MicroE Systems Mercury 1000 Installation manual
Contents
1. Mercury 2000 3000 amp 3500 Smart Programmable Encoder Systems Installation Manual and Reference Guide MicroE Systems Taking Control of Motion Manual No IM M2000 amp 3000 Rev E MicroE Systems Taking Control of Motion Don Mitchell Founder Chairman and Chief Technology Officer MicroE Systems Me Systems was founded to advance encoder technology to a level never before achieved Our objective was to design encoder systems that would be small enough to fit into densely packed OEM equipment designs affordable enough for cost sensitive applications and easy enough to enable installation setup and alignment by assemblers with little training We are pleased to say that all of these goals have been realized with ry the introduction of the 36 Mercury 2000 and 3000 encoder systems Sensor shown actual size Table Of Contents SYSTEM ILLUSTRATION PAGE Encoder with Linear scale 2 Encoder with Rotary scale 3 INSTALLATION INSTRUCTIONS Encoder System Mounting Linear 4 Encoder System Alignment Linear 5 Centering the Index amp Calibration Linear 5 Encoder System Mounting Rotary 6 Encoder System Alignment Rotary 7 Centering the Index amp Calibration Rotary 7 REFERENCE SECTION Installation of Linear Scales 8 Grounding Instructions 9 Recommendations for Power 9 Recommended Interface Termination 9 Customer Interface Cable Requirements 10 SmartSignal Module Mounting Options 11 De2. Red Alignment LED Te K z reen w i Yellow A Optimal NS UR M Alignment LED Bright Green Confirm proper alignment over IMPORTANT the full f motion A OUTPUT CALIBRATION PROCEDURE The Proper Alignment LED must remain on over the entire range If not aligned over the entire range of motion loosen the sensor mounting screws This procedure must be completed for proper system operation each time the sensor is aligned or if the SmartSignal electronics module is replaced and repeat step 5 Position the sensor at least 7mm 1 4 away Power from the index mark on the scale Next push Calibration the Index Calibration Ir amp 7 Na a button inside the ndex Panic if Coho module with a small button g F weya diameter shaft such Proper pt iE a asa bare cotton swab Alignment_ 7 The Power indicator a i Calibration indicator will flash continuously Move the scale past the sensor in both directions so that the index mark passes under the sensor Do not run off the end of the scale When the calibration procedure is complete the Power Calibration indicator stops flashing Page 5 Installation Instructions Rotary Encoders Install the sensor on your mounting surface referencing the appropriate datum surface as shown on the interface drawing Use 2 washers per mounting screw Attach your hub scale assembly to the rotary device Refer to the interface dr
3. amp flat Ze example shown with benching pins 2000 3000 amp 3500 Encoder System System View Shown with linear scale Glass scale shown mounted on a linear slide sensor shown attached on a linear slide base with mounting bracket ee SmartSignal electronics module interpolator Double shielded cable Sensor mounting holes 2 Optional sensor benching pins 3 End locator pin oe Index Calibration utton Cover Sensor cable and connector P Thumb screw Signal amp alignment indicators 15 pin High Density D sub connector Power Calibration indicator Mercury 2000 3000 amp 3500 Encoder System with Rotary scale A System View Shown with Rotary scale Sensor shown attached to a customer supplied mounting bracket Rotary scale SIL TSS SmartSignal electronics module interpolator Expanded View bl Double a shielded cable Mounting screws amp flat a8 washers 2 needed per screw Mounting hole 2 Typical user supplied sensor mounting bracket sould be locatedinere Cover Sensor cable and connector Top reflective rotary scale Rotary scale _ gt Index Calibration button Thumb screw Signal amp alignment 15 pin High Density dcas D sub connector Power Calibration indicator Page 3 Installation Instructions Linear Encoders Page 4 Attach the scale to the base slide Reference the preferred datum on
4. too high in the Z direction to scale length is the recommended location from the edge prevent mechanical interference with the sensor or sensor mount Q Benching pins gt Q Mounting the Scale MicroE Systems linear scales should be affixed to the mounting surface Two different approaches are described below Epoxy and RTV Mounting Recommended for best accuracy i Scale clam Optionally scale clamps may be used to secure the E la Make sure the mounting surface is scale while the adhesive cures Avoid damage to clean and dry the top surface End Benching Side view showing Pin Mounting clamp Mounting clamp optional scale clamps and scale Space clamps every 75mm on scales over 150 mm in length Hard epoxy e at one corner this end only RTV around entire Benching pins outside edge of scale D sign the scale by placing the edges against the benching pins Apply a hard epoxy such as Tra Con s Tra Bond 2116 to the end of the scale at the end benching pin Apply 100 Silicone RTV adhesive around the edges of the scale This method allows thermal expansion from the benched end of the scale After adhesive curing remove the scale mounting clamps or if permanently installing clamps make sure they do not interfere with the sensor or sensor mount Two Sided Adhesive Tape Mounting Make sure the mounting surface is clean and dry Peel the Gently place the scale on the mounting surface Posi
5. ation 2 The encoder sensor must be mounted so that it is electrically isolated from ground Power Supply 5 Volts 0 Volts Recommendations for Power Mercury encoders require a minimum of 4 75V DC continuously When designing circuits and extension cables to use Mercury encoders be sure to account for voltage loss over distance and tolerances from the nominal supply voltage so that at least 4 75V DC is available to the Mercury encoder under all operating conditions The input voltage should not exceed 5 25V DC Customer Differential Line Receiver Recommended Interface Termination At R 120 ohm A R 120 ohm B R 120 ohm Page 9 Reference Section Customer Interface Cable Requirements Customer cables that interface to Mercury series encoders must have the following characteristics e Twisted pair signal wiring e Characteristic impedance of 100 120 ohms e Sufficient wire gauge to meet the minimum voltage requirement at the encoder for example 24AWG gauge wire for a 2m length cable Examples of acceptable cables with 24 AWG gauge wire and 4 twisted pairs are Belden 9831 8104 and 9844 or other manufacturer s equivalents e Single shield cable with a minimum of 90 coverage Note that a double shielded cable may be required in high noise applications Signal Wiring Each differential signal should be connected to a correspondi
6. awing The reflective surface of the scale must face the sensor Benching pins may be used to locate the sensor if the system mechanical tolerances are adequate see data sheet for alignment tolerances or keep mounting screws loose for sensor alignment if benching pins are not used Be sure the source power is off before connecting the SmartSignal plug CAUTION observe precautions for handling electrostatic sensitive devices Connect the Smartsignal electronics to the controller using pinout diagram described on the interface drawing Route the sensor cable through your equipment to the SmartSignal electronics A Remove the three cover screws and the top half of the connector housing Do not pull on the 15 pin D sub connector or the circuit Insure proper system grounding Refer to the procedure on pg 9 board under the insulation layer Tighten the thumb screws B Attach the sensor s 5 X 2 connector to the Power up the system The mating 5 X 2 connector on the circuit board Power Calibration indicator will illuminate C Route the sensor cable through its channel in the center of the connector body and place the cable s hex sleeve in the matching recess Attach the top half of the connector housing to the bottom half using the three cover screws The longest screw is used in the hole adjacent to the cable exit Page 6 Installation Instructions Rotary Encoders If benching dimensions cannot be provid
7. claration of CE Conformance 11 ENCODER TROUBLESHOOTING Selected Topics 12 Cleaning Scales 12 Contact MicroE Systems Back Cover Precautions 1 Follow standard ESD precautions Turn power off before connecting the sensor Do not touch the electrical pins without static protection such as a grounded wrist strap 2 Do not touch the glass scale unless you are wearing talc free gloves or finger cots Please read this installation manual for full instructions Safety Information MicroE Systems Mercury series reflective encoders are classified as CDRH Class and IEC Class 1M laser products e Invisible laser radiation wavelength 850 nm Max power 1 5 mW CW e This product conforms to all applicable standards under 21 CFR Ch 1040 10 e CDRH Class level of laser radiation is not considered to be hazardous e CAUTION The use of optical instruments with this product will increase eye hazard DO NOT VIEW DIRECTLY WITH OPTICAL INSTRUMENTS MICROSCOPES EYE LOUPES OR MAGNIFIERS CLASS 1M LASER PRODUCT IEC 60825 1 2001 C M2000 and M3000 are CE compliant M3500 CE compliance is pending Page 1 Mercury with Linear scale eS Expanded View Mountin Washes 2 needed per screw Typical user supplied sensor mounting bracket an Center index mark Bracket mounting holes 2 es f Scale reference datum Detail A Top reflective linear scale End index mark Scale benching edge Page 2 screws
8. connector is fully seated and connected e Confirm that 5 Volts DC is being applied to pin 12 on the SmartSignal electronics 15 pin HD connector and that pin 13 is connected to ground Problem Can t get the SmartSignal electronics Signal LEDs better than red or yellow or the green Proper Alignment indicator doesn t stay illuminated over the full length of the scale Solution o Verify that the sensor has been aligned to the scale and that the mounting screws are tight Check the dimensions for the mechanical mounting holes and clamps if any to make sure that the sensor is correctly located over the scale Refer to appropriate the interface drawing e Check that the scale is firmly mounted and can t jiggle or move in other than the intended direction e Make sure that the scale is clean over its entire length or circumference Problem The green Power Calibration indicator is flashing unexpectedly Solution e Part of the normal setup procedure is to activate the SmartSignal electronics Index Calibration process by pressing the recessed button the SmartSignal electronics connector body The On Index LED will begin to flash until the index mark on the scale passes under the sensor at least one time in each direction Problem Can t Complete the Index Calibration process the green Power Calibration indicator doesn t stop flashing Solution e Verify that the sensor is mounted in the correct orientation to the scale for t
9. ed proper sensor alignment may require minor adjustments to the sensor position with respect to the scale This can be performed easily using the LED alignment indicators as illustrated below The red yellow or green LED will light depending on sensor alignment Slowly move the sensor by allowing it to slide on the mounting surface until the green or Proper Alignment LED is illuminated Optimal alignment will be displayed as a Bright Green LED IMPORTANT Confirm that the Proper Alignment LED blinks when passing over the index If not To alicn th 7 readjust the sensor in the Y direction and repeat the above procedure When alignment is completed 7 hey or 8 direct a tighten the sensor mounting screws 0 37Nm 3 3 inch lbs maximum torque m m s im mm 4 Power rz m e J D On ke Calibration C G2 BE i Power 2 alibration em Calibration gt ia Calibration fino Bans EA l gt H a a ve Ne ery j Slaa a Verru 3000 p jn way 20 ZENS f roper SENE J ae D i ae ris L O A J Alignment LED gt E Me See aF d Ag LED Ge a Alignment LED as __ Green We O T oM e Yellow OPS Optimal S Alignment LED Bright Green IMPORTANT OUTPUT CALIBRATION PROCEDURE This procedure must be completed for proper system operation each time the sensor is aligned or if the SmartSignal electronics module is replaced Position the
10. he desired index mark Refer to the interface drawing e Refer to step 5 of the installation procedure to insure proper operation Cleaning scales General Particle Removal Blow off the contamination with nitrogen clean alr or a similar gas Contamination Removal Use a lint free clean room wipe or cotton swab dampened with isopropyl alcohol or acetone only to wipe the surface clean Handle the scale by the edges Do not scrub the scale Page 12 Contacting MicroE Systems Thank you for purchasing a MicroE product You should expect the highest level of quality and support from MicroE If you have any questions or want to download the Mercury Encoder Installation Manual Data Sheet or Interface Drawing browse www microesys com and click on the Mercury Encoder Products button then the Standard Encoder Products Tab You ll tind everything you need right there MicroE Systems Taking Control of Motion World Headquarters 8 Erie Drive Natick e MA 01760 WWww microesys com info microesys com T 800 355 4047 F 508 655 7084 Copyright MicroE Systems
11. ng twisted pair as follows Mercury 3500 3000 2000 Signal Twisted Pair Pair 1 i B Pair 2 B Index Pair 3 Index 5V Pair 4 GND Shield Termination The customer s cable shield should be in 360 contact with the connector shroud and the connector shell to provide complete shielding The connector shell should be metal with conductive surfaces Suggested metal connector shells for use with Mercury 3500 3000 3000S and 2000 encoders AMP 748676 1 or equivalent for Mercury 1000 and 1500S encoders AMP 745172 3 2 or 1 where the dash number is dependent on the customer s outside cable diameter The shield should be terminated as illustrated in the following diagram 7 6 0 30 ALUMINUM POLYESTER SHIELD NOT TO BE EXPOSED IN THIS AREA JACKET DO NOT TWIST ALUMINUM POLYESTER SHIELD VLLLELLLLLLELLELLLLELERLELL LL EL BRAIDED SHIELD PEASLSDB4S44 45444544 a a a ee a r 28 7 113 Fold braided shield back over jacket Example shows double shielded cable Dimensions shown are for illustration only Page 10 Reference Section SmartSignal Module Mounting Options Declaration of CE Conformance The SmartSignal electronincs module may be mounted directly to a bulkhead connector using the integral thumb screws shown in figure A Alternatively the module may be used with an extension cable and mounted to a base plate using the mounting tabs as shown in figure B MicroE Systems EC Declaration
12. of Conformity In accordance with EN 45014 1998 We the undersigned MicroE Systems Inc 8 Erie Drive Natick Massachusetts USA 01760 1313 Declare that Equipment Positioning System including Sensor Grating and Interpolator Model Numbers M2000 and M3000 Encoder Systems In accordance with the following Directives 89 336 EEC The Electromagnetic Compatibility Directive and its amending directives Has been designed and manufactured to the following specifications EN50082 1 1997 Generic Immunity Residential Commercial and Light Industrial EN55022 1998 Emissions Tests for Radiated and Conducted EN61000 4 2 1995 Immunity Tests for Electrostatic Discharge EN61000 4 3 1996 Immunity Tests for Radiated RF Electromagnetic Field EN61000 4 4 1995 Immunity Tests for Electrical Fast Transients EN61000 4 8 1993 Immunity Tests for Power Frequency Magnetic Interference EN61000 4 6 1996 Immunity Tests for RF Common Mode Injection I hereby declare that the equipment named above has been designed to comply with the relevant sections of the above referenced specifications The unit complies with all essential requireprgnts of the Directives Signed by Date 9 ELT E Position 1 Place of Issue 8 Erie Drive Natick Massachusetts USA Page 11 Troubleshooting Problem The Power Calibration indicator will not come on Solution e Make sure that the SmartSignal electronics 15 pin D sub
13. onnecting the Smartsignal plug Connect the SmartSignal electronics to the controller using the pinout diagram described on the interface drawing Insure proper system grounding Refer to the procedure on pg 9 Tighten the thumb screws Power up the system The Power Calibration indicator will illuminate Installation Instructions Linear Encoders If benching dimensions cannot be provided proper sensor alignment may require minor adjustments to the sensor position with respect to the scale This can be performed easily using the LED alignment indicators as illustrated below The red yellow or green LED will light depending on sensor alignment Slowly move the sensor by allowing it to slide on the mounting surface until the green or Proper Alignment LED is illuminated Optimal alignment will be displayed as a Bright Green LED IMPORTANT Confirm that the Proper Alignment LED blinks when passing over the index If not readjust the sensor in the Y direction and repeat the above procedure When alignment is completed tighten the sensor mounting screws 0 37Nm 3 3 inch lbs maximum torque To align the sensor move it in the Y or O direc tions C e i Fower on Power f alibration caloration ad i aiin E Calibration BL pn aay a eo a ff Fa 11 meray 600 I A Mercury 3000 P ve pus seas E Proper A ae Improper m J Alignment LED gt e N Alignment LED
14. sensor at least 7mm 1 4 away Confirm proper alignment se tie Power from the index mark on the scale Next push over the full range of motion oe The Proper Alignment LED NSS tate 6 the Index Calibration must remain on over the ee Index NE f Ge eee den me entire range If not aligned Calibration 4 i T oe aa ae over the entire range of button jn wea diameter shaft such motion loosen the sensor C 2 gt Proper i gt a ie as a bare cotton swab Alignment __ _J The Power mounting screws and repeat step 5 Indicator CM MS Calibration indicator will flash continuously Move the scale past the sensor in both directions so that the index mark passes under the sensor Do not run off the end of the scale when using a segment scale When the calibration procedure is complete the Power Calibration indicator stops flashing Page Reference Section Installation of Linear Scales Positioning the Scale Note Before beginning mounting procedure use talc free gloves or finger cots to handle the scales Benching the scale to the system means aligning the scale by means of benching pins Pin locations are described on the appropriate interface drawing Two benching pins are recommended on the long side of the scale and one at the end as shown This is marked datum A on the interface drawing Position the benching pins in from either end 20 of the overall Be sure the benching pins do not extend
15. st be in intimate electrically conductive contact with the customer supplied mating connector which must be isolated from the controller s ground If a customer supplied shielded cable connects the encoder to the controller then the shielding on the customer supplied cable must be isolated from the controller s ground 2 The sensor mounting surface must have a low impedance DC AC connection to ground The encoder sensor mounting surface may have to be masked during painting or anodizing to insure good electrical contact with the sensor S Inner shield Insulated from outer shield sensor and connector housing Connected Electrically conducti to circuit common internally i Power ectrically conductive mechanical connection Outer Shield Connected to Sensor and Connector housing I Ca n e Do not ground shroud Sensor mounted to a surface that is grounded through bearings or a poorly grounded surface or a non conducting surface 1 15 pin D sub connector grounding The encoder s connector shell must be in intimate electrically conductive contact with the customer supplied mating connector which must be connected to the controller s ground If a customer supplied shielded cable connects the encoder to the controller then the shielding on the customer supplied cable must be connected to the controllers ground The controller must be grounded to earth at the point of install
16. the interface drawing for either end or center index orientation Depending on the mounting method attach the scale to the slide with adhesive Refer to pg 8 for details Be sure the grating surface of the scale faces the sensor Insure that there is no contact between these surfaces or damage may result CAUTION observe precautions for handling electrostatic sensitive devices Route the sensor cable through your equipment to the SmartSignal electronics A Remove the three cover screws and the top half of the connector housing Do not pull on the 15 pin D sub connector or the circuit board under the insulation layer B Attach the sensor s 5 X 2 connector to the mating 5 X 2 connector on the circuit board C Route the sensor cable through its channel in the center of the connector body and place the cable s hex sleeve in the matching recess Attach the top half of the connector housing to the bottom half using the three cover screws The longest screw is used in the hole adjacent to the cable exit Install the sensor on your mounting surface referencing the appropriate datum surface as shown on the interface drawing Use 2 washers per mounting screw Benching pins may be used to locate the sensor if the system mechanical tolerances are adequate see data sheet for alignment tolerances or keep mounting screws loose for sensor alignment if benching pins are not used Be sure the source power is off before c
17. tioning adjustments cover paper off and place the scale above the final location can be made until the scale is firmly pressed down After final positioning push down on the top of the scale to secure It End Benchin a ay Hard epoxy at one corner this end only C lt _ Benching pins gt 2 Align the scale by placing the edges against the benching pins Page 8 Reference Section Grounding Instructions for Mercury 2000 3000 and 3500 Encoder Systems For Mercury 2000 and 3000 encoder systems to operate reliably it is essential that the sensor and cable shield are grounded properly according to the following instructions The diagrams below show how to make the connections when the encoders connector Is plugged into the customer s controller chassis If a customer supplied extension cable is used it should be a double shielded cable with conductive connector shells and must provide complete shielding over the conductors contained within it over its entire length Furthermore the shields should be grounded at the connection to the controller chassis the same way as the encoder connectors in the diagrams below Note For best performance isolate encoder shield from motor cable shields and separate encoder cable as far possible from motor cables Sensor mounted with good electrical contact to a well grounded surface preferred 1 15 pin D sub connector grounding The encoder s connector shell mu
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