Application Note:

Using the TLOIS

1.0 Purpose
This Application Note provides information for using the Dimatix Thermal Low On Ink
Sensor (TLOIS) which is used in many of our reservoirs. Information includes operation,
guidance on circuit design, and an explanation of the variables that influence reliable ink
sensing.

2.0 Operation
The TLOIS is a thermal level detector. Its development was based on well-known level
detection principles found in the literature of thermistor manufacturers and summarized
here.

Teflon-Insulted Leads
Stainless Steel Housing

Epoxy Potting

Negative Temperature Coefficient (NTC)

Thermistor Bead

Figure 1 TLOIS cross-section

FUJIFILM Dimatix, Inc. Confidential Information Doc. #AN000006 Rev. 04

November 17, 2010
2 Using the TLOIS

The Spectra TLOIS uses an NTC (Negative Temperature Coefficient) thermistor

located at the end of a probe at the nominal ink level inside the ink reservoir. The
sensing circuit drives the thermistor in self-heat mode. The thermal conductivity of a
liquid (ink) is much higher than that of a gas (air), therefore self-heating is lower in
liquid than in air. A lower equilibrium temperature is reached in the liquid. The lower
temperature means the resistance of the thermistor is higher, and therefore the voltage
across the thermistor is higher. This assumes that a voltage divider circuit is used, as
shown in Figure 2.

In order for the TLOIS to work properly, the reservoir must meet certain requirements.
Some of these requirements are:

1. Reservoir must have sufficient thermal conductivity.

2. The immediate environment of the TLOIS must be at a known and constant

temperature.

3. There must be sufficient clearance to the walls of the reservoir so that:

 surface tension does not retain fluid adjacent to the TLOIS, even when the level is low,
and
 the thermal conductivity difference between ink and air is adequately reflected in the
signal.

3.0 Drive Circuit and Signal Conditioning

The voltage divider circuit in Figure 2 is recommended as an interface to the TLOIS,
usually with VRef = 12 V.
VRef

RPull-up

LOIS
Thermistor VLOIS

Figure 2 TLOIS voltage divider circuit example

The voltage measured across the thermistor is normally read by an A-to-D converter
via an input circuit such as that shown in Figure 3. The signal is processed by software
that controls an ink pump in response to the signal. In most refill software algorithms,
the approximate midpoint for the two limiting states – "in air" vs. "in ink" – is used as
the trip point for determining if the reservoir requires filling.
Doc. #AN000006 Rev. 04 FUJIFILM Dimatix, Inc. Confidential Information
November 17, 2010
 Using the TLOIS 3

Rpull-up dissipates significant heat, so must be sized accordingly (see Table 1).

12V

R2 *
390
1%

Ain
R3
30.1K R4 C1
R1 C2
1% 20.0K 1 uF
Thermistor 1%
.022 uF A to D
Converter

* Note: R2 = 158 Ohms for LOIS HM,

or 900 for Low Ambient applications

Figure 3 TLOIS input circuit example

Table 1 Recommended TLOIS Circuit Parameters

R at 25º C Rpull-up,  Max. Rpull-up power

(VRef = 12V) dissipation, W
TLOIS LT 1.2 k 390 1/4 @ 90º C
TLOIS LT (low ambient) 1.2 k 900 1/8 @ 90º C
TLOIS HM 5 k 158 1/2 @ 140ºC

The accuracy of the signal is affected by a number of factors, including the precision of
Rpull-up (R2 in Figure 3), tolerance and noise at VRef (12 V in Figure 3), and look-up table
rounding or linearization errors. Fortunately, adequate temperature sensing accuracy can
be achieved by common practices such as using 1% tolerance resistors, compensating for
supply voltage variation in the A/D circuit if necessary, and including enough data points
in the look-up table.

4.0 High and Low Temperature Versions

To provide for good signal-to-noise ratio while avoiding excessive surface temperature,
which could damage inks, there are two TLOIS models used in Spectra printheads and
reservoirs: LT (Low Temperature) and HM (Hot Melt). They differ in nominal resistance
and require different pull-up resistors. Table 1 shows the thermistor nominal resistances,
along with recommended Rpull-up values.

FUJIFILM Dimatix, Inc. Confidential Information Doc. #AN000006 Rev. 04

November 17, 2010
4 Using the TLOIS

Also shown in the table are parameters for an alternate Rpull-up that has been shown to
work well with aqueous inks, running at an ambient of 30º C (“low ambient” in Table
1). The increased pull-up resistance has the benefit of reducing the surface temperature
of the TLOIS, thereby reducing any possible effects on the ink. There is a reduction in
the signal strength, but temperature uncertainty is also reduced because the ambient
temperature is lower.

The TLOIS HM is primarily for use with hot melt ink at temperatures above 70º C. Use
of this version at lower temperatures gives a strong output signal, but also leads to a
high temperature rise. For example, at 50º C ambient, in air, the TLOIS HM surface
exceeds 110 C, while the TLOIS LT’s surface is about 90º C. On the other hand, the
TLOIS LT produces a relatively small signal if used at temperatures higher than
intended, as seen in Figure 4.
Note: There is no way to directly measure surface temperature (always less than the
thermistor’s internal temperature), therefore surface temperatures are derived
from an analytical model, whose thermal characteristics were inferred from
measurements of actual TLOISs.

Figure 4 TLOIS LT Performance

Doc. #AN000006 Rev. 04 FUJIFILM Dimatix, Inc. Confidential Information

November 17, 2010
 Using the TLOIS 5

Figures 4 and 5 show approximate output versus temperature for a TLOIS LT and a
TLOIS HM using the above circuit parameters, in Spectra Model Fluid.

Figure 5 TLOIS HM Performance

5.0 Sensitivity to Ambient Temperature

As shown in Figures 4 and 5, the TLOIS is very sensitive to the temperature of the ink
around it. Therefore, the temperature of the reservoir must be precisely controlled, usually
to better than  5º C. For applications operating at room temperature, where the reservoir
is unheated and therefore uncontrolled, calculations may have to be made to ensure
reliable refilling across the expected range of ambient temperatures. It may be necessary
to sense the reservoir temperature in real time and refer to a look-up table of TLOIS trip
points versus temperature.

For the same reason, the ink delivered to the reservoir, particularly if dispensed at a high
rate, must have approximately the same temperature as the reservoir. If not, the TLOIS
output is affected, causing overfilling if the ink is too hot, or under filling if it is too cold.

6.0 Other Error Sources

Since the TLOIS is a thermal device, there is a response lag due to the specific heat of the
thermistor and the ink around it. The signal exponentially approaches equilibrium. Worst-
case time lags are up to 2 seconds for an “in air” to “in ink” transition, or 5 seconds for an

FUJIFILM Dimatix, Inc. Confidential Information Doc. #AN000006 Rev. 04

November 17, 2010
6 Using the TLOIS

“in ink” to “in air” transition. One and three seconds, respectively, are more typical
values.

Output varies somewhat with the fluid’s properties, especially viscosity, thermal
conductivity, and thermal diffusivity.

Accelerations, such as that experienced on a scanning carriage, can also change the
TLOIS’ output. Normally, sloshing of the ink creates forced convection, which
reduces the temperature in ink and makes it appear fuller than in the static condition.
However, if the sloshing is enough to expose the sensor, the TLOIS may begin to read
low, even if no ink has been consumed.

Output values and dynamic response should be verified for each application, and
setpoints and algorithms adjusted accordingly.

7.0 Finding the Setpoint

For a particular combination of ink and reservoir, it is a good idea to empirically find
the correct setpoint. This usually differs somewhat from the values one might predict
from the graphs in this document. The approach is to find the value when a TLOIS is
truly immersed in ink (i.e., ink level "OK") versus when the TLOIS is in air (i.e., low
on ink), then pick a setpoint in the middle of these two measured values.

1. Connect the TLOIS into a circuit as described above.

2. Warm up the reservoir to operating temperature. Purge any ink out of the
reservoir. Let it sit for several minutes to make sure the reservoir, the air inside
it, and the TLOIS are all at stable thermal equilibrium.

3. Observe and record the voltage reading across the TLOIS. Because the TLOIS
is in air, and the thermal dissipation in air is much less than in molten ink, the
voltage across the TLOIS is a relatively low value, for example 3 volts. This is
the TLOIS value for this operating temperature when the printhead is low on
ink. It is NOT the TLOIS setpoint (more on that later).

4. Pump ink gradually into the reservoir. At some point, the voltage reading across
the TLOIS jumps. Pump in more ink, so the TLOIS is well immersed. Let the
system sit for a few minutes to thermally equilibrate. Observe and record the
voltage reading across the TLOIS, for example 5 volts. This is the TLOIS value
(for this operating temperature) when the reservoir has sufficient ink (not the
TLOIS setpoint). If there is concern about possibly overfilling the reservoir
during this process, simply disconnect the meniscus tubing during this
procedure. If the reservoir overfills, the ink seeps out of the meniscus fitting. A
long purge or two drops the ink level back to a safe place.

Doc. #AN000006 Rev. 04 FUJIFILM Dimatix, Inc. Confidential Information

November 17, 2010
 Using the TLOIS 7

5. The TLOIS setpoint can now be determined. The voltage halfway between the low
condition voltage and the full condition voltage is the usual starting point, so in the
example above, the average of 3 and 5 is 4 volts. This setpoint is not always
optimal, but is a good starting place. Depending on fire frequency, dutycycle, ink
usage, and other variables such as ambient temperature and the temperature of the
incoming ink, it may be necessary to adjust this setpoint.

If changing the operating temperature is necessary, a new TLOIS setpoint must be

determined. The TLOIS setpoint is inextricably linked to the operating temperature of the
reservoir.

8.0 Minimizing Surface Temperature

For volatile inks or fluids sensitive to temperature, it may be necessary to modify the
circuit parameters to minimize the surface temperature, while maintaining signal at a
specific operating temperature. Refer to Figures 6 and 7, which illustrate the sensitivity of
performance to variation in VRef and RPull-up.

Figure 6 TLOIS Sensitivity to Supply Voltage

FUJIFILM Dimatix, Inc. Confidential Information Doc. #AN000006 Rev. 04

November 17, 2010
8 Using the TLOIS

Figure 7 TLOIS Sensitivity to Series Resistance

Doc. #AN000006 Rev. 04 FUJIFILM Dimatix, Inc. Confidential Information

November 17, 2010