hand) but do not over tighten.
11. Turn on the facility supply (input) air.
12. Adjust the drive air and return air pressures (as recorded, above).

2-2

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TMP7000 Installation & Maintenance

2.5 TROUBLESHOOTING
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 appropriate maintenance
instructions to repair or replace the component. If these procedures fail to correct the problem, contact Telesis Customer
Support.

NOTICE
Refer to the marking system Controller Operation Manual
for details on using the system software.

Table 2-1. Troubleshooting the Marking Head

PROBLEM

CORRECTIVE ACTION

Marker will not move

CAUTION
Do not connect or disconnect the marker cable
while the controller power is ON. Turn power off
before connecting/disconnecting the cable.
1. Ensure the marking head cable is securely connected to the marker and
the controller. Check cable. If defective, replace as required.
2. Ensure the controller is energized. Refer to the Controller
Installation/Maintenance Manual.
3. Check the pin cartridge; ensure pin is not stuck in extended position.
4. Using the marking system software, place the marker Online.
5. Ensure the marker isn't stalled. Using the marking system software, Reset
the marker.
6. Using the marking system software, Jog the marker to move the marking
head.

Marking pin does not fire

1. Check the supply air, drive air regulator, and return air regulator.
2. Ensure the air lines are not crimped or broken. Replace as required.
3. Verify the filter is not clogged.
4. Using the marking system software, Pulse the marking pin.
5. If the solenoid valve makes a clicking noise when pulsed, replace the
solenoid valve.

Marking pin fires but does not mark

1. Ensure the pin stroke does not exceed its maximum limit. Reduce the
distance between the retracted pin and the marking surface as required.
2. Ensure the pin is not binding in the pin cartridge. Clean or replace as
necessary.
3. Ensure the drive air is at least 40 psi (2.8 bars); ensure the return is at
least 10 psi (0.7 bar). Adjust as required.
4. Ensure the filter is not clogged. Clean as necessary.
5. Using the marking system software, display the Marker Properties and
ensure the Marking Speed and Pin Type parameters are set properly.
6. Check marker cable continuity. If defective, replace as required.
7. Check solenoid resistance. If defective, replace as required.
(continued on next page)

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Table 2-1. Troubleshooting the Marking Head (continued)
PROBLEM
Poor marking performance

CORRECTIVE ACTION
1. If the marker was performing properly in previous marks, check the
fixturing of the part. Poor marks may be caused by the marker having
been moved or by part-fixturing problems.
2. Ensure the drive air is at least 40 psi (2.8 bars); ensure the return is at
least 10 psi (0.7 bar). Adjust as required.
3. Ensure the pin cartridge bore is not worn. Replace if necessary
4. Ensure the pin is not binding in the pin cartridge. Clean or replace as
necessary, and lubricate.
5. Ensure the pin cartridge movement is not restricted in either axis.
6. Using the marking system software, display the Marker Properties and
reduce the Marking Speed parameter setting, as required.

Mark too light

1. Ensure the hardness of the part being marked has not changed. Harder
material may require adjustments to the pin stroke, the drive air pressure,
or both.
2. Ensure the drive air is at least 40 psi (2.8 bars); ensure the return is at
least 10 psi (0.7 bar). Adjust as required.
3. Ensure the differential pressure between drive air and return air is
sufficient. Try to maintain the largest possible differential pressure.
4. Ensure the air lines are not crimped or broken. Replace as required.
5. Ensure the pin is not binding in the pin cartridge. Clean or replace as
necessary.
6. Ensure the filter is not clogged. Clean as necessary.
7. Ensure the marking pin is not dull or broken. Replace as required.
8. Check for a broken pin cartridge, or scarred mating surface. Replace as
required.
9. Using the marking system software, display the Marker Properties. Ensure
the Pin Type parameter is set for the type of pin installed in the marker.

Marker starts marking in an unexpected

location

Using the marking system software, view the pattern object definition(s).
Adjust the X/Y Anchor parameters and/or Justification parameter
settings, as required.

Marker will not respond to external I/O

(Host, Discrete I/O, or TTL Input)

CAUTION
Do not connect or disconnect the marker cable
while the controller power is ON. Turn power off
before connecting/disconnecting the cable.
1. Ensure the marking head cable is securely connected to the marking head
and to the controller.
2. Ensure the controller is energized. Refer to the Controller
Installation/Maintenance Manual.
3. Using the marking system software, place the marker Online.
4. Check for a Serial Communications fault, Discrete I/O fault, or TTL Input
fault, as applicable. Refer to the Controller Installation/Maintenance Manual.
(continued on next page)

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

CORRECTIVE ACTION

Marker sounds as if motors are running, but no

motion in one or both axes

CAUTION
Do not connect or disconnect the marker cable
while the controller power is ON. Turn power off
before connecting/disconnecting the cable.
1. Remove air pressure from marking system and disconnect marker cable
from marker. Remove marking head cover. Inspect both belts; replace if
damaged.
2. Try to physically move the axis that will not move electrically. Check the
tension on the belt. Check security of motor installation; tighten mounting
screws as required. Check for pulley slippage on motor shaft; replace
pulley as required.
3. Check drive pulley is tight on motor; check driven pulley is tight on drive
screw.
4. Check the motor resistance. If out of tolerance, replace the drive motor.

Marker does not initialize when placed online;

Marker does not move.

CAUTION
Do not connect or disconnect the marker cable
while the controller power is ON. Turn power off
before connecting/disconnecting the cable.
1. Ensure the marking head cable is securely connected to the marking head
and to the controller. Check cable. If defective, replace as required.
2. Ensure the controller is energized. Refer to the Controller
Installation/Maintenance Manual.
3. Check the motor resistance; replace if defective.
4. Check the continuity of the marker cable; replace if defective.
5. Ensure the optos are functioning properly and the flags are not damaged
or missing. Note: There are LEDs mounted on the limit/connector board
that should illuminate when flags are positioned at the Home position.

Marker does not initialize properly. Appears to

be seeking home, but continues running after
mechanical limits are reached.

1. Ensure the carriage and/or the pin cartridge is not obstructed, preventing
the drive mechanism from reaching the home position.
2. If both motors are stalled at the Home position, a common factor such as
power or a connector associated with the home limits could be at fault.
Remove power and physically position the marker to the Home position.
Apply power and verify the LEDs on the limit/connector board illuminate.
(The LEDs are visible through the cartridge side opening in the enclosure.)
3. If only one axis is stalled, the Home position sensor for the stalled axis
may be defective. Inspect the flag and opto associated with the stalled
axis. The flag must pass between the opposed legs of the opto.
4. The Home position flag may be out of position for the stalled axis. When
positioning the flags, ensure there is safe passage of the flag between the
opto legs. Ensure the flags are properly oriented when installed.
5. Defective cable. Contact an authorized maintenance agency for repair.

Marking is not properly oriented

Using the marking system software, view the pattern object definition(s). Adjust
the X/Y Anchor parameters and/or Justification parameter settings, as required.
A slip or stall may have occurred while marking due to an internal or external
interference or obstruction.
1. Using the marking system software, place the marker Online.
2. Ensure the marker isn't stalled. Using the marking system software, Reset
the marker.
3. If still not resolved, contact an authorized maintenance agency for repair.
(continued on next page)

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Table 2-1. Troubleshooting the Marking Head (continued)
PROBLEM
Message is cut off or truncated

CORRECTIVE ACTION
The message length may be too long to print within the marking window.
Using the marking system software, edit the pattern object as required:
1. Adjust the X/Y Anchor parameters to relocate the object within the window.
2. Change the Justification parameter setting to reposition the object within
the window.
3. Decrease the Width or Pitch parameter (or both) as required.
4. The pin may be hanging up in the cartridge. Clean the pin and cartridge
as required.
5. The solenoid may not be operating. Using the marking system software,
Pulse the marking pin. If the solenoid valve makes a clicking noise when
pulsed, replace the solenoid valve.

Depth is insufficient

1. Ensure the drive air pressure and return air pressure are correct for this
application.
2. Ensure the marking pin is not dull or broken. Replace as required.
3. Ensure the pin cartridge bore is not worn. Replace if necessary.
4. Using the marking system software, display the Marker Properties. Ensure
the Pin Type parameter is set for the type of pin installed in the marker.

The indentation is too deep for the character

size.

The drive air pressure may be set too high. Reduce the drive air
pressure as required. The return air may need to be readjusted to assist
in optimizing performance.

The accuracy of character formation is poor

The marker speed is too fast, requiring additional settling time. Using the
marking system software, display the Marker Properties and reduce the
Marking Speed parameter setting, as required.

The marked characters are grouped in

intervals. Gaps exist between character
intervals or characters are overlapped

The carriage mechanism may be locked up. Inspect the rails and
saddles to determine if they are free. They are worn and causing
binding, replace the marking head.

The indentation depth is inconsistent.

1. The drive air tubing to the marking head may be undersized causing
restricted air flow. The drive air supplying the regulators should be no less
than 13mm (1/2") and the tubing supplying the marker should be 6mm
minimum and not exceed 11m (37 ft.).
2. The drive air tube may be restricted causing decreased flow to the valves,
or plugged exhaust port. 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.
3. The return air may be set incorrectly. The correct return air pressure is
essential to the quick return of the pin. The specific application may
requires some trial settings. Return air is normally set from 10 to 20 psi
(0.7 to 1.4 bars).
4. The drive air pressure or return air pressure regulator may be defective.
Verify that the outlet air pressure is regulating properly. Replace if
pressure variations of more than 5 psi (0.3 bars) are common.
5. The solenoid valve may be dirty or defective. Check solenoid resistance
and operation; replace solenoid as required.
(continued on next page)

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Table 2-1. Troubleshooting the Marking Head (continued)
PROBLEM
Indentation depth is inconsistent in a particular
area of the marking window.

CORRECTIVE ACTION
1. The coiled drive air tubing may be kinked or restricted when traversing.
Inspect the tubing from the valve to the manifold for cracks, restrictions or
crimps in the tubing.
2. Ensure the return air tubing is connected correctly, and is not blocked,
kinked, or broken.
3. Loose or incorrectly mounted head cartridge. Check for a loose cartridge,
leaking air, or a cartridge mounted incorrectly.
4. Worn cartridge, or excessive dirt/oil in the drive air making the pin stick.
Inspect the pin cartridge for excessive "blow by" air. Remove the
cartridge, clean with isopropyl alcohol and try again.

The indentations within the characters are not

placed accurately (e.g., skewed, lines not
straight, not parallel, not perpendicular).

The marked characters are wholly or partially

garbled or skewed.

1. A slip may have occurred while marking due to an interference. 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.

The marker or material to be marked may be moving relative to each

other during the marking cycle. In order to assure a high quality mark, it
is important that there is no relative movement between the marker and
material being marked.

2. Excessive vibration of the marker in the plane of the marking surface,

normal to the indentation forces, may have caused a slip 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.
3. 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
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.
4. The belt or pulley may be loose. Check the belt tension. Ensure the drive
pulley is not loose. Torque to 100 in-lb.
Marking time is too long

The marker is supplied with the factory parameters set to provide the
highest degree of quality and best practical speed for all font selections
and resolutions. The parameter values may be changed, giving you the
ability to customize the setting for your particular application.

In most cases, marking times will be reduced if you increase the marking
speed. Using the marking system software, display the Marker
Properties and adjust the marking speed parameter, as required, to
increase the speed settings.

Change the settings as required to better meet your needs, but ensure
the quality of the resulting mark is acceptable.

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2.6 TESTING PROCEDURES
This section provides reference tables to check the circuitry of the TMP7000 marking head.

2.6.1 Stepper Motor Resistance

The following information is provided to check the resistance values of the stepper motor circuit.
1.

Remove electrical power from the marking system.

2.

Remove air pressure from the marking system.

3.

Disconnect the marker cable from the marking head.

4.

Measure the resistance values for the stepper motor at the 26-pin connector on the marking head.
Refer to Table 2-2 for acceptable values.

Table 2-2. Stepper Motor Resistance Values

Marker Connector (on Marking Head)

PIN-TO-PIN

DESCRIPTION

RESISTANCE VALUE

B to C

A MOTOR PHASE B

5.5 ohms 10%

D to E

A MOTOR PHASE A

5.5 ohms 10%

G to H

B MOTOR PHASE B

5.5 ohms 10%

J to K

B MOTOR PHASE A

5.5 ohms 10%

2.6.2 Solenoid Resistance

The following information is provided to check the resistance values of the solenoid circuit.
1.

Remove electrical power from the marking system.

2.

Remove air pressure from the marking system.

3.

Disconnect the marker cable from the marking head.

4.

Measure the resistance values for the solenoids at the 26-pin connector on the marking head.
Refer to Table 2-3 for acceptable values.

Table 2-3. Solenoid Resistance Checks

Marker Connector (on Marking Head)

2-8

PIN-TO-PIN

DESCRIPTION

RESISTANCE VALUE

W to X

SOLENOID #1

12 ohms 5%

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2.6.3 Marker Extension Cable Continuity
The following information is provided to check the continuity of the marking head cable.
The cable connects between the marking head and the controller.
1.

Remove electrical power from the marking system.

2.

Remove air pressure from the marking system.

3.

Disconnect the marker cable from the marking head.

4.

Disconnect the marker cable from the controller.

5.

Check the pin-to-pin continuity of the marker cable.

Refer to Table 2-4 for pin numbers and signal information.

Table 2-4. Marker Cable Pin Assignments

Marker Cable Connector J1

(Marking Head End)
FROM
J1

TO
J2

Marker Cable Connector J1

(Controller End)
FUNCTION

X MOTOR PHASE 1

X MOTOR PHASE 2

X MOTOR PHASE 3

X MOTOR PHASE 4

Y MOTOR PHASE 1

Y MOTOR PHASE 2

Y MOTOR PHASE 3

Y MOTOR PHASE 4

12

SOLENOID #1

SOLENOID COMMON

29

START PRINT +

21

+ 5 VDC

20

+5 VDC RETURN

22

X HOME

25

Y HOME

37

V through a

CHASSIS GROUND
(not used with standard TMP7000 markers)

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2.7 REPAIR PROCEDURES
Authorized repair of the TMP7000 marking head is limited to impact pin reconditioning. Any other repair of the marking
head must be performed by repair agencies authorized by Telesis Technologies, Inc.

2.7.1 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 2-5 lists the lengths for new and reconditioned pins. The pin cone angle and length are illustrated in
Figure 2-2.

Table 2-5. Impact Pin Length (New and Reconditioned)

PIN TYPE

NEW LENGTH

MINIMUM LENGTH

150

5.25 in. (133.35 mm)

5.18 in. (131.57 mm)

Figure 2-2. Pin Cone Angle and Length

Note: For best results, carbide pins should not be sharpened to a fine point. Doing so will cause the point to chip. Sharpen
carbide pins so that a very small radius tip (or flattened tip) remains.

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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.

WARNING
Prior to reconditioning the impact pins, you should read the appropriate
Material Safety Data Sheets (MSDS) to become familiar with handling and/or
reconditioning hazards.
Always wear a respirator, safety glasses, and gloves when grinding metal. Use
the appropriate precautions, coolant, and abrasive for the pin material and the
grinding techniques described in the MSDS.
If you need assistance in obtaining the current MSDS sheets for the impact
pins, contact Telesis Customer Support.

The following will assure properly reconditioned pins:

1.

Remove the impact pin / pin cartridge from the marking head. (see replacement 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.

9.

Install the impact pin / pin cartridge onto the marking head. (see replacement procedure)

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2.8 REPLACEMENT PROCEDURES
Authorized replacement of the TMP7000 marking head components are listed in the following paragraphs. Component
replacement procedures not explicitly contained in this document must be performed by repair agencies authorized by
Telesis Technologies, Inc.

NOTE
Refer to the Reference Data section of this manual for
part numbers and descriptions of replacement parts.

2.8.1 Marking Pin / Pin Cartridge

Removal
1.

Remove electrical power from the marking system.

2.

Remove air pressure from the marking system.

3.

Remove two M3 socket head cap screws securing the cartridge to the cartridge base.

4.

Remove the pin cartridge from the marker.

5.

Tip the cartridge to remove the impact pin.

Installation
1.

Insert the impact pin (pointed end first) into the top of the pin cartridge.

2.

Orient alignment holes in top of cartridge with dowel pins protruding from the cartridge base.

3.

Install two M3 socket head cap screws to secure the cartridge to the cartridge base.

4.

Tighten screws securely but do not over tighten.

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2.8.2 Marking Head Enclosure
Removal
1.

Remove electrical power from the marking system.

2.

Remove air pressure from the marking system.

3.

If the enclosure is being removed to perform additional maintenance:

a.

Disconnect the marker cable from the connector on top of the marking head.

b.

Disconnect the drive and return air lines from fittings on top of the marking head.

c.

Remove the marking head from its mounting fixture, as applicable.

d.

Place the head top side down (pin pointing upward) on a flat, stable, and clean work surface.

4.

Remove screws around the perimeter of the enclosure.

5.

Lift the enclosure from marking head base plate.

Installation
1.

Position the enclosure over the marking head base plate. Orient the label on the enclosure toward the side opposite
the air fittings and marker cable connector. Align all mounting holes.

2.

Install screws around the perimeter of the enclosure. Tighten securely.

3.

Perform the following, as applicable:

a.

Attach the marking head to its mounting fixture, as applicable.

b.

Connect the drive air (black) line to drive air fitting (D) on top of the marking head.

c.

Connect the return air (neutral) line to return air fitting (R) on top of the marking head.

d.

Connect the marker cable to the connector on top of the marking head.

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2.8.3 Drive Belt
The X-axis drive belt is the one attached to the main spine.
The Y-axis drive belt is the one attached to the moveable carriage.
Removal
1.

Remove the marking head enclosure. See Replacement Procedures.

2.

Loosen (but do not remove) four socket head cap screws that attach the drive motor.

3.

Carefully, slip the belt over the drive screw pulley (at the end opposite the motor).
Note: It may be necessary to tilt the motor slightly to allow the belt to fit over the pulley flange.

4.

Remove the belt from the drive motor pulley.

Installation
1.

Obtain a replacement belt.

2.

Check the security of both pulleys on their respective shafts.

3.

Place the belt over the drive motor pulley.

4.

Carefully slip the belt over the drive screw pulley.

Note: It may be necessary to tilt the motor slightly to allow the belt to fit over the pulley flange.

5.

Slightly tighten the four socket head cap screws that attach the drive motor.

6.

Tension the drive belt by pulling in line with the centerline through both pulleys.
Do not pry against the rail assemblies.
Note: Correct belt tension is 10 to 13 lb. (5 to 6 kg) measured in line with the centerline.

7.

2-14

While maintaining belt tension, tighten the drive motor mounting screws securely.

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2.8.4 Motor Pulley
The X-axis motor pulley is the one attached to the main spine.
The Y-axis motor pulley is the one attached to the moveable carriage.
Removal
1.

Remove the marking head enclosure. See Replacement Procedures.

2.

Remove the drive belt. See Replacement Procedures.

3.

Using a 2mm hex key, loosen the two set screws that secure the pulley to the drive motor shaft.

4.

Remove the pulley from the drive motor shaft.

Installation
1.

Obtain a replacement motor pulley.

2.

Using a 2mm hex key, remove the set screws from the drive pulley.

3.

Slide the pulley, collar first, onto the motor shaft as far as possible.
Note: Allow just enough access to the set screws for a 2mm hex key to rest flat against the motor mount.

4.

Rotate the pulley until one of the set screws aligns with the flat surface on the motor shaft.

5.

Apply LOCTITE 222 to each set screw.

6.

Using a 2mm hex key, tighten the set screws to secure the pulley to the motor shaft.

7.

Install the drive belt. See Replacement Procedures.

8.

Install the marking head enclosure. See Replacement Procedures.

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2.8.5 Drive Motor
The X-axis drive motor is the one attached to the main spine.
The Y-axis drive motor is the one attached to the moveable carriage.
Removal
1.

Remove the marking head enclosure. See Replacement Procedures.

2.

Remove the drive belt. See Replacement Procedures.

3.

Remove the motor pulley. See Replacement Procedures.

4.

Remove the pan head screw and P-clip securing the wires to the base plate.

5.

Disconnect the motor assembly wires:

X-axis motor.

Disconnect motor wires from limit/connector board connector J2.

Y-axis motor.

Disconnect motor wires from limit/connector board connector J3.

Remove the protective wrap from the wire bundle.

6.

Carefully pull the motor wires/connector through the hole in the main spine.

7.

Remove four socket head cap screws, four lock washers, and four flat washers that attach the drive motor.

8.

Remove the drive motor and two motor retaining plates.

Installation
1.

Obtain a replacement drive motor.

2.

Orient the motor for attachment:

X-axis motor.

Orient the drive motor assembly such that the motor wires are facing inward (toward the main
spine). Route the motor wires/connector through the hole in the spine.

Y-axis motor.

Orient the drive motor assembly such that the motor wires are facing outward (toward the
marker cable connector in the base plate). Route the motor wires/connector through the hole in
the main spine (at end opposite X-axis drive motor).

3.

Place one motor retaining plate on each side of the motor with the notched sides toward the motor.

4.

Insert four socket head cap screws (with one lock washer and one flat washer each) through the pulley-side of the
motor mount and thread into the motor retaining plates. Do not tighten the cap screws at this time.

5.

Connect the motor assembly wires:

6.

X-axis motor.

Connect motor wires to limit/connector board connector J2.

Y-axis motor.

Connect motor wires to limit/connector board connector J3.

Secure the wires to the base plate with one P-clip and one pan head screw:
X-axis motor.

Secure the X-axis motor wires and X-axis opto wires in the P-clip.

Y-axis motor.

Install the protective wrap over the Y-axis motor wires, Y-axis opto wires, and solenoid wires.
Position the protective wrap such that it covers the wires where they pass through the main
spine. Secure the end of the protective wrap in the P-clip.

7.

Install motor pulley. See Replacement Procedures.

8.

Install the drive belt. See Replacement Procedures.

9.

Install the marking head enclosure. See Replacement Procedures.

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2.8.6 Internal Air Tubing (4mm OD)
The internal air tubing connects the following components:

between the base plate and the X-axis carriage

between the X-axis carriage and the cartridge base

The drive air and return air tubing is identical. When replacing tubing, carefully note the connection points or replace only
one piece of tubing at a time to avoid cross-connecting drive air and return air fittings.

Tubing Between Base Plate and X-axis Carriage

Removal
1.

Remove the marking head enclosure. See Replacement Procedures.

2.

At the fitting on the base plate, push inward on the fitting collar while pulling outward on the tubing.

3.

At the opposite end of the tubing, carefully pull the tubing from the barbed fitting on the X-axis carriage.

Installation
1.

Obtain a replacement length of 4mm OD air tubing that contains eight (8) full coils.

2.

Push one end of the air tubing onto the barbed fitting on the X-axis carriage.

3.

Push the opposite end of the air tubing into the push-in fitting on the base plate.

4.

Install the marking head enclosure. See Replacement Procedures.

Tubing Between X-axis Carriage and Cartridge Base

Removal
1.

Remove the marking head enclosure. See Replacement Procedures.

2.

Carefully pull the tubing from the barbed fitting on the X-axis carriage.

3.

At the opposite end of the tubing, carefully pull the tubing from the barbed fitting on the cartridge base.

Installation
1.

Obtain a replacement length of 4mm OD air tubing that contains five (5) full coils.

2.

Push one end of the tubing onto the barbed fitting on the cartridge base.

3.

Push the opposite end of the tubing onto the barbed fitting on the X-axis carriage.

4.

Install the marking head enclosure. See Replacement Procedures.

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2.8.7 Opto Assembly, X-Axis
The X-axis opto assembly is mounted on the main spine, behind the X-axis drive motor.
Removal
1.

Remove the marking head enclosure. See Replacement Procedures.

2.

Disconnect the opto wires from limit/connector board connector J4.

3.

Remove the pan head screw and P-clip securing the wires to the base plate.

4.

Carefully, pull the opto wires/connector through hole in main spine.

5.

Move the X-axis carriage down the rail (away from the X-axis home limit) to gain access to the opto.

6.

Remove two pan head screws, flat washers, and spacers that attach the opto to the main spine.
Do not lose the spacers.

7.

Remove the opto assembly from the marking head.

Installation
1.

Obtain a replacement X-axis opto assembly.

2.

Place the opto on the main spine, just behind the X-axis drive motor.
Orient the opto such that:
the wires are pointing downward (toward the base plate).
the slotted opening in the opto is parallel with the X-axis carriage movement.

3.

Apply Vibra-Tite to two pan head screws. Using spacers between the opto and the main spine, attach the opto to
the spine with the two screws and flat washers (finger tight only).

4.

Carefully, move the X-axis carriage up the rail to the X-axis home limit.

Note:

Slotted holes in the opto allow for slight adjustment along the X-axis to fine tune the Home position.
Ensure the limit flag passes through the gap in the opto without interference.
Carefully bend the flag (if required).

5.

Move the X-axis carriage down the rail (away from the X-axis home limit).

6.

Securely tighten the pan head cap screws that attach the opto to the frame.

7.

Carefully, route the opto wires/connector through the hole in the main spine (near the X-axis motor) to the
limit/connector board.

8.

Connect the opto wires to limit/connector board connector J4.

9.

Secure the X-axis opto wires (and X-axis motor wires) to the base plate with one P-clip and one pan head screw:

10. Install the marking head enclosure. See Replacement Procedures.

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2.8.8 Opto, Assembly, Y-Axis
The Y-axis opto assembly is mounted on the edge of the X-axis carriage (near the air fittings).
Removal
1.

Remove the marking head enclosure. See Replacement Procedures.

2.

Disconnect the opto wires from limit/connector board connector J5.

3.

Remove the pan head screw and P-clip securing the wires to the base plate.

4.

Remove the protective wrap from the wire bundle.

5.

Carefully, pull the opto wires/connector through hole in the main spine.

6.

Carefully, cut the cable tie securing opto wires (and solenoid wires) to the edge of the X-axis carriage.

7.

Move the Y-axis carriage down the rail (away from the Y-axis home limit) to gain access to the opto.

8.

Remove the pan head screw and flat washer that attach the opto to the X-axis carriage.

9.

Remove the opto assembly from the marking head.

Installation
1.

Obtain a replacement Y-axis opto assembly.

2.

Place the opto on the X-axis carriage (near the air fittings).
Orient the opto such that:
the wires are pointing downward (toward the base plate).
the slotted opening in the opto is parallel with the Y-axis carriage movement.

3.

Secure the opto assembly using one pan head screw and flat washer.

4.

Carefully, move the Y-axis carriage up the rail to the Y-axis home limit.
Note:

Ensure the limit flag passes through the gap in the opto without interference.
Carefully bend the flag (if required).

5.

Route the opto wires under the X-axis carriage.

6.

Using cable tie, secure the opto wires (and solenoid wires) to the edge of the X-axis carriage.

7.

Carefully, route the opto wires/connector through the hole in the main spine (at end opposite the X axis motor) to
the limit/connector board.

8.

Connect the opto wires to limit/connector board connector J5.

9.

Ensure movement of the X-axis carriage does not chafe the wiring. Adjust wire routing as required.

10. Install the protective wrap over the Y-axis motor wires, Y-axis opto wires, and solenoid wires. Position the protective
wrap such that it covers the wires where they pass through the main spine.
11. Secure the wires to the base plate with one P-clip and one pan head screw.
Note:

Ensure the end of the protective wrap is secured in the P-clip.

12. Install the marking head enclosure. See Replacement Procedures.

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2.8.9 Solenoid Valve
The solenoid valve is mounted to the Y-axis carriage, adjacent to the pin cartridge.
Removal
1.

Remove the marking head enclosure. See Replacement Procedures.

2.

Disconnect the solenoid wires from limit board assembly connector J3.

3.

Remove the pan head screw and P-clip securing the wires to the base plate.

4.

Remove the protective wrap from the wire bundle.

5.

Carefully, pull the solenoid wires/connector through hole in the main spine.

6.

Carefully, cut the cable tie securing solenoid wires (and opto wires) to the edge of the X-axis carriage.

7.

Remove the socket head cap screw, flat washer, and P-clip securing the solenoid wires to the opposite side of the X
axis carriage.

8.

Remove two socket head cap screws and two lock washers at the base of the solenoid valve.

9.

Gently pull the valve from the cartridge base.

10. Remove the old gasket and clean the cartridge base, as required.
Installation
1.

Obtain a replacement solenoid valve assembly and gasket.

2.

Place the new gasket on the cartridge base. Orient the gasket to align with air holes in the cartridge base.

3.

Position the solenoid valve on the gasket. Orient the valve such that the wires extend inward (toward the air fittings
in the cartridge base).

4.

Apply LOCTITE 222 to two socket head cap screws. Install the two screws and two M3 lock washers to attach the
solenoid valve to the cartridge base.

5.

Slide the protective sleeve on the solenoid wires close to the solenoid. Allow some slack in the leads, then fold the
leads over the top of the solenoid. Secure the wires in this position with an 8-in. long wire tie wrapped around the
solenoid.

6.

Route wires under the X-axis carriage. Allow sufficient slack in wires for travel of the Y-axis carriage.

Note: Ensure the wire routing does not interfere with movement of the Y-axis limit flag.
7.

Secure wires to underside of the X-axis carriage with one P-clip, flat washer, and socket head cap screw.
Note:

Ensure the end of the protective wrap is secured in the P-clip.

8.

Using a cable tie, secure solenoid wires (and Y-opto wires) to the opposite edge of the X-axis carriage.

9.

Carefully, route the solenoid wires/connector through the hole in the main spine (near end opposite the X axis motor)
to the limit/connector board.

10. Connect the solenoid wires to limit/connector board connector J7.

11. Ensure movement of the X-axis carriage does not chafe the wiring. Adjust wire routing as required.
12. Install the protective wrap over the Y-axis motor wires, Y-axis opto wires, and solenoid wires. Position the protective
wrap such that it covers the wires where they pass through the main spine.
13. Secure the wires to the base plate with one P-clip and one pan head screw.
Note:

Ensure the end of the protective wrap is secured in the P-clip

14. Install the marking head enclosure. See Replacement Procedures.

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2.9 REFERENCE DATA
The following information will assist you in obtaining components to maintain the marking head.

2.9.1 Replacement Parts

Refer to Table 2-6 for a list of replaceable components and their part numbers.
Table 2-7 lists the pin cartridge assembly and the various marking pins that may be used with the TMP7000.

Table 2-6. TMP7000 Replacement Parts

PART NO.

DESCRIPTION

32118

Belt, Timing, 116 x L037, 11.6-in. Long, 58 Teeth, 3/8-in. Wide

(X-axis)

32119

Belt, Timing, 096 x L037, 9.6-in. Long, 48 Teeth, 3/8-in. Wide

(Y-axis)

23695

Cable Assembly, Marker, 4m (13.1 ft.) long, Standard

23696

Cable Assembly, Marker, 5m (16.4 ft.) long, Optional

23697

Cable Assembly, Marker, 6m (19.7 ft.) long, Optional

23698

Cable Assembly, Marker, 8m (26.2 ft.) long, Optional

23699

Cable Assembly, Marker, 10m (32.8 ft.) long, Standard

23700

Cable Assembly, Marker, 12m (39.4 ft.) long, Optional

23701

Cable Assembly, Marker, 15m (49.2 ft.) long, Optional

24176

Cable Extension Assembly, Marker, 8m (26.2 ft.) long, Optional

39797

Enclosure Cover, TMP7000

51672

Marking Head Assembly, TMP7000

39776

Motor, Assembly, Stepper, X-Axis, TMP7000

39777

Motor, Assembly, Stepper, Y-Axis, TMP7000

40644

Opto Assembly, TMP7000, X-Axis

41677

Opto Assembly, TMP7000, Y-Axis

40826

Pneumatic Assembly, Filter/Regulator, Mini

32120

Pulley, 30 x L037, 1/4-in. Bore, 3/8-in. Wide

35084

Tubing Set, Pneumatic, 6mm diameter, 4m (13 ft.) long

32117

Tubing, Retractable, 2.5mm ID, 4mm OD

15665

Valve, Solenoid, 12 VDC (with tabs)

Table 2-7. TMP7000 Pin Cartridge and Impact Pins

PART NO.

DESCRIPTION

51673

Cartridge Assembly, 150, Single-Pin, TM7000, Bolt-on

14780

Pin, Impact,150 Size, Powdered Metal, 30

23835

Pin, Impact,150 Size, Powdered Metal, 45

32156

Pin, Impact,150 Size, Tool Steel, Carbide Tip, 30

(Note: Pin not provided.)

2.9.2 Ordering Parts

If you need parts for the marking system, be sure to specify the marking head model number and serial number when
ordering. Refer to Telesis Customer Support at the end of this manual for contact information.

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2.9.3 Telesis Customer Support
Telesis Customer Support offers the following assistance.
Phone Support

Telesis Customer Support offers free phone support to answer questions during normal business hours.

On-Site Service

Telesis can send Customer Support 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
support if a problem should occur.
Factory Service

Telesis Customer Support can repair defective parts in our factory to save you money.

Contact Telesis at one of the following locations for more information on any of these services.
If you need parts or service for your marking system, be sure to specify the equipment model number and serial number.
Telesis Technologies, Inc.
Corporate Headquarters
28181 River Drive
P.O. Box 1000
Circleville, Ohio, USA 43113
+1 (740) 477 5000
+1 (800) 654 5696 (U.S. and Canada)
+1 (800) 867 8670 (after hours)
+1 (740) 477 5001 (fax)
email: sales@telesistech.com
email: technical_services@telesistech.com
Telesis Worldwide Locations
For contact information, please visit our website at: www.telesis.com

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