Next Generation Ruggedized TM Mercury 2000 Smart Encoder Systems Design Replaces Mercury 2100 Programmable Interpolation in Integer Steps to 0.078μm Reflective Linear and Rotary Encoder Systems New design for more robust performance Resolution Linear: 5μm to 0.078μm Rotary: 6,600 to 4.2M CPR Accuracy Linear: ± 1μm available ± 3μm to ± 5μm standard Rotary: Up to ± 2.1 arc-sec Output A-quad-B and Index Pulse Sensor the size of a dime The New Mercury 2000 encoder represents the next level of encoder performance. With programmable interpolation, smallest sensor size, easiest alignment, and superior noise immunity, the M2000 delivers Best-in-Class performance. Imagine what you can do with this! Table of Contents The new Mercury 2000 can reduce the cost and size of your system, and improve its performance all at once! MicroE Systems’ Mercury 2000 kit encoders are System & Sensor pg 1-5 smaller, higher performance, faster to install, and easier to set up and align than SmartPrecision Electronics pg 6-7 any other encoder. The tiny sensor fits into very tight spaces and works in both linear and rotary applications. SmartPrecision Software pg 8 New features Scales pg 9 ™ New metal enclosure for SmartPrecision electronics Ordering Information pg 10 Best-in-Class noise immunity for harsh environments Shorter length for smaller, tighter cabinets Frame mounting compatible for easy installation Optional features Robust metal housing with easy access locking screws Glass scale length or diameter Double shielded long life cable Linear lengths from 5mm to 2m CE compliant Rotary diameters from 12mm to 108mm Cable length of 0.5m, 1m, 2m, or custom Standard features SmartPrecision Software 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 0.078µm (linear); 4.2M CPR (rotary) LED set up indicators for sensor alignment and index location Bi-directional index signal is repeatable to encoder resolution System Configurations Standard and Optional Equipment M2000 Smart Encoder Systems Standard Equipment Encoder Sensor M10 Same for linear and rotary scales. Sensor Cable The standard cable is double shielded and available in lengths of 0.5m, 1m or 2m. ™ SmartPrecision Electronics Module New Metal Enclosure Provides Best-in-Class Noise Immunity A 15 pin high density D-sub connector mates to the customer controller. M2000 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 Eliminate the Frustration of Touchy Encoder Alignment T Th he et ta a Z Z A Alliig gn nm me en nt t T To olle er ra an nc ce e Mercury Solves this Problem for Good ± 0.5° ± 2° ± 0.006° 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. M Me er rc cu ur ry y B Br ra an nd d Y Y B Br ra an nd d X X 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* Brand X Brand Y Mercury vs. Best Competitor Z Standoff ± 0.15mm ± 0.1mm ± 0.1mm Mercury is 50% better Y ± 0.20mm for linear ± 0.1mm unspecified Mercury is 100% better > _ ± 0.10mm for rotary 19mm dia. theta X ± 1.0° unspecified ± 1.0° theta Y ± 2.0° ± 0.1° ± 1.0° Mercury is 100% better theta Z ± 2.0° ± 0.006° ± 0.5° Mercury is 300% better *Measured at a constant temperature for one axis at a time with all other axes at their ideal positions. **Based on published specifications Mercury Can Reduce System Size and Cost S St ta an nd do of ff f C Clle ea ar ra an nc ce e Mercury’s sensor height is 44% shorter than competitive encoders, making it easy to fit into your design. This reduction can also cut total M Me er rc cu ur ry y system weight and cost by allowing the use of smaller motors and 2.4mm* stages. Safe system operation is also enhanced thanks to Mercury’s ± 0.15mm generous standoff clearance– 200% greater than other encoders. B Br ra an nd d Y Y And its standoff tolerance is 50% greater than the best alternative. This significantly relaxes mechanical system tolerances, while reducing system costs. 0.8mm ± 0.1mm Mechanical Dimension Comparison** B Br ra an nd d X X 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 0.5mm Standoff tolerance ± 0.15mm ± 0.1mm ± 0.1mm 50% better ± 0.1mm System height 11.7mm 28.5mm 15.8mm 26% better **Based on published specifications * 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 2000 systems have programmable interpolation from x4 to x256 in integer steps. Below is a table of sample values. Linear - 20μm grating pitch Interpolation Resolution Maximum Speed* x4 5.000µm/count 7200mm/s x10 2.000µm/count 7200mm/s x20 1.000µm/count 7200mm/s x50 0.400µm/count 7200mm/s x80 0.250µm/count 7200mm/s x100 0.200µm/count 5760mm/s x200 0.100µm/count 2880mm/s x250 0.080µm/count 2300mm/s To calculate desired linear interpolation multiplier, use the following equation Interpolation Multiplier = Grating Pitch (20µm) / Desired Resolution (µm/count) Rotary - 20μm grating pitch Rotary Fundamental Interpolation Glass Scale Resolution Note: The range of available values is x4 to x256 Diameter in integer steps; example values below. 0.472” [12.00mm] 1650 CPR x4 x100 x256 interpolated resolution (CPR) 6,600 165,000 422,400 interpolated resolution (arc-sec/count)** 196.4 7.85 3.08 interpolated resolution (µrad/count)** 952 38.0 14.85 maximum speed* (RPM) 13090 10470 4090 0.750” [19.05mm] 2500 CPR x4 x100 x256 interpolated resolution (CPR) 10,000 250,000 640,000 interpolated resolution (arc-sec/count)** 129.6 5.18 2.03 interpolated resolution (µrad/count)** 628.3 25.1 9.8 maximum speed* (RPM) 8640 6912 2700 1.250” [31.75mm] 4096 CPR x4 x100 x256 interpolated resolution (CPR) 16,384 409,600 1,048,576 interpolated resolution (arc-sec/count) ** 79.1 3.16 1.24 interpolated resolution (µrad/count)** 383.5 15.3 6.0 maximum speed* (RPM) 5273 4219 1648 2.250” [57.15mm] 8192 CPR x4 x100 x256 interpolated resolution (CPR) 32,768 819,200 2,097,152 interpolated resolution (arc-sec/count)** 39.6 1.58 0.618 interpolated resolution (µrad/count)** 191.7 7.7 3.0 maximum speed* (RPM) 2637 2109 824 4.250” [107.95mm] 16384 CPR x4 x100 x256 interpolated resolution (CPR) 65,536 1,638,400 4,194,304 interpolated resolution (arc-sec/count)** 19.7 0.791 0.309 interpolated resolution (µrad/count)** 95.9 3.83 1.5 maximum speed* (RPM) 1318 1054 412 *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 - 0.078µm 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. Microradians Arc-Seconds 12.00mm ±100 ±21 19.05mm ±63 ±13 31.75mm ±38 ±7.8 57.15mm ±19 ±3.9 107.95mm ±10 ±2.1 *Based on ideal scale mounting concentricity Sensor Size W: 12.70mm 0.500" L: 20.57mm 0.810" H: 8.38mm 0.330" Operating and Electrical Specifications Power Supply 5VDC ±5% @ 330mA (30mA for sensor) Temperature Operating: 0 to 70°C Storage: -20 to 70°C Humidity: 10 - 90% RH non-condensing EMI: CE Compliant Shock: 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”) 6 Flex Life: 20 x 10 cycles @ 20mm bending radius Mechanical Information - Sensor .272 6.91 .166 4.22 A A SENSOR MTG. SURFACE SENSOR MTG SURFACE 19.7 [500] or 39.4 [1000] or 78.7 [2000] ±.50 [12.7] .13 3.4 .058 1.47 .037 0.94 .810 20.57 .083 2.11 B .405 10.29 .155 3.94 .142 [3.61] CABLE DIAMETER .24 6.2 .334 8.5 .500 12.70 .345 8.75 All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE 2X .106 2.69 .080 2.03 Systems is not responsible for errors. THRU. .650 16.5 C Page 5 of 10 TM SmartPrecision Electronics Module The Mercury 2000 encoder system includes a SmartPrecision electronics module. This compact, fully-featured signal processing system performs the following functions: Interpolation - up to 256X 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 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 SmartPrecision module enclosure provides “Best-in-Class” connector that is bulkhead mounted, or the module may be mounted noise immunity for high noise environments. to the frame of your motion system and connected using an extension cable Programmable Interpolation The electronics module has programmable interpolation that is Mercury 2000 Outputs: selectable over the range x4 to x256 in integer steps, providing output 15-pin high density Male D-sub connector resolutions that can be matched to your application requirements. This PIN FUNCTION feature provides linear resolutions from 5µm to 0.078µm in convenient increments (e.g. x200 interpolation = 0.1µm) and rotary resolutions 1 Reserved - do not connect from 6,600 CPR to 4.2M CPR. Specify the interpolation value at the 2 Serial programming interface -transmit* time of ordering or select the interpolation at your site using 3 Serial programming interface -receive* SmartPrecision Software. 4 A - quadrature Programmable Maximum Output Frequency 5 A + quadrature For encoder applications combining high resolution and high speed, 6 Reserved - do not connect the SmartPrecision electronics module supports up to 28.8 million 7 Reserved - do not connect quadrature state changes per second**. By specifying the maximum 8 Reserved - do not connect output frequency to match your controller's capability - ranging from 9 B- quadrature 900,000 up to 28.8 million quadrature state changes per second - the Mercury encoder system will never produce encoder counts faster than 10 B+ quadrature your controller can read them. Specify the encoder’s maximum output 11 Reserved - do not connect frequency at the time of ordering or select the setting at your site 12 +5V using MicroE's SmartPrecision Software. 13 Ground * The electronics module’s serial computer programming interface can be translated to be RS-232 14 I+ index compatible using the MicroE SmartPrecision Computer Interface Adapter or a voltage translation circuit of your own design. 15 I- index ** “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. *** Future availability, contact MicroE. All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors. Page 6 of 10 2 2 Mechanical Information - electronics module 2.11 [53.5] 2.03 [51.5] 1.89 [48.0] .75 [19.1] 2.18 [55.4] 1.50 [38.1] Ø.13 [Ø3.3] PIN 1 PIN 5 .85 [21.5] .46 [11.6] PIN 15 .10 [2.4] PI PIN 1 N 10 1 Male D connector Maximum Quadrature Output Frequency Output Frequency A-quad-B Output Rate Dwell Time (or edge separation) 7.2MHz 28.8M quadrature states / sec 0.035µsec 3.6MHz 14.4M quadrature states / sec 0.069µsec 1.8MHz 7.2M quadrature states / sec 0.139µsec 900kHz 3.6M quadrature states / sec 0.278µsec 450kHz 1.8M quadrature states / sec 0.555µsec 225kHz 900k quadrature states / sec 1.111µsec Output Signals Signal Termination for A-Quad-B and Index Quadrature TTL A Pins 4 & 5 Pins 9 & 10 B 120 Ω Cable Zo=120Ω Mercury 2000 Customer Electronics encoder Pins 14 & 15* I *Note: The index pulse may be aligned with A- or B- at some interpolation values. 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 The encoder signal plot, or Lissajous plot, reveals the underlying strength Read the encoder's hour meter to monitor system usage and uniformity of the sensor’s output. Capture alarms while system operates unattended Diagnose Mercury Encoder Performance How to Order SmartPrecision Software Capture signal data and email it to MicroE for rapid diagnostic support To Purchase the SmartPrecision Software system, use this Model Monitor alarms, view the alarm history log Number: SSWA120 for 120 VAC, 60Hz US Standard 2-prong plug or SSWA220 for 220 VAC, 50 Hz European Std. 2-prong plug System Description The SmartPrecision Software system includes Software on CD, a computer interface adapter, computer cable, and a power adapter. 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 need- ed. 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] Scale Length 0.036 [0.9] Measured Length Specifications is always 5 mm less Accuracy ±3µm standard then total length ±1µm available 0.250 [6.35] Material Soda lime glass Typical CTE 8ppm/°C End Index Center Index Index Center or End Model L18 L30 L55 L80 L105 L130 Scale Length 0.709 [18] 1.181 [30] 2.165 [55] 3.150 [80] 4.134 [105] 5.118 [130] Measured Length 0.512 [13] 0.984 [25] 1.969 [50] 2.953 [75] 3.937 [100] 4.921 [125] Custom scales available Standard Long Linear Scales 155mm and Longer Key: inches[mm] 0.098 [2.5] Scale Length Specifications Measured Length is always 5 mm less Accuracy ±5 µm <1m then total length ±5 µm/m >1m 0.787 [20.00] Material Soda lime glass Typical CTE 8ppm/°C Center Index Index Center or End End Index Model L155 L225 L325 L425 L525 L1025 L2025 Scale length 6.102 [155] 8.858 [225] 12.795 [325] 16.732 [425] 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. Page 9 of 10 Standard Rotary Scales HUB THICKNESS SCALE SCALE O.D. PATTERN Specifications HUB I.D. Material Soda lime glass MOUNTING OPTICAL DIAMETER Typical CTE 8ppm/°C HOLES Key: inches[mm] Model No. Scale Outer Scale Inner Optical Hub Inner Hub Fundamental Diameter Diameter Diameter Diameter Thickness CPR +.0005/-0.0000 R1206 0.472 [12.00] 0.250 [6.35] 0.413 [10.50] 0.1253 [3.18] 0.040 [1.02] 1650 R1910 0.750 [19.05] 0.375 [9.52] 0.627 [15.92] 0.1253 [3.183] 0.040 [1.02] 2500 R3213 1.250 [31.75] 0.500 [12.70] 1.027 [26.08] 0.2503 [6.358] 0.050 [1.27] 4096 R5725 2.250 [57.15] 1.000 [25.40] 2.053 [52.15] 0.5003 [12.708] 0.060 [1.52] 8192 R10851 4.250 [107.95] 2.000 [50.80] 4.106 [104.30] 1.0003 [25.408] 0.080 [2.03] 16384 Custom scales available How to Order Mercury 2000 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): M2000-M10-256-1-L55-C1 Example (Rotary Encoder): M2000-M10-256-1-R1910-HA Maximum Output M2000 - Cable Length - Interpolation - Frequency - Scale Model - Scale Mounting M05 = 0.5 m 4 = 4x 1 = 7.2 MHz Lxxx or Rxxxx For linear scales: T = Tape mounting M10 = 1.0 m 5 = 5x 2 = 3.6 MHz M20 = 2.0 m 3 = 1.8 MHz C1 = 3 scale clamps* 4 = 900 kHz C2 = 10 scale clamps** 5 = 450 kHz 256 = 256x 6 = 225 kHz Hubs for Rotary Scales: NH = Without Hub HE = for R1206 How to Order SmartPrecision Software HA = for R1910 HB = for R3213 SmartPrecision Software HC = for R5725 HD = for R10851 SSWA120 for 120 VAC, 60Hz US Standard 2-prong plug or SSWA220 for 220 VAC, 50 Hz European Std. 2-prong plug * 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. M Miic cr ro oE E S Sy ys st te em ms s – World Headquarters: 125 Middlesex Turnpike Bedford MA 01730 DS-M2000 Rev G © 2008 MicroE Systems Page 10 of 10 www.microesys.com info@microesys.com T. [ 781]-266-5700 F. [781]-266-5112