MicroE Systems | Mercury 1000 | Installation manual | MicroE Systems Mercury 1000 Installation manual

Mercury 2000, 3000 & 3500
™
Smart Programmable Encoder Systems
Installation Manual
and Reference Guide
Taking Control of Motion
Manual No. IM-M2000&3000 Rev E
Taking Control of Motion
Don Mitchell
Founder, Chairman and Chief Technology Officer
MicroE Systems
M
icroE 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
Sensor shown
the introduction of the
actual size
Mercury 2000 and
M10
3000 encoder
systems.
Table Of Contents
Precautions
SYSTEM ILLUSTRATION
Encoder with Linear scale
Encoder with Rotary scale
PAGE
2
3
INSTALLATION INSTRUCTIONS
Encoder System Mounting - Linear
Encoder System Alignment - Linear
Centering the Index & Calibration - Linear
Encoder System Mounting - Rotary
Encoder System Alignment - Rotary
Centering the Index & Calibration - Rotary
4
5
5
6
7
7
REFERENCE SECTION
Installation of Linear Scales
Grounding Instructions
Recommendations for Power
Recommended Interface Termination
Customer Interface Cable Requirements
SmartSignal Module Mounting Options
Declaration of CE Conformance
8
9
9
9
10
11
11
ENCODER TROUBLESHOOTING
Selected Topics
Cleaning Scales
Contact MicroE Systems
12
12
Back Cover
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 I and IEC Class 1M laser products.
• Invisible laser radiation (wavelength: 850 nm). Max power 1.5 mW CW.
• This product conforms to all applicable standards under 21 CFR Ch. I 1040.10.
• CDRH Class I level of laser radiation is not considered to be hazardous.
• 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)
M2000 and M3000 are CE compliant. M3500 CE compliance is pending
Page 1
Mercury 2000, 3000 & 3500 Encoder System
with Linear scale
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)
SmartSignal electronics module (interpolator)
Double
shielded cable
Expanded View
Mounting screws & flat
washers (2 needed per screw)
Sensor mounting holes (2)
Optional sensor benching pins (3)
End locator pin
Typical user-supplied
sensor mounting bracket
Index / Calibration
button
Center index mark
Cover: Sensor cable
and connector
Bracket mounting holes (2)
Thumb screw
15 pin High Density
D-sub connector
Scale reference datum;
example shown with benching pins
Detail A
Top reflective linear scale
End index mark
Scale benching edge
Page 2
Signal & alignment
indicators
Power/Calibration
indicator
Mercury 2000, 3000 & 3500 Encoder System
with Rotary scale
System View
Shown with Rotary scale
Sensor
(shown attached to a customer-supplied
mounting bracket)
Rotary scale
SmartSignal electronics module (interpolator)
Expanded View
Double
shielded cable
Mounting screws & flat
washers (2 needed per screw)
Mounting hole (2)
Typical user-supplied
sensor mounting bracket
would be located here
Cover: Sensor cable and connector
Top reflective
rotary scale
Index / Calibration button
Rotary scale
Thumb screw
15 pin High Density
D-sub connector
Signal & alignment
indicators
Power/Calibration
indicator
Page 3
Installation Instructions
Linear Encoders
1
Attach the scale to the base
slide. Reference the preferred
datum on the interface drawing
for either end or center index
orientation.
2
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.
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.
Be sure the source power is off before
connecting the SmartSignal plug.
CAUTION: observe precautions for handling
electrostatic sensitive devices.
3
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.
Page 4
4
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.
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).
Power/
Calibration
Power/
Calibration
Improper
Alignment LED
Red
Improved
Alignment LED
Yellow
6
Confirm proper alignment over
the full range of motion.
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
and repeat step 5.
5
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.
θ
To align the sensor, move
it in the Y or θz directions.
Power/
Calibration
Proper
Alignment LED
Green
Optimal
Alignment LED
Bright Green
7
Power/
Calibration
indicator
Index /
Calibration
button
Proper
Alignment
indicator
IMPO RTANT
OUTPUT C ALIBRATION 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 sensor at least 7mm (1/4”) away
from the index mark on the scale. Next, push
the Index/Calibration
button inside the
module with a small
diameter shaft, such
as a bare cotton swab.
The Power/
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
1
Attach your hub/scale
assembly to the rotary
device. Refer to the
interface drawing. The
reflective surface of the
scale must face the sensor.
CAUTION: observe precautions for handling
electrostatic sensitive devices.
3
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.
Page 6
2
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 connecting the
SmartSignal plug.
4
Connect the SmartSignal electronics
to the controller using 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
Rotary Encoders
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).
Power/
Calibration
Power/
Calibration
Improper
Alignment LED
Red
6
To align the sensor, move it
in the Y or θz directions.
Power/
Calibration
Proper
Alignment LED
Green
Optimal
Alignment LED
Bright Green
Improved
Alignment LED
Yellow
7
Confirm proper alignment
over the full range of motion.
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 and repeat
step 5.
5
θ
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.
Power/
Calibration
indicator
Index /
Calibration
button
Proper
Alignment
indicator
IMPO RTANT
OUTPUT C ALIBRATION 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 sensor at least 7mm (1/4”) away
from the index mark on the scale. Next, push
the Index/Calibration
button inside the
module with a small
diameter shaft, such
as a bare cotton swab.
The Power/
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 7
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.
the benching pins in from either end. 20% of the overall
1 Position
scale length is the recommended location from the edge.
sure the benching pins do not extend too high in the Z direction to
2 Beprevent
mechanical interference with the sensor or sensor mount.
0.2L
0.6L
L
0.2L
End
Benching
Pin
MicroE Systems
Benching pins
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)
sure the mounting surface is
1 Make
clean and dry.
End Benching
Pin
Mounting clamp
Hard epoxy
at one corner,
this end only.
scale clamps may be used to secure the
3 Optionally,
scale while the adhesive cures. Avoid damage to
Scale clamp
with adhesive
the top surface.
L
Mounting clamp
MicroE Systems
Mounting clamp
Benching pins
2 Align the scale by placing the edges against the benching pins.
Side view showing
optional scale clamps
and scale. Space
clamps every 75mm
on scales over 150
mm in length.
RTV around entire
outside edge of scale.
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
4 Apply
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
Gently place the scale on the mounting surface. Positioning adjustments
Make sure the mounting surface is clean and dry. Peel the
be made until the scale is firmly pressed down. After final positioning,
1 cover paper off and place the scale above the final location. 3 can
push down on the top of the scale to secure it.
End Benching
Pin
Hard epoxy at
one corner,
this end only.
L
MicroE Systems
Benching pins
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 encoder's 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 must be in intimate, electrically conductive contact with the customersupplied 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.
Inner shield: Insulated from outer shield,
sensor, and connector housing. Connected
to circuit common internally (pin 4).
Power
Supply
5 Volts
0 Volts
Electrically conductive
mechanical connection
(as supplied by MicroE
Systems).
Outer Shield: Connected to Sensor
and Connector housing
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 controller's ground. The controller must be grounded to earth at the point of installation.
2. The encoder sensor must be mounted so that it is electrically isolated from ground.
Power
Supply
5 Volts
0 Volts
Outer Shield: Connected to Sensor
and Connector housing
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
A+
R
A-
120 ohm
B+
R
B-
120 ohm
IW+
I+
R
IWI-
120 ohm
Page 9
Reference Section
Customer Interface Cable Requirements
Customer cables that interface to Mercury series encoders must have the following characteristics:
• Twisted pair signal wiring.
• Characteristic impedance of 100-120 ohms.
• 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.
• 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 corresponding twisted pair as follows:
Mercury 3500, 3000, 2000
Signal
Twisted Pair
A+
AB+
BIndex+
Index+5V
GND
Pair 1
Pair 2
Pair 3
Pair 4
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, 3000Si, 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.
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
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.
A
B
Declaration of
CE Conformance
Page 11
Troubleshooting
Problem
The Power/Calibration indicator will not come on.
Solution
• Make sure that the SmartSignal electronics’ 15-pin D-sub connector is fully seated and connected.
• 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
• 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.
• Check that the scale is firmly mounted and can't jiggle or move in other than the intended direction.
• Make sure that the scale is clean over its entire length or circumference.
Problem
The green Power/Calibration indicator is flashing unexpectedly.
Solution
• 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
• Verify that the sensor is mounted in the correct orientation to the scale for the desired index mark. Refer to the interface drawing.
• Refer to step 5 of the installation procedure to insure proper operation.
Cleaning scales
General Particle
Removal
Blow off the
contamination with
nitrogen, clean air,
or a similar gas.
Contamination
Removal
Use a lint-free cleanroom 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 find everything you need right there.
Taking Control of Motion
World Headquarters: 8 Erie Drive • Natick • MA 01760
www.microesys.com • info@microesys.com • T. [800] 355-4047 • F. [508] 655-7084
Copyright MicroE Systems
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