Mercury

TM

3000

Smart Encoder Systems

Programmable Interpolation in Integer Steps to 0.020

μm

Reflective Linear and Rotary Encoder Systems

Next Generation Ruggedized

Design Replaces Mercury 3100

New design for more robust performance

Sensor the size of a Dime

Resolution

Linear: 5μm to 0.020μm

Rotary: 6,600 to 16.8 M CPR

Accuracy

Linear: ± 1μm available

± 3μm to ± 5μm standard

Rotary: Up to ± 2.1 arc-sec

Output

A-quad-B and Index Pulse

The New Mercury 3000 encoder represents the next level of encoder performance. With programmable interpolation, smallest sensor size, easiest alignment, and superior noise immunity, the M3000 delivers Best-in-Class performance.

Imagine what you can do with this!

The new Mercury 3000 can reduce the cost and size of your system, and improve its performance all at once! MicroE Systems’ Mercury 3000 kit encoders are smaller, higher performance, faster to install, and easier to set up and align than any other encoder. The tiny sensor fits into very tight spaces and works in both linear and rotary applications.

New features

• New metal enclosure for SmartPrecision ™ electronics

Best-in-Class noise immunity for harsh environments

Shorter length for smaller, tighter cabinets

Frame mounting compatible for easy installation

Robust metal housing with easy access locking screws

• Double shielded long life cable

• CE compliant

Standard features

• Smallest sensor- 1/3 the size of other encoders

• Revolutionary bolt-in alignment for many applications

• Advanced SmartPrecision electronics built into shielded D-sub connector

• A-quad-B output with programmable interpolation in integer steps for resolutions to 0.020µm (linear); 16.8M CPR (rotary)

• LED set up indicators for sensor alignment and index location

• Bi-directional index signal is repeatable to encoder resolution

Table of Contents

System & Sensor pg 1-5

SmartPrecision Electronics pg 6-7

SmartPrecision Software pg 8

O

rdering Information

Optional features pg 10

• Glass scale length or diameter

Linear lengths from 5mm to 2m

Rotary diameters from 12mm to 108mm

• Cable length of 0.5m,1m, 2m, or custom

• SmartPrecision Software

System Configurations

Standard and Optional Equipment

M3000 Smart Encoder Systems

Standard Equipment

M10

Encoder Sensor

Same for linear and rotary scales.

Sensor Cable

The standard cable is double shielded and available in lengths of

0.5m, 1m or 2m.

A 15 pin high density

D-sub connector mates to the customer controller.

SmartPrecision ™ Electronics

Module

New Metal Enclosure Provides

Best-in-Class Noise Immunity

M3000

Optional Equipment

RS 232 Interface

Adapter

The adapter provides connections to a PC, the encoder system and the controller.

SmartPrecision ™ Software

The software module enables all programmable and diagnostic features plus displays encoder output and signal strength.

See page 8 for details.

Page 2 of 10

Broader Alignment Tolerances,

Increased Standoff Clearance, Smallest Sensor and More

Why Mercury Encoders Make It Easier To Design High Performance Into Your Equipment

M errc

± 2°

Brra nd gn me ntt T olle nc

± 0.5° ± 0.006°

Brra nd

Eliminate the Frustration of Touchy

Encoder Alignment

Mercury Solves this Problem for Good

Fussy alignment is no longer a concern. With Mercury’s patented PurePrecision ™ optics, advanced SmartPrecision ™ electronics and LED alignment indicators, you can push the sensor against your reference surface, tighten the screws and you’re finished. Try that with brand X or Y.

This performance is possible thanks to relaxed alignment tolerances, particularly in the theta Z axis. Mercury offers a

± 2° sweet spot– that’s a 300% improvement over the best competitive encoder. And that will result in dramatic savings in manufacturing costs.

No other commercially available encoder is easier to align, easier to use, or easier to integrate into your designs.

Alignment Tolerance Comparison**

Mercury*

Z Standoff

Y

± 0.15mm

± 0.20mm for linear

Brand X

± 0.1mm

± 0.1mm

Brand Y Mercury vs. Best Competitor

± 0.1mm

Mercury is 50% better unspecified Mercury is 100% better theta X theta Y

± 1.0°

± 2.0° unspecified ± 1.0°

± 0.1° theta Z ± 2.0°

*Measured at a constant temperature for one axis at a time with all other axes at their ideal positions.

**Based on published specifications

± 1.0°

Mercury Can Reduce System Size and Cost

Mercury’s sensor height is 44% shorter than competitive encoders, making it easy to fit into your design. This reduction can also cut total system weight and cost by allowing the use of smaller motors and stages. Safe system operation is also enhanced thanks to Mercury’s generous standoff clearance– 200% greater than other encoders.

And its standoff tolerance is 50% greater than the best alternative.

This significantly relaxes mechanical system tolerances, while reducing system costs.

M cu

Brra nd

Mercury is 100% better

Mercury is 300% better

Stta nd Clle arra nc e

2.4mm*

± 0.15mm

0.8mm

± 0.1mm

Mechanical Dimension Comparison**

Mercury Brand X Brand Y Mercury vs.

Best Competitor

Sensor Z height 8.4mm

23mm 15mm 44% better

Standoff clearance 2.4mm

0.5mm

0.8mm

200% better

Standoff tolerance ± 0.15mm ± 0.1mm ± 0.1mm

50% better

System height 11.7mm

28.5mm 15.8mm

26% better

**Based on published specifications

Brra nd

0.5mm

± 0.1mm

* Dimensions shown illustrate encoder system standoff clearance; see Mercury

Encoder Interface Drawings for correct design reference surfaces.

Page 3 of 10

System Specifications

Resolution and Maximum Speed

Mercury 3000 systems have programmable interpolation from x4 to x1024 in integer steps.

Below is a table of sample values.

Linear - 20μm grating pitch

Interpolation Resolution x4 x10 x20 x40 x80 x100 x200 x400 x1000

5.000µm/count

2.000µm/count

1.000µm/count

0.500µm/count

0.250µm/count

0.200µm/count

0.100µm/count

0.050µm/count

0.020µm/count

To calculate desired linear interpolation multiplier, use the following equation

Interpolation Multiplier = Grating Period (20µm) / Desired Resolution (µm/count)

Maximum Speed*

7200mm/s

7200mm/s

7200mm/s

7200mm/s

7200mm/s

5760mm/s

2880mm/s

1440mm/s

576mm/s

Rotary - 20μm grating pitch

Rotary Fundamental

Glass Scale Resolution

Diameter

Interpolation

Note: The range of available values is x4 to x1024 in integer steps; example values below.

0.472” [12.00mm] 1650 CPR

0.750” [19.05mm] 2500 CPR

1.250” [31.75mm] 4096 CPR

2.250” [57.15mm] 8192 CPR

4.250” [107.95mm] 16384 CPR interpolated resolution (CPR) x4

6,600 x100 x256 x1024

165,000 422,400 1,689,600 interpolated resolution (arc-sec/count)** 196.4 7.85 3.08 0.767

interpolated resolution (µrad/count)** 952 maximum speed* (RPM)

38.0

13090 10470

14.86

3.79

4090 1020 interpolated resolution (CPR) x4

10,000 interpolated resolution (arc-sec/count)**129.6

x100

250,000 640,000 2,560,000

5.18

x256 x1024

2.03 0.506

interpolated resolution (µrad/count)** 628.3

maximum speed* (RPM) 8640

25.1

6912

9.8

2700

2.5

675 interpolated resolution (CPR) x4

16,384 x100 x256 x1024

409,600 1,048,576 4,194,304 interpolated resolution (arc-sec/count)** 79.1 3.16 1.24 0.309

interpolated resolution (µrad/count)** 383.5

maximum speed* (RPM) 5273

15.3

4219

6.0

1.5

1648 412 interpolated resolution (CPR) x4

32,768 interpolated resolution (arc-sec/count)** 39.6 x100

819,200 2,097,152 8,388,608

1.58 x256 x1024

0.618 0.154

interpolated resolution (µrad/count)** 191.7

maximum speed* (RPM) 2637

7.7

2109

3.0 0.7

824 206 interpolated resolution (CPR) x4

65,536 interpolated resolution (arc-sec/count)** 19.7 x100

1,638,400 4,194,304 16,777,216

0.791 x256 x1024

0.309 0.0772

interpolated resolution (µrad/count)** 95.9

maximum speed* (RPM) 1318

3.83

1054

1.5 0.4

412 103

*Maximum speed produces an encoder quadrature output of up to 28.8 million states per second.

** Resolution values shown are approximate. To calculate exact resolution values, convert from CPR (Counts Per Revolution) to the desired units.

Note: Specifications assume XOR function which is available in all standard controllers.

To calculate desired rotary interpolation multiplier, use the following equation

Interpolation Multiplier = Desired Resolution (CPR) / Fundamental Scale Resolution (CPR)

All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors.

Page 4 of 10

System Specifications

System

Grating Period 20µm

Signal Period 20µm

System Resolution 5µm - 0.020µm in integer interpolation steps (factory set or user programmed using MicroE SmartPrecision Software)

Linear accuracy*

Interpolation accuracy: Better than ± 0.12µm over any 20µm movement

Long-travel accuracy: ±1µm accuracy available - consult MicroE

Better than ± 3µm for scales up to 130mm

Better than ±5µm for scales 155mm to 1m

Better than ±5µm per meter for scales 1m or more

*Maximum peak to peak error over the specified movement when compared to a NIST-traceable laser interferometer standard, used at room temperature and with MicroE interpolation electronics.

Rotary Accuracy* Scale O.D.

12.00mm

Microradians Arc-Seconds

±100 ±21

19.05mm

31.75mm

57.15mm

±63 ±13

±38

±19

±7.8

±3.9

107.95mm

±10 ±2.1

*Based on ideal scale mounting concentricity

Sensor Size

W: 12.70mm

L: 20.57mm

H: 8.38mm

0.500"

0.810"

0.330"

Operating and Electrical Specifications

Power Supply 5VDC ±5% @ 330mA (30mA for sensor)

Temperature

Operating:

Storage:

Humidity:

0 to 70°C

-20 to 70°C

10 - 90% RH non-condensing

EMI:

Shock:

CE Compliant

1500G 0.5 ms half sine (Sensor)

Sensor Weight: 5.0g (Sensor without cable)

Cable: Double Shield. Maximum length 2m. Diameter: 3.6mm (0.142”)

Flex Life: 20 x 10 6 cycles @ 20mm bending radius

Mechanical Information - Sensor

.272

.166

6.91

4.22

A A

19.7 [500] or 39.4 [1000] or 78.7 [2000] ±.50 [12.7]

.058

1.47

.142 [3.61]

CABLE DIAMETER

All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE

Systems is not responsible for errors.

B

.083

2.11

.155

3.94

.500

12.70

.334

8.5

2X

THRU.

.106

2.69

.810

20.57

.650

16.5

.13

3.4

.037

0.94

.405

10.29

.24

6.2

.345

8.75

.080

2.03

C

Page 5 of 10

SmartPrecision

TM

Electronics Module

The Mercury 3000 encoder system includes a SmartPrecision electronics module. This compact, fully-featured signal processing system performs the following functions:

• Interpolation - up to 1024X with 28.8 million quadrature states / sec.

• Programmable interpolation level and output bandwidth

• Accuracy optimization - sensor signals are automatically optimized to improve system accuracy and maximize repeatability

• Signal strength indication - red / yellow / green LEDs assist during setup and provide diagnostics at a glance

• Index centering - centers the bi-directional index output pulse for repeatability to +/-1LSB

• Low Signal/Over Speed alarm

• Power-indicating LED

• Computer interface - for programming and data acquisition using

SmartPrecision software

• Superior EMI / RFI immunity - CE compliant

• Mounting options - all electronics are within the EMI-shielded connector housing and can be screwed directly into a mating connector that is bulkhead mounted, or the module may be mounted to the frame of your motion system and connected using an extension cable

Programmable Interpolation

The electronics module has programmable interpolation that is selectable over the range x4 to x1024 in integer steps, providing output resolutions that can be matched to your application requirements. This feature provides linear resolutions from 5µm to

0.020µm in convenient increments (e.g. x200 interpolation = 0.1µm) and rotary resolutions from 6,600 CPR to 16.8M CPR. Specify the interpolation value at the time of ordering or select the interpolation at your site using SmartPrecision Software.

Programmable Maximum Output Frequency

For encoder applications combining high resolution and high speed, the SmartPrecision electronics module supports up to 28.8 million quadrature state changes per second**. By specifying the maximum output frequency to match your controller's capability - ranging from

900,000 up to 28.8 million quadrature state changes per second - the

Mercury encoder system will never produce encoder counts faster than your controller can read them. Specify the encoder’s maximum output frequency at the time of ordering or select the setting at your site using MicroE's SmartPrecision Software.

* The electronics module’s serial computer programming interface can be translated to be RS-232 compatible using the MicroE SmartPrecision Computer Interface Adapter or a voltage translation circuit of your own design.

** “Quadrature state changes per second" is the reciprocal of "dwell time" or "edge separation". For example, 28.8 million states per second = 0.035µsec dwell time.

All Specifications are subject to change. All data is accurate to the best of our knowledge.

MicroE Systems is not responsible for errors.

SmartPrecision module enclosure provides “Best-in-Class” noise immunity for high noise environments.

Mercury 3000 Outputs:

11

12

13

14

15

7

8

9

10

5

6

3

4

1

2

15-pin high density Male D-sub connector

PIN FUNCTION

Reserved - Do not connect

Serial programming interface -transmit*

Serial programming interface -receive*

A- quadrature

A+ quadrature

Reserved - Do not connect

Reserved - Do not connect

Reserved - Do not connect

B- quadrature

B+ quadrature

Alarm

+5VDC

Ground

I+ index

I- index

Note: Contact MicroE for pin assignments and software protocols for the high speed serial output version.

Page 6 of 10

Mechanical Information - electronics module

2.11 [53.5]

2.03 [51.5]

1.89 [48.0]

1.50 [38.1]

.75 [19.1]

2.18 [55.4]

Ø.13 [Ø3.3]

PIN 1 PIN 5

.85 [21.5]

.10 [2.4]

.46 [11.6]

PIN 15

Male D-sub connector

Maximum Quadrature Output Frequency

Output Frequency

7.2MHz

3.6MHz

1.8MHz

900kHz

450kHz

225kHz

A-quad-B Output Rate

28.8M quadrature states / sec

14.4M quadrature states / sec

7.2M quadrature states / sec

3.6M quadrature states / sec

1.8M quadrature states / sec

900k quadrature states / sec

Dwell Time (or edge separation)

0.035µsec

0.069µsec

0.139µsec

0.278µsec

0.555µsec

1.111µsec

Output Signals

Quadrature TTL

Signal Termination for

A-Quad-B and Index

Pins 4 & 5

Pins 9 & 10

A+

B+

Pins 14 & 15* I+

Mercury

3000 encoder

Cable Zo=120

Ω

*Note: The index pulse may be aligned with A- or B- at some interpolation values.

120

Ω

Customer

Electronics

All Specifications are subject to change. All data is accurate to the best of our knowledge.

MicroE Systems is not responsible for errors.

Page 7 of 10

SmartPrecision Software for

Mercury 2000 and 3000 Encoder Systems

SmartPrecision Software makes Mercury the industry’s easiest to use encoder. It helps you program, set up, use, and diagnose Mercury

2000 and 3000 encoders with the click of a mouse. Compatible with

Windows 95, 98, ME,

NT, 2000, and XP.

Program Mercury Encoder Electronics

• Set interpolation in integer steps from x4 to x256 (Mercury 2000) or x4 to x1024 (Mercury 3000)

• Set maximum output frequency to match your controller

Install Mercury Encoder System

• Align sensor using Signal Level display and Encoder Signal data plot

• Locate index and see when sensor is over the scale’s index mark

• Verify sensor output over length of scale using the Signal Strength plot

Monitor Mercury Encoder Operation

• Read encoder position in engineering units of your choice

• Read the encoder's hour meter to monitor system usage

• Capture alarms while system operates unattended

Diagnose Mercury Encoder Performance

• Capture signal data and email it to MicroE for rapid diagnostic support

• Monitor alarms, view the alarm history log

System Description

The SmartPrecision Software system includes Software on CD, a computer interface adapter, computer cable, and a power adapter.

The encoder signal plot, or Lissajous plot, reveals the underlying strength and uniformity of the sensor’s output.

How to Order SmartPrecision Software

To Purchase the SmartPrecision Software system, use this Model

Number: SSWA120 for 120 VAC, 60Hz US Standard 2-prong plug or SSWA220 for 220 VAC, 50 Hz European Std. 2-prong plug

All Specifications are subject to change. All data is accurate to the best of our knowledge.

MicroE Systems is not responsible for errors.

Page 8 of 10

Scale Specifications

Standard and Customized Scales

MicroE Systems offers a wide array of chrome on glass scales for the highest accuracy and best thermal stability. Easy to install, standard linear and rotary scales meet most application requirements. Customized linear, rotary, and rotary segment scales are available where needed. All scales include an optical index. Mercury's glass scales save time by eliminating motion system calibrations or linearity corrections required by other encoders, and provide better thermal stability than metal tape scales.

Options include:

• Standard linear: 18mm - 2m

• Standard rotary: 12mm - 107.95mm diameter, with or without hubs

• Custom linear*: special lengths, widths, thickness, index mark locations and special low CTE materials

• Custom rotary*: special ID's, OD's (up to 304.8mm), index mark outside the main track and special low CTE materials

• Mounting of hubs for rotary scales: MicroE Systems can mount and align standard, custom, or customer-supplied hubs

• Rotary segments*: any angle range; wide range of radius values

*Custom scales or rotary segments are available in OEM quantities. Contact your local MicroE Systems sales office.

Standard Short Linear Scales

130mm and Shorter

Key: inches[mm]

0.036 [0.9]

Scale Length

0.250 [6.35]

Model

Scale Length

Measured Length

End Index

L18

0.709 [18]

0.512 [13]

Center Index

L30

1.181 [30]

0.984 [25]

Measured Length is always 5 mm less then total length

L55

2.165 [55]

1.969 [50]

Specifications

Accuracy

L80

3.150 [80]

2.953 [75]

Material

Typical CTE

Index

L105

4.134 [105]

3.937 [100]

±3µm standard

±1µm available

Soda lime glass

8ppm/°C

Center or End

L130

5.118 [130]

4.921 [125]

Custom scales available

Standard Long Linear Scales

155mm and Longer

Key: inches[mm]

0.098 [2.5]

Scale Length

0.787 [20.00]

Measured Length is always 5 mm less then total length

Center Index

Specifications

Accuracy

Material

Typical CTE

Index

±5 µm <1m

±5 µm/m >1m

Soda lime glass

8ppm/°C

Center or End

End Index

Scale length 6.102 [155] 8.858 [225]

L325

12.795 [325]

L425

16.732 [425]

L525 L1025 L2025

20.669 [525] 40.354 [1025] 79.724 [2025]

Measured length 5.906 [150] 8.661 [220] 12.598 [320] 16.535 [420] 20.472 [520] 40.157 [1020] 79.528 [2020]

Custom scales available

All Specifications are subject to change. All data is accurate to the best of our knowledge.

MicroE Systems is not responsible for errors.

Standard Rotary Scales

HUB THICKNESS

SCALE

PATTERN

SCALE O.D.

MOUNTING

HOLES

Key: inches[mm]

Model No. Scale Outer

Diameter

R1206

R1910

R3213

0.472 [12.00]

0.750 [19.05]

1.250 [31.75]

R5725 2.250 [57.15]

R10851 4.250 [107.95]

Scale Inner

Diameter

0.250 [6.35]

0.375 [9.52]

0.500 [12.70]

1.000 [25.40]

2.000 [50.80]

HUB I.D.

OPTICAL DIAMETER

Optical

Diameter

0.413 [10.50]

0.627 [15.92]

1.027 [26.08]

2.053 [52.15]

4.106 [104.30]

Custom scales available

Hub Inner

Diameter

+.0005/-0.0000

0.1253 [3.18]

0.1253 [3.183]

0.2503 [6.358]

0.5003 [12.708]

1.0003 [25.408]

Specifications

Material

Typical CTE

Soda lime glass

8ppm/°C

Hub

Thickness

Fundamental

CPR

0.040 [1.02]

0.040 [1.02]

0.050 [1.27]

0.060 [1.52]

0.080 [2.03]

1650

2500

4096

8192

16384

How to Order Mercury 3000 Encoder Systems

To specify your Mercury encoder with the desired scale, level of interpolation, maximum output frequency, cable length and software, consult the chart below to create the correct part number for your order. Call MicroE Systems’ Rapid

Customer Response team for more information [508] 903-5000.

Example (Linear Encoder): M3000-M10-1024-1-L55-C1

Example (Rotary Encoder): M3000-M10-1024-1-R1910-HA

M3000 Cable Length Interpolation -

Maximum Output

Frequency -

M05 = 0.5 m

M10 = 1.0 m

M20 = 2.0 m

4 = 4x

5 = 5x

1024 = 1024x

1 = 7.2 MHz

2 = 3.6 MHz

3 = 1.8 MHz

4 = 900 kHz

5 = 450 kHz

6 = 225 kHz

Scale Model

Lxxx or Rxxxx

How to Order SmartPrecision Software

SmartPrecision Software

SSWA120 for 120 VAC, 60Hz

US Standard 2-prong plug or

SSWA220 for 220 VAC,

50 Hz European Std. 2-prong plug

Scale Mounting

For linear scales:

T = Tape mounting

C1 = 3 scale clamps *

C2 = 10 scale clamps **

Hubs for Rotary Scales:

NH = Without Hub

HE = for R1206

HA = for R1910

HB = for R3213

HC = for R5725

HD = for R10851

* 3 clamps for linear scales up to 130mm

** 10 clamps for linear scales 155mm or longer

All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors.

DS-M3000 Rev E

© 2006 MicroE Systems crro E S mss – World Headquarters: 8 Erie Drive • Natick • MA 01760 www.microesys.com • [email protected] • T. [508] 903-5000 • F. [508] 655-7084

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